STIHL BGA 85 00- STIH)
. Introduction. Safety Precautions. Specifications 5. Motor 5. Maximum air flow rate 5. Air velocity 5.4 Dimensions 5.5 Weight 5.6 Tightening Torques 6 4. Troubleshooting 7 4. Flowchart 7 4. Battery 9 4. Machine 0 5. Testing the Battery 5. Acceptance 5. Testing with ADG Battery Analyzer 8. Blower 9 8. Blower Tube 9 8. and Installation the Blower 9 8. Disassembling and Reassembling the Blower 0 8.. Disassembling 0 8.. Assembling the Blower 9. Electrical Components 9. Testing with ADG Digital Analyzer 9. Switch 9. Motor 4 9.4 Electronic Module 4 9.5 Wiring Harness 5 0. Special Servicing Tools 7 6. Blower Housing, 6. Intake Screen 6. Blower Housing 7. Handle Housing / Cover 7. the Handle Housing 7. Cover 7. Locking Levers 4 7.4 Spring 5 7.5 Handle Housing 6 7.6 Trigger Switch Lockout 7 7.7 Trigger 7 7.8 Retaining Latch 8 RA_86_00_0_0 q ANDREAS STIHL AG & Co. KG, 0 BGA 85
. Introduction This service manual contains detailed descriptions of all the repair and servicing procedures specific to this power tool. You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies. Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts. A fault on the machine may have several causes. To help locate the fault, consult the chapter on "Troubleshooting" and the "STIHL Service Training System" for all assemblies. Refer to the Technical Information bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until a revised edition is issued. The special tools mentioned in the descriptions are listed in the chapter on "Special Servicing Tools" in this manual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: In the descriptions: : = Action to be taken that is shown in the illustration (above the text) = Action to be taken that is not shown in the illustration (above the text) In the illustrations: A Pointer adirection of movement @ 4. = Reference to another chapter, i.e. chapter 4. in this example. Service manuals and all technical information bulletins are intended exclusively for the use of properly equipped repair shops. They must not be passed to third parties. Always use original STIHL replacement parts. They can be identified by the STIHL part number, the { logo and the STIHL parts symbol K This symbol may appear alone on small parts. Preparations for servicing 997RA000 GM Always switch off the machine, remove the battery () and set the retaining latch () to ƒ before carrying out any repairs or transporting the machine. BGA 85
. Safety Precautions If the power tool is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the instruction manual. Improper handling may result in burns or other serious injuries. Battery Use only original STIHL rechargeable batteries. Use STIHL batteries only with STIHL power tools and recharge them only with STIHL chargers. Charge the battery before use. Never use or charge a defective, damaged or deformed battery. Do not open or repair, damage or drop the battery. Store the battery out of the reach of children. Protect from rain do not immerse it in fluids. Protect from direct sunlight, heat and fire never throw into a fire risk of explosion. Never expose the battery to microwaves or high pressures. Never insert objects into the battery's cooling slots. Never bridge the battery terminals with metallic objects (short circuit). The battery may be damaged by a short circuit. Keep a battery that is not in use away from metal objects (e.g. nails, coins, jewelry). Do not use metal containers for transportation risk of explosion and fire. Fluid may leak from the battery if it is damaged or not used properly avoid contact with the skin! Leaking battery fluid can cause skin irritation and chemical burns. In the event of accidental contact, wash affected areas of skin thoroughly with soap and water. If fluid gets into your eye(s), do not rub your eye(s) and rinse water over the open eye(s) for 5 minutes at least. Also seek medical attention. Charger and battery analyzer Use only original STIHL chargers and STIHL battery analyzer. Only use for charging matching STIHL batteries of type AP with a maximum capacity of 0 Ah and a maximum voltage of 4 V. Never charge or test defective or deformed batteries. Connect the charger only to a power supply with the voltage and frequency specified on the rating plate. Never use a charger with a damaged housing or damaged power supply cord. Do not open or repair. Store out of the reach of children. Protect from dampness. Use and store only indoors in dry rooms. Operate and store the battery only in a temperature range from - 0 C to max. + 50 C. BGA 85
