Wacker Neuson BTS 635s, Operator'S Manual

Page 1: ...Operator s manual Gasoline cut off saw BTS 630 635 635s 12 2011 0217780en 006...

Page 2: ...Manufacturer Wacker Neuson Produktion GmbH Co KG Preu enstra e 41 80809 M nchen www wackerneuson com Tel 49 0 89 354 02 0 Fax 49 0 89 354 02 390 Translation of the original operator s manual in German...

Page 3: ...of combustion engines 17 3 8 Safety during cut off saw operation 20 3 9 Maintenance 24 3 10 Safety and information labels 25 3 11 Safety and information icons 28 3 12 Safety devices 29 4 Scope of deli...

Page 4: ...washers 54 10 3 5 Cleaning Changing the air cleaner 55 10 3 6 Checking cleaning replacing the spark plug 57 10 3 7 Replacing the V belt 59 10 3 8 Replacing the fuel filter 62 10 3 9 Setting the idle s...

Page 5: ...ccordance with the instructions in this operator s manual Your reward will be troublefree operation and a high degree of availability Defective machine parts must be replaced immediately Please contac...

Page 6: ...notice indicates immediate hazards that result in serious injury or even death f Danger can be avoided by the following the actions mentioned WARNING This warning notice indicates possible hazards tha...

Page 7: ...liate or your Wacker Neuson dealer You can find the addresses in the Internet at www wackerneuson com The address of the manufacturer is located at the beginning of this operator s manual 2 3 Describe...

Page 8: ...iquely identifies your machine This infor mation is needed to order spare parts and when requesting additional technical information f Enter the information of your machine into the following table It...

Page 9: ...with the machine and the material to be cut The machine may not be used for the following purposes Cutting wood Cutting plastics Cutting materials that contain asbestos or other hazardous materials Cu...

Page 10: ...the installation regulations in this operator s manual Do not drill into the housing e g to install signs Water could penetrate the housing and damage the machine Requirements for operation The abili...

Page 11: ...proper handling Using of spare parts which are not from Wacker Neuson and not equivalent to the original parts in design and quality Using of accessories which are not from Wacker Neuson Operator s ma...

Page 12: ...rate the machine The following rules also apply You are at least 18 years of age You are physically and mentally fit You have received instruction on how to independently operate the machine You have...

Page 13: ...ear Work clothing Clothing should be appropriate i e should be close fitting but not restrict your movement When on construction sites do not wear long hair loosely loose clothing or jewelry including...

Page 14: ...to hand on the worksite Do not exceed the service life The machine produces vibrations and generates noise Observe the regulations which apply in your country and guidelines concerning the maximum ser...

Page 15: ...cles in the work and traffic area Load bearing capacity of the ground The measures needed to cordon off the construction site from public traffic in particular The measures needed to secure walls and...

Page 16: ...clothing away from moving or rotating machine parts Parts of your body being pulled in or crushed can cause serious injuries Caution with toxic materials Some materials may contain toxic chemicals whi...

Page 17: ...e familiar with and always wear suitable breathing protection 3 6 Safety during the operation of hand machines Safe working with hand machines Secure loose workpieces with suitable methods While worki...

Page 18: ...ediate vicinity of the machine Make sure that waste such as paper dry leaves or grass do not accumulate around the exhaust muffler The waste materials may ignite Safety precautions when refueling Plea...

Page 19: ...aning the engine Clean the engine when it is cool to remove any dirt Do not use gasoline or solvents Danger of explosion Health hazard due to exhaust fumes Warning The engine s exhaust fumes contain c...

Page 20: ...working as a rule hold the machine on the provided handles with both hands Do not use the upper quarter of the cutting blade to cut Make sure that the material does not shift out of place Ensure that...

Page 21: ...using cutting blades with a hole diameter greater than the machine shaft use the suitable adapter ring Only use undamaged cutting blades Ensure that you also follow the instructions of the cutting bl...

Page 22: ...or wet cutting Before ending the wet cutting process allow the cutting blade to run without the water sprayer until it is dry Notes regarding work methods Set the protective hood such that its lower s...

Page 23: ...ine on the provided handles with both hands Cutting several materials at once Do not cut several materials in one cutting procedure Cutting very thin materials Make sure that very thin materials do no...

Page 24: ...electrical equipment is present this can pose a serious injury risk from electric shocks Assembling safety devices If it was necessary to dismantle safety devices they must be reassembled and checked...

Page 25: ...e sure that all the labels are kept legible Replace any missing or illegible labels The item numbers for the labels are in the parts book Item Label Description 1 Do not exceed the maximum cutting bla...

Page 26: ...s Only wear clothing made of material that is not easily flammable 2 Before operation read and follow the information in the operator s manual 2 Smoking and open flames are prohibited Danger of fire 2...

Page 27: ...a powerful exhaust air fan 3 EU emission information label 3 This label is an example only and may vary from machine to machine EPA emission information label for EPA machines Emission Control Exhaust...

Page 28: ...art 3 Stop 4 The machine may only be operated with a fuel mixture consisting of unleaded gasoline and two cycle engine oil The mixture ratio is 50 1 5 Mark for setting the V belt tension 6 Machine s d...

