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Wacker Neuson BTS 1030-8339 Repair Manual

Manual is about: Cut-Off Saws

Summary of 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 3: Table Of Contents

    Bts repair table of contents wc_br0118754entoc.Fm 1 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 mounti...

  • Page 4: Table Of Contents

    Table of contents bts repair wc_br0118754entoc.Fm 2 7. Hood system / air filter / winter operation 22 7.1 air filter ...............................................................................................22 7.2 winter operation ...................................................................

  • Page 5: Table Of Contents

    Bts repair table of contents 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 ..............................................

  • Page 6: Table Of Contents

    Table of contents bts repair wc_br0118754entoc.Fm 4.

  • Page 7: Bts Repair

    Bts repair technical data wc_td000126gb.Fm 5 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) ...

  • Page 8: Special Tools

    Special tools bts repair wc_tx000326gb.Fm 6 2. Special tools ref. Part number description 1. 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. 01...

  • Page 9: Bts Repair

    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 scre...

  • Page 10: Clutch

    Clutch bts repair wc_tx000298gb.Fm 8 3.2 mounting muffler and heat plate see graphic: wc_gr001386 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 se...

  • Page 11: Bts Repair

    Bts repair clutch wc_tx000298gb.Fm 9 3.4 mounting the clutch/drum see graphic: wc_gr001387 3.4.1 before installing the clutch drum, the needle bearing 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. • (...

  • Page 12: Ignition System

    Ignition system bts repair wc_tx000299gb.Fm 10 4. Ignition system 4.1 checking the spark plug see graphic: wc_gr001388 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 hold to ground (3). Pull o...

  • Page 13: Bts Repair

    Bts repair ignition system wc_tx000299gb.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: Ignition System

    Ignition system bts repair wc_tx000299gb.Fm 12 4.3 removing/assembling the ignition / short circuit cable see graphic: wc_gr001390, wc_g001391, wc_gr001392 and wc_gr001393 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 ...

  • Page 15: Bts Repair

    Bts repair ignition system wc_tx000299gb.Fm 13 assembling 4.3.1 when mounting the short circuit cable, make sure that the connection between the connector lug of 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 mo...

  • Page 16: Ignition System

    Ignition system bts repair wc_tx000299gb.Fm 14 4.4 removing/checking/mounting the ignition armature see graphic: wc_gr001394 removing 4.4.1 unscrew starting device. 4.4.2 remove the two screws (1) of the ignition armature. Clip off ignition and short circuit cable. Checking 4.4.1 in the event of a f...

  • Page 17: Bts Repair

    Bts repair ignition system wc_tx000299gb.Fm 15 4.5 removing/mounting the flywheel see graphic: wc_gr001395 removing 4.5.1 block the piston using the piston stop wedge. 4.5.2 unscrew bolt (2) and remove washer (3). 4.5.3 remove flywheel with pulling device 0037576 (a). Caution: to avoid damage to the...

  • Page 18: Starting System

    Starting system bts repair wc_tx000300gb.Fm 16 5. Starting system 5.1 removing/mounting the starter / return spring see graphic: wc_gr001396 removing the starter 5.1.1 remove air duct (1). 5.1.2 relieve the tension on the return spring by pulling out the starter cable (2) slightly. 5.1.3 hold cable ...

  • Page 19: Bts Repair

    Bts repair starting system wc_tx000300gb.Fm 17 5.2 pretensioning/checking the return spring see graphic: wc_gr001367 pretensioning the return spring wrap the starter cable as far as possible around the drum. Hold cable tight and turn the drum with the cable 2-3 times to pretension (a). Checking the ...

  • Page 20: Carburetor

    Carburetor bts repair wc_tx000301gb.Fm 18 6. Carburetor 6.1 setting the carburetor see graphic: wc_gr001398 set idling nozzle “l” at 1 3/8 (-1/16) turn for the basic setting, turn in the idling nozzle “l” carefully as far as it will go. Then back off “l” nozzle 1 3/8 turn. For fine tuning, the “l” n...

  • Page 21: Bts Repair

    Bts repair carburetor wc_tx000301gb.Fm 19 6.2 removing the carburetor and intake hose see graphic: wc_gr001399 removing the carburetor 6.2.1 remove intake elbow with carburetor. 6.2.2 remove choke shaft (1), choke rod (2) and throttle control rod (3). Unscrew the two fixing screws (4). 6.2.3 remove ...

  • Page 22: Carburetor

    Carburetor bts repair wc_tx000301gb.Fm 20 6.3 carburetor - dismantling/testing the control side see graphic: wc_gr001400 dismantling the control side 6.3.1 unscrew cover (1). Carefully remove the seal (2) and diaphragm (3) from the control lever (4). 6.3.2 remove control lever, spring (5) and inlet ...

  • Page 23: Bts Repair

    Bts repair carburetor wc_tx000301gb.Fm 21 6.4 carburetor - dismantling/testing the pump side see graphic: wc_gr001401 dismantling the pump side unscrew cover (8). Remove seal (9) and diaphragm (10) from the carburetor. Testing the pump membrane the two valve flaps (arrow) must rest flat on the body ...