Operate at ambient temperatures between + 5 C and + 40 C. Do not cover the charger to ensure it can cool down normally. Never bridge the charger's contacts with metallic objects (e.g. nails, coins, jewelry). The charger may be damaged by a short circuit. In the event of smoke or fire in the charger, disconnect it from the wall outlet immediately. To reduce the risk of electric shock or short circuit, do not insert any objects in the charger's cooling slots. Do not operate the charger on an easily combustible surface (e.g. paper, textiles) or in an easily combustible environment risk of fire. Do not operate in a hazardous location, i.e. in a location where there are combustible liquids (fumes), vapors or dusts. The chargers can produce sparks, which may ignite the dust or vapors risk of explosion. Check the charger's power supply cord regularly for damage. If the power supply cord is damaged, immediately disconnect the plug from the power supply to avoid the risk of electrocution. Never jerk the power supply cord to disconnect it from the wall outlet. To unplug, grasp the plug, not the cord. Have a damaged power supply cord repaired by an experienced electrician Do not use the power supply cord for any other purpose, e.g. for carrying or hanging up the charger. Check the power supply cord and plug for damage. Never use damaged cords and plugs or power supply cords that do not comply with regulations. Position and mark the power supply cord so that it cannot be damaged or endanger others this helps reduce the risk of stumbling. To reduce the risk of electric shock: Always connect the charger to a properly installed wall outlet. Transporting the cordless blower Always switch off the machine, set the retaining latch to ƒ and remove the battery. Remove the battery from the machine. This avoids the risk of the motor starting unintentionally. Make sure the insulation of the power supply cord and plug is in good condition. Unplug the charger from the wall outlet when it is not in use. 4 BGA 85
. Specifications. Motor BGA 85 Rated current: 6,7 A Current limit: 70 A Rated voltage: 6 V Enclosure EN 60 59: IP 0 Insulation: III Rated speed: 8,00 rpm. Maximum air flow rate with round nozzle: 650 m /h with fan nozzle: 75 m /h without nozzle: 845 m /h. Air velocity with round nozzle: with fan nozzle: 46 m/s 45 m/s.4 Dimensions Length: Height: Depth: 987 mm 85 mm 67 mm.5 Weight without battery:. kg BGA 85 5
.6 Tightening Torques DG and P (Plastoform) screws are used in polymer and light metal components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without impairing the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason it is essential to use a torque wrench. Fastener Thread size For component Torque Remarks Nm Screw P 5x8 Blower housing, left / right,0 Screw P 5x8 Left handle molding / right handle molding,0 Screw M 5x0 Ball bearing / motor shaft 6,0 ) ) Binding head, micro-encapsulated Use the following procedure when refitting a DG or P screw in an existing thread: Place the screw in the hole and rotate it counterclockwise until it drops down slightly. Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly. Power screwdriver setting for polymer: DG and P screws max. 500 rpm Do not use an impact wrench for releasing or tightening screws. 6 BGA 85
4. Troubleshooting 4. Flowchart Machine does not run or only hums Check battery for state of charge, correct installation and external damage (housing, seal, contacts) Battery - Charged? - Properly installed? - Good condition? no Charge / install properly / replace. yes Check light emitting diodes (LEDs) on the battery no Machine runs? yes no LEDs glow or flash red? LEDs flash yes 4 LEDs flash LEDs glow LED glows Fault in power tool, check power tool Fault in battery, check with ADG and replace if necessary Power tool too hot allow power tool to cool down Battery too hot / too cold, allow it to cool down / warm up Machine runs? no yes BGA 85 7
Inspect machine for external damage: - Blower housing, - Blower tube - Controls - Housing Machine damaged? no yes Replace damaged parts Use ADG to check electrical components for damage and correct operation and replace if necessary. no Machine runs? yes no Machine runs? yes Machine in order 8 BGA 85
