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Wacker Neuson BTS635s Operator's Manual
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Wacker Neuson BTS635s Operator's Manual

Wacker Neuson BTS635s Operator's Manual

Gasoline cut-off saw
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Operator's manual
Gasoline cut-off saw
BTS635s
BTS635s
5100011077
07.2022
06
en

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Summary of Contents for Wacker Neuson BTS635s

  • Page 1 Operator's manual Gasoline cut-off saw BTS635s Model BTS635s Document 5100011077 Issue 07.2022 Version Language...
  • Page 2 Any breach of the statutory regulations, in particular the protection of copyright, will lead to civil and criminal prosecution. Wacker Neuson Produktion GmbH & Co. KG is constantly working on the improvement of its products as part of the technical further development. Therefore, we reserve the right to make changes to the illustrations and descriptions in this documentation without incurring any obligation to make changes to machines already delivered.
  • Page 3 Inhaltsverzeichnis Preface ............................4 Introduction ..........................5 Means of representation for this operator's manual ..............5 Wacker Neuson representative ....................5 Described machine types ......................5 Identification of the machine ......................6 Safety ............................7 Principle ............................7 Qualification of the operating personnel ..................9 Protective gear..........................
  • Page 4 This operator's manual contains important information and procedures for the safe, proper and economic operation of this Wacker Neuson machine. Carefully reading, understanding and observing is an aid to avoiding hazards, repair costs and downtime, and therefore to increasing the availability and service life of the machine.
  • Page 5 This symbol is used for lists.  Wacker Neuson representative Depending on your country, your Wacker Neuson representative is your Wacker Neuson service, your Wacker Neuson affiliate or your Wacker Neuson dealer. You can find the addresses in the Internet at www.wackerneuson.com.
  • Page 6 2 Introduction Identification of the machine Nameplate data The nameplate lists information that uniquely identifies your machine. This information is needed to order spare parts and when requesting additional technical information.  Enter the information of your machine into the following table: Designation Your information Group and model...
  • Page 7 It is no problem to install spare parts from Wacker Neuson. It is no problem to install accessories that are available in the Wacker Neuson product range of your machine. Please refer to the installation regulations in this operator's manual.
  • Page 8 Have damaged or defective components replaced immediately! For further information, refer to chapter Troubleshooting. Spare parts, accessories Use only spare parts from Wacker Neuson or such that are equivalent to the original parts in design and quality. Only use accessories from Wacker Neuson.
  • Page 9 3 Safety Operator's controls Always keep the operator's controls of the machine dry, clean and free of oil or grease. Operating elements such as ON/OFF switch, throttle levers etc. may not be locked, manipulated or changed without authorization. Checking for signs of damage Inspect the machine when it is switched off for any signs of damage at least once per work shift.
  • Page 10 Emptying the tank Wacker Neuson recommends that the fuel tank be emptied and the carburetor run dry prior to transporting it. Fuel could run out, e.g. if the machine is tilted. Observe the national safety guidelines and the hazardous materials regulations that apply to the respective means of transportation.
  • Page 11 3 Safety Restarting Machines, machine parts, accessories or tools that were detached for transport purposes must be re- mounted and fastened before restarting. Only operate in accordance with the operating instructions. Operating safety Explosible environment Never operate the machine in a potentially explosive environment. Work environment Familiarize yourself with your work environment before you start work.
  • Page 12 3 Safety No persons endangered Be sure that no persons are endangered by flying or falling materials. Always work very attentively, and anticipate potential hazards. Switching off the machine Switch off the engine in the following situations: Before breaks.  If you are not using the machine.
  • Page 13 3 Safety Dangers during operation Combustion engines can be dangerous, particularly during operation and when refueling. Read and follow all safety instructions. Otherwise there is a risk of personal injury and/or damage to property! Do not start the engine near spilt fuel or if you smell fuel – this may cause an explosion! Remove the machine from such areas.
  • Page 14 3 Safety Health hazard due to exhaust fumes Warning The engine's exhaust fumes contain chemicals which are known to the State of California to cause cancer, congenital defects or other reproductive anomalies. Do not use any starter sprays Highly flammable starter sprays pose a fire hazard. Do not use any starter sprays.
