Wacker Neuson BTS 1030-8339 Repair Manual Download

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Table of Contents

BTS Repair

wc_br0118754enTOC.fm

Hood System / Air Filter / Winter Operation

7.1

Air Filter ...............................................................................................22

7.2

Winter Operation .................................................................................23

Front Handle / Vibration Absorbers

8.1

Removing and replacing the bracket handle .......................................24

8.2

Replacing the vibration absorbers .......................................................24

Fuel Tank / Fuel Filter

9.1

Removing/inserting the ventilation valve .............................................25

9.2

Replacing the throttle lever mechanism ..............................................25

9.3

Replacing the fuel pipe ........................................................................26

9.4

Testing the fuel filter ............................................................................26

10. Cylinder / Piston / Decompression Valve

10.1

Dismantling/mounting the cylinder / piston ..........................................27

10.2

Testing the decompression valve ........................................................28

11. Crankcase / Crankshaft

11.1

Crankcase / crankshaft ........................................................................29

12. Cutting Attachment

12.1

Replacing the pressure disc ................................................................30

12.2

Removing / mounting the V-belt pulley ................................................30

12.3

Replacing the drive axle ......................................................................31

12.4

Removing the complete pressure ring .................................................31

12.5

Cutter guard holding attachments .......................................................31

12.6

Replacing the guard stop ....................................................................32

12.7

Replacing the fixing screw ...................................................................32

Summary of Contents for BTS 1030-8339

Page 1: ...www wackergroup com Cut Off Saws BTS 930 8340 BTS 935 8341 BTS 1030 8339 BTS 1035 7975 REPAIR MANUAL 0118754en 005 0903 0 1 1 8 7 5 4 E N ...

Page 2: ......

Page 3: ...11 4 3 Removing assembling the ignition short circuit cable 12 4 4 Removing checking mounting the ignition armature 14 4 5 Removing mounting the flywheel 15 5 Starting System 16 5 1 Removing mounting the starter return spring 16 5 2 Pretensioning checking the return spring 17 5 3 Replacing the starter ratchet 17 6 Carburetor 18 6 1 Setting the carburetor 18 6 2 Removing the carburetor and intake h...

Page 4: ...ottle lever mechanism 25 9 3 Replacing the fuel pipe 26 9 4 Testing the fuel filter 26 10 Cylinder Piston Decompression Valve 27 10 1 Dismantling mounting the cylinder piston 27 10 2 Testing the decompression valve 28 11 Crankcase Crankshaft 29 11 1 Crankcase crankshaft 29 12 Cutting Attachment 30 12 1 Replacing the pressure disc 30 12 2 Removing mounting the V belt pulley 30 12 3 Replacing the dr...

Page 5: ...ntents wc_br0118754enTOC fm 3 12 8 Removing mounting the cutting device bearings 33 12 9 Adjusting the cutter guard holding attachment 34 12 10 Tensioning the V belt 34 13 Torques 35 13 1 BTS 930 BTS 935 BTS 1030 BTS 1035 35 ...

Page 6: ...Table of Contents BTS Repair wc_br0118754enTOC fm 4 ...

Page 7: ...llotson HS 273 A Ignition system with speed limitation type electronic Spark plug type NGK BPMR 7A BOSCH WSR 6F CHAMPION RCJ 6Y Electrode gap mm in 0 5 0 020 Fuel consumption1 l h qts h 1 85 2 2 36 2 5 Specific consumption1 g kWh 500 500 Fuel tank capacity l qts 1 1 1 2 1 1 1 2 Mixture ratio fuel two stroke oil 50 1 50 1 Cutting disc for 80 m sec 2 DSA approved mm 3 300 20 0 5 350 24 5 5 300 20 0 ...

Page 8: ... 0068900 Puller for flywheel 2 0117570 Puller for oil seals 3 0117573 Puller for ball bearing counter support 4 0117569 Puller for ball bearing inside puller 5 0117575 Set of piston ring tenson belt 6 0117571 Piston stop wedge 7 0117574 Mounting tool for clutch hub 3 4 5 6 1 2 7 wc_gr001381 ...

Page 9: ...he cover arrow 3 1 3 The side strut is fixed with 3 screws 7 to the tank and the collector for the right upper damper device 3 1 4 The cover for the V belt is fixed to the crankcase with 3 screws 8 3 1 5 To remove the clutch and drum the piston must be blocked To do this unscrew the 3 screws 9 fixing the muffler 10 and insert the piston stop wedge 0117571 into the exhaust port of the cylinder 11 3...