4. Battery Test the battery with the ADG battery analyzer, b 5.. Condition Cause Remedy Battery cannot be pushed fully home Battery inserted wrong way round, guide lugs on cover broken Fit new cover and check contacts. Battery does not engage when pushed into the machine Locking levers defective Fit new locking levers, check torsion springs and replace if necessary. Contacts bent Check contacts, replace wiring harness or battery as necessary. Battery remains in same position after it is unlocked battery is not ejected Spring is bent or broken Check the spring, straighten or replace if necessary. Guides / contacts very dirty, battery jammed Clean the guides / contacts. BGA 85 9
4. Machine Test electrical components of the power tool with the ADG digital analyzer, b 9.. Condition Cause Remedy Machine does not run Trigger switch broken Fit new trigger switch. Machine does not run Blower wheel blocked Remove cause of blockage (e.g. foreign body) Machine shuts down Machine is too hot Carry out visual inspection and allow machine to cool down, see also light emitting diodes on battery. 0 BGA 85
5. Testing the Battery Before starting the test procedure, make sure the malfunction is not being caused by the blower wheel. Always check its freedom of movement first. 5. Acceptance Always carry out a visual inspection first. 5. Testing with ADG Battery Analyzer Never open or repair a battery. Always replace a faulty battery. Do not start the machine if the blower wheel is stiff or jammed this may cause the motor and battery to overheat and be damaged. 90RA70 TG : Check the contacts (arrows) If there are signs of external damage (e.g. bent or damaged contacts, deformation, cracks in housing), always install a new battery. 90RA7 TG Test the battery with the STIHL ADG battery analyzer, see separate instruction manual for ADG. Observe the information in the instruction manual. 90RA84 TG The battery is sealed (arrow) when it leaves the factory. Never attempt to open or repair the battery. Observe safety precautions, b. BGA 85
6. Blower Housing, 6. Intake Screen 6. Blower Housing Remove the protective screen, b 6. 997RA00 GM 997RA0 GM : Place the right half of the housing on the left half, making sure they fit exactly and no wires are pinched. : Take out the screws (arrows). : Remove the protective screen () from the blower housing. Inspect the protective screen and replace it if necessary : Take out the screws (arrows). Remove the right half of the housing. 997RA00 GM Insert the mounting screws. Tightening torques, b.6 Install the protective screen, b 6. Installing To remove the left half of the housing: Remove the blower tube, b 8., blower, b 8., with electronic module, b 9.4, and handle housing, b 7. 997RA00 GM Check both housing halves and replace if necessary Installing : Position the top of the protective screen () against the blower housing and line up the lug () with the recess (). : Push home the protective screen () until it is properly seated. Insert the mounting screws. Tightening torques, b.6 4 Install the handle housing (), b 7, blower (), b 8., with electronic module (), b 9.4, and blower tube (4), b 8., in the left half of the housing. 997RA004 GM BGA 85
7. Handle Housing / Cover 7. the Handle Housing Remove the right half of the housing, b 6. Lift the electronic module out of its guides and disconnect the wires, b 9.4 7. Cover Remove the handle housing, b 7. : Pull the bottom end of the cover () out of the retaining ledge () on the handle housing. 905RA009 AM 997RA0 GM : Take the handle housing () out of the left half of the housing. Installing 997RA00 GM : Take out the screws (arrows). Hold the housing securely, e.g. clamp it in a vise, use protective jaws. Take care not to damage the housing. 997RA0 BL : Continue pulling the cover away from the handle housing until it disengages from the other retaining ledge (). Inspect the cover and replace if necessary. 905RA00 AM 4 997RA0 GM : Push the locking levers (arrows) inwards and hold them in that position. : Fit the handle housing in the left half of the housing: Locate recess () on peg (). Locate adapter () on peg (4). Reassemble in the reverse sequence. BGA 85