  • Page 15 3 Safety Preventing pinching Prevent the cut from becoming constricted and pinching the cutting blade during the cutting process. Support the material such that the cut remains open and does not become constricted during the entire cutting process. Notes regarding cutting blades The cutting blade must be suitable for use with the cut-off saw.
  • Page 16 3 Safety Wet cutting Use a water sprayer when dust formation is excessive, e.g. when cutting concrete or stone. Only use cutting blades that are suitable for wet cutting. Whenever feasible use water when working with superabrasive wheels. Do not use water with bonded abrasive blade unless otherwise specified by the blade manufacturer. Before ending the wet cutting process, allow the cutting blade to run without the water sprayer until it is dry.
  • Page 17 Maintenance work Service and maintenance work must only be carried out to the extent described in these operating instructions. All other procedures must be performed by your Wacker Neuson representative. For further information, refer to chapter Maintenance. Switching off the engine Before carrying out care or maintenance work, switch off the engine and allow it to cool down.
  • Page 18 3 Safety 3.10 Safety devices WARNING Danger of injury due to open moving parts.  Only operate the machine with properly installed and functioning safety de- vices.  Do not modify or remove safety devices. Item Designation Protective hood Protective hood Never operate the machine without a protective hood.
  • Page 19 4 Safety and information labels Safety and information labels Your machine has adhesive labels containing the most important instructions and safety information. Make 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...
  • Page 20 4 Safety and information labels Item Label Description Before operation, read and follow the in- formation in the operator's manual. Smoking and open flames are prohibited. Danger of fire. Maximum spindle speed.  Maximum peripheral speed.  The speed allowed for the cutting blade must be the same as or higher than the maximum machine spindle speed.
  • Page 21 4 Safety and information labels Safety and information icons Item Symbol Description Choke. Start. Stop. 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. Mark for setting the V-belt tension. Machine's direction of rotation.
  • Page 22 5 Scope of delivery Scope of delivery Item Designation Item Designation Machine 6 mm Allen wrench Operator's manual Combination wrench 13/19 mm Parts book Blade Collar 20 mm 5 mm Allen wrench 100_0303_sd_0001.fm...
  • Page 23 6 Structure and function Structure and function Application Use the machine only as intended, see chapter Safety, Proper use. Functionality 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 machine has an electronic ignition system that is maintenance-free.
  • Page 24 7 Components and operator's controls Components and operator's controls Item Designation Item Designation Front handle Fuel tank Water supply Recoil starter Multifunction switch Cutting blade Throttle lever lock Protective hood Rear handle Decompression valve Throttle lever Fuel pump Lock button Water supply You can connect a water supply unit to the water supply connection.
  • Page 25 7 Components and operator's controls Multifunction switch You can switch the machine on and off with the multifunction switch. The multifunction switch has a choke setting for cold starts. Throttle lever lock Unintentional pressing of the throttle lever is prevented by the throttle lever lock. You can only press the throttle lever if you are pressing the throttle lever lock at the same time.
  • Page 26 8 Transport Transport WARNING Improper handling can result in injury or serious material damage.  Read and follow all safety information of this operator's manual, see chapter Safety. WARNING Hazard of fire and explosions by fuel. Any fuel that escapes can ignite and cause severe burns. ...
  • Page 27 9 Initial start up Initial start up WARNING Improper handling can result in injury or serious material damage.  Read and follow all safety information of this operator's manual, see chapter Safety. Mounting the cutting attachment on the outside By default the cutting attachment is mounted in the center of the machine. The cutting attachment can be mounted on the outside to maneuver around obstacles that are very close to the cutting line (e.g.
  • Page 28 9 Initial start up Converting the protective hood Item Designation Hose connection (2 pieces) Vibration dampers 1. Unscrew both hose connections and remove them. 2. Rotate the protective hood clockwise as far as it will go. 3. Unscrew and remove the vibration dampers. Item Designation Adjustment handle...
  • Page 29 9 Initial start up Slackening the V-belt Item Designation Item Designation Screw (2 pieces) Belt guard Adjusting screw 1. Loosen both belt guard screws by approximately one turn. 2. Rotate the adjusting screw counter-clockwise until the V-belt is slackened com- pletely.