Page 29: ...ting cutting blade Diverts workpiece particles and sparks or chips from a damaged cutting blade away from the operator Set the protective hood such that its lower section is almost in contact with the...

Page 30: ...delivery BTS 630 635 30 Operator s manual 4 Scope of delivery Item Designation Item Designation 1 Machine 4 5 mm Allen wrench 2 Operator s manual 5 6 mm Allen wrench 3 Parts book 6 Combination wrench...

Page 31: ...ty Principle The machine is a gasoline cut off saw It is driven by a two cycle combustion engine The powertrain from the engine to the cutting blade is driven by a centrifugal clutch and V belt The ma...

Page 32: ...s and operator s controls Item Designation Item Designation 1 Front handle 8 Fuel tank 2 Water supply 9 Recoil starter 3 Multifunction switch 10 Cutting blade 4 Throttle lever lock 11 Protective hood...

Page 33: ...lock also returns to its original position Throttle lever The machine speed can be continuously varied using the throttle lever Lock button The lock button can lock the throttle lever in the half gas...

Page 34: ...Operator s manual Fuel pump The fuel pump is used to fill the fuel lines and the carburetor after the machine has not been used for a while The integrated return pipe prevents too much fuel from enter...

Page 35: ...a suitable means of transport 5 Secure the machine against falling over and down or sliding WARNING Improper handling can result in injury or serious material damage f Read and follow all safety infor...

Page 36: ...the cutting attachment is in the external position using the guide cart makes it even easier to see the cutting line Performing preparations 1 Switch off the engine 2 Let machine cool off 3 Detach th...

Page 37: ...move the vibration dampers 4 Rotate the protective hood counter clockwise until the mounting hole in the vibration damper is visible 5 Position the vibration damper and tighten it 6 Unscrew the adjust...

Page 38: ...belt guard screws by approximately one turn 2 Rotate the adjusting screw counter clockwise until the V belt is slackened completely 3 Unscrew the belt guard screws and remove them 4 Remove the belt gu...

Page 39: ...chment 180 and place it in position 4 Place the V belt in position 5 Place the belt guard in position and affix it with screws 6 Rotate the adjusting screw clockwise until the square nut is located be...

Page 40: ...ial start up BTS 630 635 40 Operator s manual 9 Turn the thrust washer 2 3 times to make sure the tension is equal across the V belt 10 Check the V belt tension again and re tighten the V belt if nece...

Page 41: ...r defects eliminated immediately Damage to the cutting blade cracks sections broken off deformation off balance etc Fuel level see chapter Maintenance V belt tension see chapter Maintenance Tightness...

Page 42: ...ther with the thrust washer 3 Clean thrust washer and spindle of the machine 4 Place the cutting blade onto the spindle in the correct rotation direction 5 Place the screw together with the thrust was...

Page 43: ...he appropriate position Cold engine Position choke Warm engine Position I 3 Press the fuel pump bellows repeatedly until the bellows is completely filled with fuel 4 Actuate the decompression valve If...

Page 44: ...position 1 Press and hold the throttle lever lock and the throttle lever 2 Press the lock button 3 Release the throttle lever The throttle lever is locked in the half gas position 4 Release the lock...

Page 45: ...slowly until compression resistance can be felt and then let it slowly roll back in again NOTICE Improper handling can damage the machine f Do not pull the starter rope as far as it can go f Let star...

Page 46: ...function switch from the Choke position to the I position If necessary actuate the decompression valve once again 5 Pull the starter rope with force but not suddenly several times if necessary until t...

Page 47: ...cut Holding and guiding the machine 1 Stand in a fixed position 2 Always hold the machine with both hands using both handles Setting the protective cover f Use the adjustment handle to set the protec...

Page 48: ...Switching off the machine 1 Release the throttle lever 2 Set down the machine in such a way that it cannot tilt fall or slip 3 Set the multifunction switch to Stop 4 Detach the cutting blade and store...

Page 49: ...f service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of the emission control system and may have a bearing on the outcome of a warrant...

Page 50: ...lt as necessary Visual inspection of all parts for damage Check function of throttle lever throttle lever lock and lock button Check protective hood Damage Tightness Check cutting blade Damage Tightne...

Page 51: ...hey are not lost as easily 10 3 1 Cleaning the machine f Wipe the housing with a damp and clean cloth 10 3 2 Topping up with fuel Performing preparations 1 Switch off the engine 2 Let the machine cool...

Page 52: ...remove the fuel cap Note Slowly unscrew the fuel cap so that any overpressure can slowly escape 2 Top up with fuel See chapter Technical data for the fuel specification See chapter Technical data for...

Page 53: ...h off the engine Tightening the V belt 1 Loosen both belt guard screws by approximately one turn 2 Rotate the adjusting screw clockwise until the square nut is flush with the mark 3 Tighten both belt...

Page 54: ...or s manual 10 3 4 Checking the thrust washers 1 Check the thrust washers for wear and sharp edges In case of wear or damage change the thrust washers 2 Clean the thrust washers Item Designation 1 Thr...