Installing 7. Locking Levers The locking levers hold the battery in the machine. Inspect the torsion spring and locking lever, replace if necessary. Installing Remove the cover, b 7. 905RA0 AM : Push the cover () onto the handle housing. The retaining lugs () and the guides (arrows) at both sides fit into the recesses in the housing. : Push the cover home until it snaps into place at the top and bottom. Insert the screws. Tightening torques, b.6 Install the handle housing, b 7. : Carefully ease the two bearing points () apart and remove the locking lever () with torsion spring. The ends of the torsion spring are under tension. Remove the torsion spring if necessary as follows: 905RA0 AM : Hold the torsion spring () so that it matches the locking lever (arrows). : Push the winding () of the torsion spring () onto the pivot pin (). 905RA04 AM 905RA05 AM 905RA0 AM : Fit the torsion spring () on the other side, taking care not the overstretch the spring. : Disengage the torsion spring () from the retaining lug (). : Carefully pull the windings () of the torsion spring in the direction of the arrows, taking care not to overstretch the spring. 4 BGA 85
905RA09 AM 7.4 Spring Remove the cover if necessary, b 7. 905RA06 AM : Hold the torsion spring () down and engage it behind the retaining lug (arrow). : Carefully ease the bearing points apart (arrows) and fit the second pivot pin () in the second bearing point (). 905RA0 AM Positioning the locking lever: The grip () faces the compartment opening, the retaining edge () points into the battery compartment. : Fit one locking lever pivot pin in the bearing point (arrow). Stop () outside the guide. Both ends () of the torsion spring face outwards. 905RA07 AM 905RA08 AM : Engage the two ends () of the torsion spring behind the guides (). Check that both locking levers move freely. Reassemble all other parts in the reverse sequence. 905RA00 AM : Squeeze the spring () together, disengage it from the retaining lugs () and pull it out in the direction of the compartment opening. Check the spring and replace it if necessary Installing : Push the spring () inwards between the guides () and fit it in the retainer (). 905RA0 AM BGA 85 5
7.5 Handle Housing : Squeeze both sides () of the spring together and fit them under the retaining lugs (). Reassemble all other parts in the reverse sequence. Check operation the spring must push the battery about cm out of the compartment when the locking levers are operated. 905RA0 AM Remove the cover, b 7. Remove the right half of the handle, making sure the trigger switch lockout does not pop out and the torsion spring does not drop out of the trigger switch lockout. To assemble the left half of the handle: Remove the trigger switch lockout, b 7.6, trigger, b 7.7, switch, b 9., wiring harness, b 9.5, and retaining latch, b 7.8 Check both halves of handle and replace as necessary. : Place the right half of the handle () on the left half, making sure they fit exactly and no wires are pinched. Fit the cover, b 7. Check operation of trigger: Move the retaining latch to, depress the trigger switch lockout and trigger it must be possible to depress the trigger as far as stop. 997RA05 GM Installing 6 Check operation of retaining latch: Set retaining latch to ƒ trigger cannot be pulled when the trigger switch lockout is depressed. 4 5 997RA04 GM : Install the retaining latch (), b 7.8, wiring harness () with contact plate and adapter (), b 9.5, trigger (4), b 7.7, switch (5), b 9., and trigger switch lockout (6), b 7.6, in the left half of the handle. 6 BGA 85
7.6 Trigger Switch Lockout 7.7 Trigger Remove the right half of the handle, b 7.5 Remove the right half of the handle, b 7.5 : Fit the trigger switch lockout () in the bearing point (). 997RA07 GM Remove the trigger switch lockout, b 7.6 Take the switch out of the housing, b 9. : Remove the trigger switch lockout (), making sure the torsion spring () does not drop out. If necessary, remove the torsion spring from the trigger switch lockout. Inspect the trigger switch lockout and torsion spring, replace as necessary. 997RA06 GM : Locate the torsion spring from above on the housing ridge (). Install the right half of the handle, b 7.5 : Pull the trigger () off the pivot pin (). Check the trigger and replace it if necessary 997RA08 GM Installing Installing : Fit the torsion spring () in the trigger switch lockout (). The leg of the spring locates between the webs () and the wall of the trigger switch lockout. 905RA08 BL : Fit the trigger () on the pivot pin (). Install the switch, b 9.. Reassemble all other parts in the reverse sequence. 997RA09 GM BGA 85 7