  • Page 30 9 Initial start up Mounting the cutting attachment on the outside 1. Remove the cutting attachment. 2. Clean the cutting attachment, V-belt pulley, belt guard and screws. 3. Rotate the cutting attachment 180° and place it in position. 4. Place the V-belt in position. Item Designation Item...
  • Page 31 10 Use and operation Use and operation WARNING Improper handling can result in injury or serious material damage.  Read and follow all safety information of this operator's manual, see chapter Safety. 10.1 Prior to starting the machine 10.1.1 Checks before startup Checking the machine Always check the following points before beginning work: Damage to the machine and to all components.
  • Page 32 10 Use and operation Changing the cutting blade Item Designation Item Designation Bore Thrust washer Spindle Screw Cutting blade 1. To block the shaft, put an Allen wrench into the bore. Note: If necessary, rotate the spindle until the Allen wrench engages in the bore. 2.
  • Page 33 10 Use and operation 10.2 Starting up 10.2.1 Starting the engine Performing preparations Item Designation Item Designation Multifunction lever Fuel pump Decompression valve 1. Set down the machine such that the cutting blade can rotate freely. 2. Set the multifunction lever to the appropriate position. Cold engine: Position "choke".
  • Page 34 10 Use and operation Bringing the throttle lever into the start position Item Designation Item Designation Throttle lever lock Lock button Throttle lever 1. Press and hold the throttle lever lock and the throttle lever. 2. Press the lock button. 3.
  • Page 35 10 Use and operation Starting the engine NOTICE Improper handling can damage the machine.  Do not pull the starter rope as far as it can go.  Let starter rope slowly roll back in. CAUTION Incorrect handling during starting can result in minor injuries. ...
  • Page 36 10 Use and operation 10.3 Operating the machine Note: Hold and lightly press for properly functioning anti-vibration cushion and a particularly narrow cut. Holding and guiding the machine WARNING Injuries from insufficiently guided or uncontrolled machine.  Always hold machine with both hands and stand firmly. 1.
  • Page 37 10 Use and operation 10.4 Decommissioning Switching off the machine Item Designation Multifunction switch Throttle lever 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.
  • Page 38 Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/ service center authorized by Wacker Neuson. The use of 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 warranty claim.
  • Page 39 11 Maintenance 11.2 Maintenance schedule Task Daily be- Daily after Every Every fore oper- operation 50 hours 90 hours ation or every or once a year months Check fuel system for: Fuel tank fill level.   Leaks in fuel tank and fuel ...
  • Page 40 11 Maintenance 11.3.2 Topping up with fuel WARNING Hazard of fire and explosions by fuel and fuel vapors.  Do not smoke.  Do not refuel near open flames.  Turn off the engine before refueling and allow it to cool down. ...
  • Page 41 11 Maintenance 11.3.3 Tightening the V-belt Performing preparations 1. Switch off the engine. Tightening the V-belt Item Designation Item Designation Screw (2 pieces) Square nut Adjusting screw 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.
  • Page 42 11 Maintenance 11.3.4 Checking the thrust washers Item Designation Thrust washer (2 pieces) Cutting blade 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. 100_0303_mt_0001.fm...
  • Page 43 11 Maintenance 11.3.5 Cleaning/Changing the air cleaner NOTICE Operating the engine without air cleaner can cause rapid engine wear.  Do not run the engine without an air cleaner or air cleaner cap. Item Designation Item Designation Air cleaner cap Air cleaner cover Prefilter Air cleaner cartridge...
  • Page 44 11 Maintenance Changing the air cleaner cartridge NOTICE Dirt can fall into the engine combustion chamber and damage the engine.  Before changing the air cleaner, clean the machine thoroughly. 1. Unscrew and remove the air cleaner cover. 2. Remove the air cleaner cartridge. 3.
  • Page 45 11 Maintenance 11.3.6 Checking/cleaning/replacing the spark plug CAUTION Touching a hot spark plug can cause burns.  Only remove the spark plug when the engine has cooled down. Performing preparations 1. Switch off the engine. 2. Let the machine cool off. Removing the spark plug Item Designation...