  • Page 24: Bts Repair

    Hood system / air filter / winter operation bts repair wc_tx000302gb.Fm 22 7. Hood system / air filter / winter operation 7.1 air filter see graphic: wc_gr001402 only well-maintained filters will guarantee efficient engine performance and a long working life. Damaged or worn filters must therefore b...

  • Page 25: Bts Repair

    Bts repair hood system / air filter / winter wc_tx000302gb.Fm 23 7.2 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 tempe...

  • Page 26: Bts Repair

    Front handle / vibration absorbers bts repair wc_tx000303gb.Fm 24 8. Front handle / vibration absorbers 8.1 removing and replacing the bracket handle see graphic: wc_gr001404 to dismantle the front handle, the strut (1) with 3 screws and the foot (2) with 2 screws must be unscrewed. 8.2 replacing th...

  • Page 27: Bts Repair

    Bts repair fuel tank / fuel filter wc_tx000304gb.Fm 25 9. Fuel tank / fuel filter 9.1 removing/inserting the ventilation valve see graphic: wc_gr001406 removing push the ventilation valve with a pin into the tank (arrow) and remove with pointed pliers through the filler opening (a). Inserting press ...

  • Page 28: Fuel Tank / Fuel Filter

    Fuel tank / fuel filter bts repair wc_tx000304gb.Fm 26 9.3 replacing the fuel pipe see graphic: wc_gr001407 unscrew tank cap, remove suction head (7) from tank and pull off the suction pipe (8). Pull suction pipe upwards out of the tank. 9.4 testing the fuel filter see graphic: wc_gr001407 dirty fel...

  • Page 29: Bts Repair

    Bts repair cylinder / piston / decompression valve wc_tx000305gb.Fm 27 10. Cylinder / piston / decompression valve 10.1 dismantling/mounting the cylinder / piston see graphic: wc_gr001408 and wc_gr001409 dismantling the cylinder 10.1.1 to dismantle the cylinder, unscrew the 4 screws (1) from the cyl...

  • Page 30: Bts Repair

    Cylinder / piston / decompression valve 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: Bts Repair

    Bts repair crankcase / crankshaft wc_tx000306gb.Fm 29 11. Crankcase / crankshaft 11.1 crankcase / crankshaft see graphic: wc_gr001410 and wc_gr001411 complete crankcase the complete crankcase is divided into the crankcase magnet side (2) “ms”, and the crankcase clutch side (1) “ks”. Removing the cra...

  • Page 32: Cutting Attachment

    Cutting attachment bts repair wc_tx000307gb.Fm 30 12. Cutting attachment 12.1 replacing the pressure disc see graphic: wc_gr001412 12.1.1 undo screw (1) and remove pressure disc. Note: with the 25.4 mm (1") axle, the inner flange is located behind the recess of the axle (2). 12.1.2 remove axle and f...

  • Page 33: Bts Repair

    Bts repair cutting attachment wc_tx000307gb.Fm 31 12.3 replacing the drive axle see graphic: wc_gr001413 to remove the axle (7), the pressure disk (8) and the v-belt pulley must be dismantled. Note: when mounting the inner flange disk, make sure that the spacer sleeve (9) 0108151 is mounted. 12.4 re...

  • Page 34: Cutting Attachment

    Cutting attachment bts repair wc_tx000307gb.Fm 32 12.6 replacing the guard stop see graphic: wc_gr001414 knock the shaft (1) 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...

  • Page 35: Bts Repair

    Bts repair cutting attachment wc_tx000307gb.Fm 33 12.8 removing / mounting the cutting device bearings see graphic: wc_gr001415 removing 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 ex...

  • Page 36: Cutting Attachment

    Cutting attachment bts repair wc_tx000307gb.Fm 34 12.9 adjusting the cutter guard holding attachment see graphic: wc_gr001416 if the guard is subjected to high stresses, the holding attachment and the guard may no longer be aligned (arrows). For correction, loosen screws (8) and adjust holding attac...

  • Page 37: Bts Repair

    Bts repair torques wc_tx000327gb.Fm 35 13. Torques 13.1 bts 930 / bts 935 / bts 1030 / bts 1035 assembly 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.) car...

  • Page 38: Torques

    Torques bts repair wc_tx000327gb.Fm 36.

  • Page 39: Threadlockers and Sealants

    Threadlockers and sealants threadlockers and sealants threadlocking adhesives and sealants are specified throughout this manual by a notation of “s” plus a number (s#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°c (350°f). If a screw or b...

  • Page 40: Threadlockers and Sealants

    Threadlockers and sealants loctite primer t hernon 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 p...

  • Page 41: Torque Values

    Torque values torque values metric fasteners (din) torque values (based on bolt size and hardness) wrench size size ft.Lb. Nm ft.Lb. Nm ft.Lb. Nm inch metric inch metric m3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 - 2.5 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 ...

  • Page 42: Torque Values

    Torque values inch fasteners (sae) size ft.Lb. Nm ft.Lb. Nm ft.Lb. Nm inch metric inch metric no.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 - no.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 - no.8 *22 2.5 *31 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 ...

  • Page 44

    Wacker construction equipment ag · preußenstraße 41 · d-80809 münchen · tel.: +49-(0)89-354 02 - 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 o...