7.8 Retaining Latch Remove the adapter, b 9.5 905RA0 BL : Take the retaining latch () out of the left half of the housing. Inspect the retaining latch and replace if necessary. Installing 905RA04 BL : Fit the retaining latch () in the left half of the housing. The retaining latch () fits in or on the guides (arrows) in the handle housing. Reassemble all other parts in the reverse sequence. 8 BGA 85
8. Blower 8. Blower Tube Remove right half of blower housing, b 6. Place the blower and blower tube in the left half of the blower housing. Fit the right half of blower housing, b 6. 8. and Installation the Blower Remove right half of blower housing, b 6. Remove the blower tube, b 8. Lift the electronic module out of its guides and disconnect the wires, b 9.4 997RA005 GM : Lift the blower tube () and blower () at the blower tube end. : Pull the blower tube () off the blower (). Inspect the blower tube and replace if necessary. Installing 4 : Lift the blower () and electronic module () out of the left half of the blower housing. If necessary, disassemble the blower housing, b 8. Installing 997RA009 GM If necessary, assemble the blower housing, b 8. 4 997RA006 GM : Lift the blower tube end of the blower (). : Push the blower tube () onto the blower and line it up: The lugs () at either side locate in the recesses (4) in the blower housing. 4 : Line up the blower: The lug () locates in the recess (). 997RA00 GM BGA 85 9
Place the blower in the left half of the blower housing and position the wires () of the electronic module in the channel (4). Reassemble all other parts in the reverse sequence. 8. Disassembling and Reassembling the Blower 8.. Disassembling Remove the blower, b 8. Disconnect the electronic module from the motor, b 9.4 : Disengage the retainers (arrows) and remove the outlet cone. 997RA04 BL 997RA0 GM : Unlock outlet stator () at both sides (arrows). 997RA05 BL : Hold the blower wheel () steady and take out the screw (). The micro-encapsulated screw has a binding head and must not be reused. 997RA0 GM : Pull off the outlet stator () with outlet cone (). 997RA06 BL : Pull the ball bearing () and outlet blower wheel () off the motor shaft. 0 BGA 85
8.. Assembling the Blower Clean the thread at the outlet end of the motor shaft with a tap do not use oil. 997RA0 BL 997RA00 GM The two ball bearings, the blower wheels and stators are identical. : Pull the carrier () out of the outlet blower wheel. : Pull the inlet cone () and ball bearing () off the motor. Take the ball bearing () out of the inlet cone (). 4 997RA0 BL : Unlock inlet stator () at both sides (arrows) and remove it. : Use circlip pliers to remove the circlip (). 997RA07 BL 997RA08 GM : Pull the inlet blower wheel () off the motor shaft. Check the individual parts and replace if necessary. 997RA0 BL : Push the blower wheel () onto the motor shaft as far as stop projecting fins () facing outlet end. : Fit the inlet cone () on the motor; the printed circuit board locates in the recess (4). Push the ball bearing onto the motor shaft as far as stop in the inlet cone and secure with a new circlip. Install a new circlip. 4 : Push the stator () over the blower wheel; check installed position: 997RA04 BL BGA 85
The arrowheads (, ) on the stator and inlet cone must be in alignment. Locking tabs (4) on stator must engage audibly on the inlet cone. Insert the carrier in the second blower wheel. Always use a new microencapsulated screw for installation. : Insert the new microencapsulated screw (). Tightening torques, b.6 997RA05 BL 4 997RA07 BL : Push the blower wheel with carrier () onto the motor shaft (), turning it back and forth at the same time until the slots () in the carrier engage the first blower wheel. : Fit the second stator (); check installed position: The arrowheads (, ) on the stators must be in alignment. Locking tabs (4) of stators must engage audibly. : Push the second ball bearing () onto the motor shaft () as far as stop. The micro-encapsulated screw has a binding head and must not be reused. Do not use Loctite to secure the screw: Capillary action can cause Loctite to enter and gum up the ball bearing. 997RA06 BL : Engage outlet cone's locking tabs () in the stator's recesses (small arrows) so that they snap into position. Connect electronic module to motor, b 9.4 Install the blower, b 8. 997RA08 BL BGA 85