Page 10: ... gasket 13 and muffler 3 3 Repairing the clutch See Graphic wc_gr001386 3 3 1 The tension springs of the clutch can be removed replaced with pointed pliers b If spares are required the 3 tension springs are only available as individual parts 3 3 2 The tension springs should only be replaced as a set if replacement is required 3 3 3 If the hub flyweight is defective the complete clutch must be repl...

Page 11: ... that is pressed in must be greased Alvania 2 3 4 2 When mounting the drum and the clutch be careful to mount the washers in the right order 1 Ring sits in the groove of the crankshaft 2 End collar with recess towards ring 3 Guide washer 4 Clutch guide washer before assembly Press into the support on the back of the clutch hub 1 2 3 4 wc_gr001387 a ...

Page 12: ...r cable If no spark is produced repeat procedure with new spark plug Note Switch 4 must be in position I 4 1 4 Combustion and motor performance will be improved if the spark plugs function properly Dirty or faulty spark plugs should therefore be cleaned or replaced The spark plug pictured a has serious oil carbon deposits Clean or replace spark plug This spark plug b is showing signs of wear burni...

Page 13: ...gb fm 11 4 2 Replacing the plug connector See Graphic wc_gr001389 Hold the plug connector spring using pointed pliers and push the rubber cap backwards over the ignition cable Note Grease the ignition cable slightly beforehand a wc_gr001389 ...

Page 14: ...osen short circuit cable from the socket connection b 4 3 8 Loosen the hose clamp 3 of the intake hose 4 3 9 Pull the suction hose 4 off the cylinder 4 3 10 Loosen the locking device of the intake elbow from the tank housing To do this push both levers inwards arrows and lift the intake elbow slightly 4 3 11 Push throttle control rod towards the cylinder using pointed pliers pulling upwards out of...

Page 15: ...the short circuit cable and the contact spring is in order a 4 3 2 Twist ignition cable into the ignition armature Note To prevent moisture leaking in fill protective cap 4 with silicone before replacing 4 3 3 As a safety measure lay the short circuit cable in the brackets underneath the ignition cable during assembly b 7 8 5 6 c d wc_gr001392 wc_gr001393 b 4 a ...

Page 16: ...circuit cable Checking 4 4 1 In the event of a fault first check the ignition ground connection To do this loosen and then tighten the screws 1 a few times then check ignition once again Mounting 4 4 1 Connect ignition and short circuit cable 4 4 2 Position with 0 012 0 016 0 3 mm 0 4 mm a between ignition device and magnet on the flywheel 4 4 3 Press ignition device firmly whilst at the same time...

Page 17: ... Unscrew bolt 2 and remove washer 3 4 5 3 Remove flywheel with pulling device 0037576 a CAUTION To avoid damage to the crankshaft always use the protective cap included with the pulling device Mounting 4 5 1 Before mounting the flywheel the cone seat and the crankshaft 4 must be cleaned 4 5 2 The flywheel is tightened with a torque of 23 ft lbs 30 Nm wc_gr001395 2 3 a 4 ...

Page 18: ...ble from rope drum Let drum spool back slowly Removing the return spring 5 1 1 To remove the return spring remove the circlip ring 3 the return spring 4 is in a cartridge which is fixed to the fan housing with three screws 5 Note Lightly grease new spring Mounting the return spring starter cable 5 1 1 Thread cable through knotting 6 into the cable drum and knotting 7 into the starter grip 8 5 1 2 ...

Page 19: ...and turn the drum with the cable 2 3 times to pretension a Checking the return spring When the starter cable is fully extended the rope drum must still turn at least half a turn b 5 3 Replacing the starter ratchet See Graphic wc_gr001367 5 3 1 Knock out the bolts with a punch c 5 3 2 To assemble push the punch in so far that there is only 0 06 0 07 0 15 mm 0 2 mm between the ratchet and the bolt 1...

Page 20: ...ly needs to be changed by max 1 16 of a turn S Idling Screw When during idling the engine speed is too high moving of cutting disc or too low engine stalls correct the the setting of idling screw S speed accordingly H Main Nozzle BTS 930 935 The main nozzle H is set at the factory to 6 8 of a turn BTS 1030 1035 The main nozzle H is set at the factory to 7 8 of a turn except for machines built in 2...

