Wacker Neuson BTS 930-8340, Repair Manual

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...

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Page 3: ...1 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 t...

Page 4: ...ttle 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 decomp...

Page 5: ...tents 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 9...

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

Page 7: ...lotson 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...

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...

Page 9: ...e 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...

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 spring...

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 wit...

Page 12: ...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 Dir...

Page 13: ...b 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...

Page 14: ...sen 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 elbo...

Page 15: ...he 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 replaci...

Page 16: ...ircuit 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...

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...

Page 18: ...le 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 hous...

Page 19: ...nd 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 sta...

Page 20: ...y 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 spe...

Page 21: ...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...

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 Fau...

Page 23: ...rane 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...

Page 24: ...onsists 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 replacin...

Page 25: ...inter 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...

Page 26: ...ration 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...

Page 27: ...iller 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...

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 eng...

Page 29: ...ers 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 t...

Page 30: ...e 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...

Page 31: ...ate 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 gask...

Page 32: ...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 pulle...

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...

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...

Page 35: ...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...

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...

Page 37: ...mbly 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...

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

Page 39: ...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 f...

Page 40: ...n 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...

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 1...

Page 42: ...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 7...

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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...