9. Electrical Components 9. Testing with ADG Digital Analyzer Test the power tool with the STIHL ADG digital analyzer see ADG instruction manual. 9. Switch Remove the right half of the handle, b 7.5 Installing 905RA050 BL : Take the switch () with connector () out of the left half of the handle. 997RA040 GM : Fit the connector () so that it engages audibly. 4 905RA05 BL : Unlock (small arrow) and disconnect the connector (). 905RA049 BL : Fit the connector () and switch () in their seats in the handle molding. The lock side () of the connector faces outwards. The switch plunger (4) butts against the trigger. Check the switch and connector, replace if necessary. BGA 85
9. Motor 9.4 Electronic Module Disassemble the blower, b 8. Remove right half of blower housing, b 6. 905RA05 BL Check that all wires are properly positioned in the housing. Wires (, ) from the switch to the connector. Wires () from the connector to the adapter. Reassemble all other parts in the reverse sequence. Check the motor and replace it if necessary Assemble the blower, b 8. 997RA04 BL : Pull the electronic module () out of the guides in the blower housing. 997RA007 GM 997RA008 BL : Disconnect the terminals (, ) and unplug the connector () from the electronic module. Remove the blower from the left half of the blower housing, b 8. 4 BGA 85
4 : Disconnect terminals (,, ) from the motor. : Take wire out of retainer and remove the connector (4). Check the electronic module and replace if necessary. Installing 997RA09 GM Fit the blower in the left half of the blower housing, b 8. : Connect the terminals (, ) and plug the connector () into the electronic module. The terminals have different widths. 997RA04 BL 9.5 Wiring Harness Remove the handle housing, b 7. Remove the right half of the handle, b 7.5 Remove the trigger switch lockout, b 7.6, switch, b 9., and trigger, b 7.7 997RA044 BL 4 5 : Connect electronic module to the motor: The connector tags are marked "YLW" (), "BLU" () and "RED" (). : Connect the wires of the corresponding colors to the connector tags. : Fit the connector (4). : Fit the wire in the retainer (5) (strain relief) on the inlet cone. 997RA09 BL : Insert electronic module in the guides () in the left half of the blower housing. Position the wires in the guide at the same time. Fit right half of the blower housing, b 6. 997RA04 BL : Take the adapter () with wiring harness () and contact plate () out of the left half of the handle. : Pull the wiring harness () out of the guides (arrows) in the adapter. Check the wiring harness and replace it if necessary 997RA045 GM BGA 85 5
Installing The cable tie () fits in the recess (). 4 : Fit the adapter () in the left half of the handle housing. Engage recess () on large peg () and recess (4) on the smaller peg (5). 5 997RA046 GM : Fit wiring harness in the guides (,, ) in the adapter. Guides and : Red and black wires at the bottom and the wire with connector on top. Guide : Wire with connector at bottom, then the red wire and the black wire on top. Reassemble all other parts in the reverse sequence. 997RA048 BL 997RA049 GM : Fit the contact plate () in the guides (arrows) in the handle molding and clamp it securely. The lug () on the contact plate locates behind the housing wall. 997RA047 GM : Lay the wiring harness in the guides in the handle housing. 6 BGA 85
0. Special Servicing Tools Existing Special Tools No. Description Part No. Application Rem. ADG 4850 840 000 Battery analyzer (EU) ADG 4850 840 00 Battery analyzer (GB) ADG 4850 840 00 Battery analyzer (US) ADG 4850 840 00 Battery analyzer (AU/NZ) ADG 4850 840 004 Battery analyzer (CA) ADG 4850 840 000 Digital analyzer (EU, West) ADG 4850 840 00 Digital analyzer (GB) ADG 4850 840 00 Digital analyzer (US) ADG 4850 840 00 Digital analyzer (AU/NZ) ADG 4850 840 004 Digital analyzer (CA) ADG 4850 840 005 Digital analyzer (EU, East) ADG 4850 840 006 Digital analyzer (JP) ADG 4850 840 007 Digital analyzer (RU) Torque wrench 590 890 00 0.5 to 8 Nm 4 Screwdriver bit, T 7 x 5 08 54 04 and installing spline socket screws with electric or pneumatic screwdrivers; tightening down screws with torque wrench 5 Screwdriver bit, T 7 x 50 590 890 400 IS-P screws BGA 85 7
8 BGA 85
englisch / english 0455 86 0. M,8. A. FST. Printed in Germany