Page 21: ...d throttle control rod 3 Unscrew the two fixing screws 4 6 2 3 Remove the carburetor from the intake elbow 6 2 4 The seal 5 must not block the bore 6 for ventilating the control side of the carburetor compensation system Intake hose 6 2 1 Pull the intake hose 7 out of the intake elbow and check for damage 6 2 2 Replace the insert 8 in the intake hose again before assembling the carburetor 7 8 wc_g...

Page 22: ... lever spring 5 and inlet needle 6 from the carburetor Testing the control membrane 6 3 1 After removing the control diaphragm it must remain flat The rim around the stiffening plate 7 must be even Faulty diaphragm must be replaced immediately Testing the control unit 6 3 1 After removing the control diaphragm remove the intake pin with valve rocker and spring Note If there is visible wear arrows ...

Page 23: ...brane The two valve flaps arrow must rest flat on the body of the carburetor Damaged diaphragms must be replaced immediately as starting and running problems may otherwise occur 6 5 Carburetor Cleaning the fuel filter See Graphic wc_gr001401 The fuel filter 11 may be carefully removed from the carburetor body for cleaning with a pointed object After cleaning replace the fuel filter with a pin 9 8 ...

Page 24: ...consists of the pre filter 1 the paper cartridge 2 and the inside filter 3 Cleaning the pre filter 7 1 1 Clean the pre filter a in lukewarm soapy water using normal liquid detergent Dry before replacing Note If the inserts are extremely dusty the pre filter may need to be oiled slightly Cleaning the paper cartridge 7 1 1 Unscrew the 4 screws on the cover hood 4 To clean fan the paper cartridge b o...

Page 25: ...Winter Operation See Graphic wc_gr001403 Temperatures below zero may cause the filter carburetor to freeze Remove summer winter insert from summer mode 6 and insert in winter mode 7 as shown Return to summer mode when temperature is above 32 F 0 C 7 6 wc_gr001403 c d ...

Page 26: ...bration absorbers See Graphic wc_gr001405 The system consists of 4 vibration absorbers 3 of which are on the clutch side 8 2 1 To dismantle them the front handle filter system and tank must be removed 8 2 2 The fourth vibration absorber is on the flywheel side To dismantle it the starter device must be removed 8 2 3 The vibration absorbers are slotted into the housing Mount the sleeves 3 4 with th...

Page 27: ...filler opening a Inserting Press the new ventilation valve with a pin into the housing until the white sinter plastic projects about 2 3 mm beyond the tank b 9 2 Replacing the throttle lever mechanism See Graphic wc_gr001406 Push the two cylindrical pins 1 out of the handle dish 2 The throttle lever 3 spring 4 and throttle lock 5 may now be removed The throttle lock pin 6 for half throttle can als...

Page 28: ... the tank 9 4 Testing the fuel filter See Graphic wc_gr001407 Dirty felt filters or filters which have become hardened blocked with fuel will lead to leaning of the fuel air mix and will damage the engine c Note The fuel filter must therefore be checked replaced regularly A fingernail test can be used to check whether the filter is blocked d Easy to push in filter OK Cannot be pushed in replace 8 ...

Page 29: ...iers Push piston pin out Note During assembly make sure the securing ring clicks completely into the groove Mounting the cylinder piston 10 1 1 When mounting piston the arrow on top of the piston has to point in direction of muffler Note Before assembling the piston ensure that the cylinder base gasket 3 is fitted correctly Mounting the cylinder 10 1 1 Position the fork 4 of the piston ring tighte...

Page 30: ...ve BTS Repair wc_tx000305gb fm 28 10 2 Testing the decompression valve See Graphic wc_gr001409 Unscrew valve and check valve seating a and the hole in the cylinder for dirt Replace valve if dirty Clean hole carefully 4 b a wc_gr001409 ...

Page 31: ...rate the crankcase carefully by tapping with a plastic hammer a Replacing the crankshaft bearing First push bearing onto the crankshaft then insert crankshaft with bearing 5 into the case KS Place gasket on centering pins Note To dismantle or assemble the bearings heat the crankcase to 212 248 F 100 120 C Mounting the bearing crankcase Heat the crankcase MS and fit bearing into the case b Note The...

Page 32: ...2 12 1 2 Remove axle and flange together 12 2 Removing mounting the V belt pulley See Graphic wc_gr001412 Removing Block the V belt pulley 3 To do this push a pin through the hole 4 in the V belt pulley into the housing Remove screw 5 Mounting When mounting the pulley make sure that the shim 0108152 6 is mounted between the V belt pulley and the ball bearing Note The V belt pulley is only fixed in...