  • Page 46 11 Maintenance Checking/cleaning the spark plug Item Designation Spark plug air gap Isolator 1. Check the isolator – if damaged, replace the spark plug. 2. Clean the electrodes with a wire brush. 3. Measure the spark plug gap with a feeler gauge – if necessary, correct it by bending the lateral electrode.
  • Page 47 11 Maintenance 11.3.7 Replacing the V-belt Performing preparations 1. Switch off the engine. 2. Let the machine cool off. Removing the covers Item Designation Item Designation Screw (2 pieces) Screw (3 pieces) Adjusting screw Clutch cover Belt guard 1. Rotate the adjusting screw counter-clockwise until the V-belt is slackened com- pletely.
  • Page 48 11 Maintenance Replacing the V-belt Item Designation Cutting attachment 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. 100_0303_mt_0001.fm...
  • Page 49 11 Maintenance Attaching the covers Item Designation Item Designation Screw (2 pieces) Screw (3 pieces) Adjusting screw Clutch cover Belt guard 1. Place the clutch cover in position and tighten it with screws. 2. Place the belt guard in position and affix it with screws. 3.
  • Page 50 11 Maintenance 11.3.8 Replacing the fuel filter Note: The fuel filter is located in the tank. The fuel filter cannot be cleaned. Performing preparations 1. Switch off the engine. 2. Let the machine cool off. 3. Empty the tank. Replacing the fuel filter Item Designation Item...
  • Page 51 If the engine shuts off in idle, turn the adjusting screw a bit clockwise. Note: If the cutting blade still rotates after setting the idle speed, have it repaired by your Wacker Neuson representative. 100_0303_mt_0001.fm...
  • Page 52 11 Maintenance 11.3.10 Cleaning the exhaust port CAUTION Improper handling can severely damage the machine.  Do not use hard or metallic tools for cleaning.  Make sure that no combustion residue enters the cylinder. Item Description Item Description Seal Screw (4 pieces) Muffler 1.
  • Page 53 12 Troubleshooting 12 Troubleshooting Potential faults, their causes and remedies can be found in the following table. Notify your Wacker Neuson representative in case of malfunctions you cannot or may not remedy yourself. Malfunction Cause Remedy Engine does not start.
  • Page 54 13 Accessories 13 Accessories There is a wide range of accessories available for the machine. For more information on the individual accessories, visit the following website: www.wackerneuson.com. 100_0000_0008.fm...
  • Page 55 14 Storage 14 Storage If the machine will not be operated for a while, e.g. during the winter, do the following: Performing preparations 1. Switch off the engine. 2. Detach the cutting blade and store in a dry place. 3. Let the machine cool off. Emptying the fuel system The gasoline in the fuel partially evaporates during long-term storage.
  • Page 56 15 Technical data 15 Technical data 15.1 BTS 635s Designation Unit BTS 635s Item no. 5100005408 Soft Start  Length mm (ft) 825 (2.7) Width mm (ft) 315 (1.0) Height mm (ft) 420 (1.4) Weight (without cutting kg (lb) 11,6 (25.6) blade or accessories, tank empty) Min.
  • Page 57 15 Technical data Designation Unit BTS 635s Fuel consumption (gal/h) (0.6) Fuel mixture ratio 1:50 Tank capacity l (gal) 1,1 (0.3) Oil specification ISO L-EGD Rated output Rated speed 9,300 Speed run-dry 2,800 Type of spark plug NGK BPMR-7A Spark plug air gap mm (in) 0,6 (0.24) Speed (max.
  • Page 58 15 Technical data 15.2 Fuel mixture table Note: Only use fuel in a mixture ratio of 1:50. Gasoline volume in Oil volume in liters liters (qt) (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 (0.32) 20 (21.13) 0,4 (0.42)
  • Page 59 EU Declaration of Conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Wackerstraße 6, D-85084 Reichertshofen This declaration of conformity is issued under the sole responsibility of the manufacturer. Product BTS635 Product type Gasoline cut-off saw Function of product Cutting materials...
  • Page 60 UK Declaration of Conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Wackerstraße 6, 85084 Reichertshofen (DE) This declaration of conformity is issued under the sole responsibility of the manufacturer. Product BTS635 Product type Cut-off saw Function of product Cutting materials...

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