Wacker Neuson BTS 930-8340, BTS 1030-8339, BTS 1035-7975, BTS 935-8341 Repair Manual
www.wackergroup.com
Cut-Off Saws
BTS 930-8340
BTS 935-8341
BTS 1030-8339
BTS 1035-7975
REPAIR MANUAL
0118754en 005
0903
0118754EN
BTS Repair Table of Contents
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1. Technical Data 5
1.1 BTS 930 / BTS 935 / BTS 1030 / BTS 1035 ........................................ 5
2. Special Tools 6
3. Clutch 7
3.1 Dismantling the clutch/drum ................................................................. 7
3.2 Mounting muffler and heat plate ........................................................... 8
3.3 Repairing the clutch ........................................... ..... ..... .... ..................... 8
3.4 Mounting the clutch/drum ..................................................................... 9
4. Ignition System 10
4.1 Checking the spark plug ..................................................................... 10
4.2 Replacing the plug connector ............................................................. 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 hose ......................................... 19
6.3 Carburetor - dismantling/testing the control side ................................20
6.4 Carburetor - dismantling/testing the pump side ..................................21
6.5 Carburetor - Cleaning the fuel filter ..... ..... ..... ..................................... 21
Table of Contents BTS Repair
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7. Hood System / Air Filter / Winter Operation 22
7.1 Air Filter ...............................................................................................22
7.2 Winter Operation .................................................................................23
8. Front Handle / Vibration Absorbers 24
8.1 Removing and replacing the bracket handle .......................................24
8.2 Replacing the vibration absorbers .......................................................24
9. Fuel Tank / Fuel Filter 25
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 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 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
BTS Repair Table of Contents
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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
Table of Contents BTS Repair
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BTS Repair Technical Data
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1. Technical Data
1.1 BTS 930 / BTS 935 / BTS 1030 / BTS 1035
Item No.
BTS 930
0008340
BTS 935
0008341
BTS 1030
0008339
BTS 1035
0007975
Saw
Displacement
cm³ (in³)
62 73
Bore
mm (in.)
47 (1.8) 50 (2.0)
Stroke
mm (in.)
37 (1.5) 37 (1.5)
Max. Power
kW (Hp)
3.3 (4.4) 4.2 (5.5)
Max. Torque
Nm
4.0 5.0
Idling Speed
rpm
2500 2500
Clutch engagement speed
rpm
3800 3800
Engine speed limitation
rpm
9350 9350
Max. spindle speed
rpm
4300 4300
Carburetor (diaphragm)
type
Tillotson HS-273 A
Ignition system
(with speed limitatio n)
type
electronic
Spark plug
type
NGK BPMR 7A / BOSCH WSR 6F /
CHAMPION RCJ 6Y
Electrode gap
mm (in.)
0.5 (0.020)
Fuel consumption
1)
l/h (qts./h)
1.85 (2) 2.36 (2.5)
Specific consumpti o n
1)
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)
300/20.0/5 350/24.5/5 300/20.0/5 350/24.5/5
Arbor diameter
mm
20.0 25.4 20.0 25.4
V-belt AVX 838 LA AVX 838 LA
Overall weight
4)
kg (lbs.)
9.7 (21) 9.9 (22) 9.8 (21) 10 (22)
1) At max. load per ISO 8893
2) Circumferance speed at max. engine speed
3) Outside diameter / arbor hole / thickness
4) tanks empty, without cutting disc.
Special Tools BTS Repair
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2. Special Tools
Ref. Part Number Description
1. 0068900 Puller for flywheel
2. 0117570 Puller for oil seals
3. 0117573 Puller for ball bearing count er 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
5
6
1
2
7
wc_gr001381
BTS Repair Clutch
wc_tx000298gb.fm 7
3. Clutch
3.1 Dismantling the clutch/drum
See Graphic: wc_gr001384 and wc_gr001385
3.1.1 To dismantle the clutch and drum, remove the cutting device (1), strut
(2) and V-belt cover (3).
3.1.2 To remove the cutting device, loosen the fixing screws (4). Remove
screw (5) to the point whe re the end of the screw projects from the
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).
3.1.6 Unscrew the clutch with the special tool (0117574) and a 19mm
wrench (a).
Note: left-handed thread.
7
4
2
1
3
5
wc_gr001384
9
11
a
8
10
wc_gr001385
Clutch BTS Repair
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3.2 Mounting muffler and heat plate
See Graphic: wc_gr001 38 6
When mounting the muffler (10) ensure that the heat plate (12) is
installed correctly.
Note: The heat plate goes directly onto the cylinder, then the gasket
(13) and muffler.
3.3 Repairing the clutch
See Graphic: wc_gr001 38 6
3.3.1 The tension springs of the clutch can be removed/ replaced with
pointed pliers (b). If spar es are requir ed, the 3 tension springs are onl y
available as individual parts.
3.3.2 The tension spring s shou ld on ly be re plac ed as a set if repl aceme nt is
required.
3.3.3 If the hub / flyweight is defective, the complete clutch must be
replaced.
wc_gr001386
b
BTS Repair Clutch
wc_tx000298gb.fm 9
3.4 Mounting the clutch/drum
See Graphic : wc_gr001387
3.4.1 Before installing the clutch dr um, the ne edle bear ing that is pressed i n
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.
wc_gr001387
a
Ignition System BTS Repair
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4. Ignition System
4.1 Checking the spark plug
See Graphic: wc_gr001 38 8
4.1.1 Remove filter hood.
4.1.2 Pull spark plug socket (1) off the spark plug and remove spark plug (2).
4.1.3 Connect spark plug (2) with plug socket and h old to ground (3). Pull out
starter 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 mo tor performance w ill 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 (burning off) on the
middle electrode. Spark plug must be replaced.
S
T
O
P
0,5 mm
wc_gr001388
b
a
BTS Repair Ignition System
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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
Ignition System BTS Repair
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4.3 Removing/assembling the ignition / short circuit cable
See Graphic: wc_gr001 39 0, wc_ g0 01 391, wc_gr001392 and wc_gr 001 393
Removing
4.3.1 Unscrew the starter device that is fixed with 4 screws (a).
4.3.2 Unscrew filter hood.
4.3.3 Remove ignition and short cir cuit cab le from the guide (1) of the hood .
4.3.4 Remove hood - to do this, unscrew the 3 screws (2).
4.3.5 The screw (2a) also holds the gr ounding wire.
4.3.6 Unscrew ignition from the ignition armature.
4.3.7 Loosen 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 the guide of the gas grip (c).
4.3.12 Remove intake elbow with carburetor and choke shaft from the tank
housing (d).
4.3.13 Pull short circuit cable (5) from its place in the choke shaft (6).
4.3.14 Loosen grounding wire (7) from the socket connection of the contact
spring.
wc_gr001390
a
1
2
2a
3
4
b
wc_gr001391
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