Page 55: ...t around the air cleaner cap 3 Unscrew and remove the air cleaner cap NOTICE Operating the engine without air cleaner can cause rapid engine wear f Do not run the engine without an air cleaner or air...

Page 56: ...ner cartridge 1 Unscrew and remove the air cleaner cover 2 Remove the air cleaner cartridge 3 Insert new air cleaner cartridge 4 Position the air cleaner cover and tighten it 5 Position the air cleane...

Page 57: ...the air cleaner housing and the area around the spark plug thoroughly 3 Pull off the spark plug cap from the spark plug Note Do not pull the spark plug cap off the spark plug by the ignition cable 4...

Page 58: ...er Technical data for the spark plug gap 4 Check the spark plug gasket if damaged replace the spark plug Installing the spark plug 1 First screw in the spark plug manually then tighten it with a combi...

Page 59: ...sen the belt guard screws 2 Rotate the adjusting screw counter clockwise until the V belt is slackened completely 3 Unscrew the belt guard screws and remove them 4 Remove the belt guard 5 Unscrew the...

Page 60: ...tor s manual Replacing the V belt 1 Remove the cutting attachment 2 Remove the V belt 3 Place the new V belt in position 4 Place the cutting attachment in position and thread the V belt in Item Design...

Page 61: ...it with screws 2 Place the belt guard in position and affix it with screws 3 Rotate the adjusting screw clockwise until the square nut is flush with the mark 4 Tighten the belt guard screws Torque 25...

Page 62: ...cing the fuel filter 1 Unscrew the fuel cap 2 Pull the fuel cap together with the retainer out of the fuel tank 3 Pull the fuel filter out of the fuel tank with a wire hook 4 Use a small screwdriver t...

Page 63: ...river If the cutting blade rotates in idle turn the adjusting screw for idle speed counter clockwise until the cutting blade stops If the engine shuts off in idle turn the adjusting screw a bit clockw...

Page 64: ...the cutting attachment on the outside 2 Unscrew and remove the guide plate 3 Remove the spark arrestor grid 4 Clean the spark arrestor grid using a wire brush 5 Mount and screw the guide plate and spa...

Page 65: ...on the outside 2 Remove the spark plug cap 3 Unscrew and remove the muffler 4 To stop the cylinder area from getting dirty bring the piston to the top position 5 Use a wooden tool e g stick to remove...

Page 66: ...enance BTS 630 635 66 Operator s manual 7 Screw the muffler with new seal to the cylinder Torque 18 Nm 8 Install the cutting device see chapter Initial start up mounting the cutting attachment on the...

Page 67: ...ce spark plug Spark plug is loose Tighten spark plug Spark plug gap is set incorrectly Set spark plug gap Fuel filter is clogged Replace fuel filter Engine shuts off right after starting Idle speed is...

Page 68: ...s BTS 630 635 68 Operator s manual 12 Accessories There is a wide range of accessories available for the machine For more information on the individual accessories visit the following website www wack...

Page 69: ...ycle oil in the fuel does not evaporate After long term storage the mixture ratio of gasoline to two cycle oil is no longer correct For this reason the fuel system must be be empty for long term stora...

Page 70: ...de diameter mm in 300 12 350 14 350 14 Max width mm in 4 5 0 2 4 5 0 2 4 5 0 2 Spindle diameter mm in 20 0 8 25 4 1 0 25 4 1 0 Max cutting depth mm in 103 4 1 128 5 0 128 5 0 Tank capacity l gal 1 1 0...

Page 71: ...2 ft s2 1 5 4 9 1 5 4 9 1 5 4 9 According to DIN EN ISO 19432 2006 Designation Unit BTS 630 BTS 635 BTS 635s Combustion method 2 cycle Engine type Gasoline engine Engine displacement cm in 85 8 5 2 Ra...

Page 72: ...or s manual 14 2 Fuel mixture table Note Only use fuel in a mixture ratio of 1 50 Gasoline volume in liters qt Oil volume in liters qt 1 1 06 0 02 0 02 5 5 28 0 1 0 11 10 10 57 0 2 0 21 15 15 85 0 3 0...

Page 73: ...ng all subsequent owners Manufacturer s warranty coverage The emission control system is warranted for 2 years or the length of the Wacker Neuson warranty whichever is longer If any emission related p...

Page 74: ...covered Any applicable emission related part not scheduled for required maintenance will be repaired or replaced within the warranty period The repaired or replaced part will be warranted for the rema...

Page 75: ...uretor complete assembly or replaceable components Choke Fuel Tank Fuel injection Assembly or replaceable components Fuel Cap Assembly Air Filter Fuel Feed Line and associated clamps connectors as app...

Page 76: ...15 Emission control warranty BTS 630 635 76 Operator s manual...

Page 77: ...s and requirements of the following guidelines and standards 2006 42 EG 2000 14 EG 2005 88 EG 2004 108 EG EN 55012 2007 Authorized person for technical documents Axel H ret Wacker Neuson Produktion Gm...

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