Page 33: ... the complete pressure ring See Graphic wc_gr001413 Unscrew the 3 screws with springs 10 the housing 14 and the pressure ring 11 Note The screws 10 have to be fitted at angles of 120 and are tightened to 7 3 ft lbs 10 Nm 12 5 Cutter guard holding attachments See Graphic wc_gr001413 When mounting place as follows Inside Outside 11 Pressure ring 14 Housing 12 Teflon ring 12 Teflon ring 13 Rubber par...

Page 34: ... with a pin out of the handle 2 To assemble push the new handle onto the shaft until the shaft is flush with the outside edge of the handle 12 7 Replacing the fixing screw See Graphic wc_gr001414 Push the screws 3 out of the housing Before inserting wet the stop area arrow on the screws with Loctite 609 1 2 3 wc_gr001414 ...

Page 35: ...g 12 8 1 Warm housing remove ball bearings spacer sleeve and snap rings from the housing Mounting 12 8 1 Heat housing up to approx 212 F 100 C 12 8 2 Mount external snap ring 4 12 8 3 Push ball bearing 5 up against the ring 12 8 4 Insert middle ring 6 and spacer sleeve 7 then push second ball bearing up to ring wc_gr001415 a 4 5 7 8 ...

Page 36: ... and the guard may no longer be aligned arrows For correction loosen screws 8 and adjust holding attachment 12 10 Tensioning the V belt See Graphic wc_gr001416 12 10 1 After mounting the cutting device tighten the nuts 9 by hand 12 10 2 Turn the screw 10 until the square nut 11 is aligned with the marking 12 on the hood 12 10 3 Tighten the nuts 9 to 14 ft lbs 20 Nm 9 10 10 10 8 wc_gr001416 ...

Page 37: ...embly set Nm ft lbs Muffler 10 1 7 Crankcase 10 1 7 Cylinder 14 1 10 Ignition coil 6 1 53 in lbs Front handle 7 0 5 60 in lbs Rubber mounts 7 0 5 60 in lbs Carburetor 1 5 0 5 13 in lbs Clutch 55 0 2 40 Flywheel 30 2 5 22 Spark plug 25 2 5 19 V belt pulley 25 5 19 Screws with locking serration ...

Page 38: ...Torques BTS Repair wc_tx000327gb fm 36 ...

Page 39: ...s before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and for sealing weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 300 F 28824 5 ml 25316 10 ml Loctite 609 Hernon 822 Omnifit 1730 230L Green Medium strength retaining compound f...

Page 40: ...on Primer 10 Omnifit VC Activator Aerosol Spray Fast curing primer for threadlocking retaining and sealing compounds Must be used with stainless steel hardware Recommended for use with gasket sealants 2006124 6 oz TYPE Europe COLOR USAGE PART NO SIZE ...

Page 41: ... 5 M4 26 2 9 36 4 1 43 4 9 9 32 7 3 M5 53 6 0 6 8 5 7 10 5 16 8 4 M6 7 10 10 14 13 17 10 5 M8 18 25 26 35 30 41 1 2 13 6 M10 36 49 51 69 61 83 11 16 17 8 M12 63 86 88 120 107 145 3 4 19 10 M14 99 135 140 190 169 230 7 8 22 12 M16 155 210 217 295 262 355 15 16 24 14 M18 214 290 298 405 357 485 1 1 16 27 14 M20 302 410 427 580 508 690 1 1 4 30 17 1 ft lb 1 357 Nm in lb 1 Inch 25 4 mm 8 8 10 9 12 9 ...

Page 42: ...1 3 5 42 4 7 11 32 9 9 64 No 10 32 3 6 45 5 1 60 6 8 3 8 5 32 1 4 6 8 1 9 12 12 16 7 16 3 32 5 16 13 18 19 26 24 33 1 2 13 1 4 3 8 23 31 33 45 43 58 9 16 5 16 7 16 37 50 52 71 69 94 5 8 16 3 8 1 2 57 77 80 109 105 142 3 4 19 3 8 9 16 82 111 115 156 158 214 13 16 5 8 112 152 159 216 195 265 15 16 24 1 2 3 4 200 271 282 383 353 479 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 Inch 25 4 mm ...

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Page 44: ... 0 Fax 49 0 89 354 02 390 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 1 1 262 255 0500 Fax 1 1 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Sunley Center Unit 912 9 F 9 Wing Qin Street Kwai Chung N T Hong Kong Tel 852 2406 60 32 Fax 852 2406 60 21 ...

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