Wacker Neuson BTS 630 Operator's Manual
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Wacker Neuson BTS 630 Operator's Manual

Gasoline cut-off saw
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Operator's manual
Gasoline cut-off saw
BTS
630, 635, 635s
12.2011
0217780en / 006

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Summary of Contents for Wacker Neuson BTS 630

  • Page 1 Operator's manual Gasoline cut-off saw 630, 635, 635s 12.2011 0217780en / 006...
  • Page 2 Manufacturer Wacker Neuson Produktion GmbH & Co. KG Preußenstraße 41 80809 München 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: Table Of Contents

    BTS 630, 635 Foreword ........................5 Introduction ....................... 6 2.1 Means of representation for this operator's manual ........... 6 2.2 Wacker Neuson representative ................7 2.3 Described machine types ................... 7 2.4 Identification of the machine................8 Safety ......................... 9 3.1 Principle......................
  • Page 4 10.3.11Cleaning the exhaust port ..............65 Troubleshooting ...................... 67 Accessories ......................68 Storage ........................69 Technical data ......................70 14.1 BTS 630, 635, 635s..................70 14.2 Fuel mixture table ..................... 72 Emission control warranty ..................73 EC Declaration of Conformity ................77 Operator's manual...

  • Page 5: Foreword

    Foreword This operator's manual contains information and procedures for the safe opera- tion and maintenance of your Wacker Neuson machine. In the interest of your own safety and to prevent accidents, you should carefully read through the safety information, familiarize yourself with it and observe it at all times.

  • Page 6: Introduction

    2 Introduction Introduction Means of representation for this operator's manual Warning symbols This operator's manual contains safety information of the categories: DANGER, WARNING, CAUTION, NOTICE. They should be followed to prevent danger to life and limb of the operator or dam- age to equipment and exclude improper service.

  • Page 7: Wacker Neuson Representative

    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 8: Identification Of The Machine

    2 Introduction Identification of the machine Nameplate data The nameplate lists information that uniquely identifies your machine. This infor- mation is needed to order spare parts and when requesting additional technical information. Enter the information of your machine into the following table: Item Designation Your information...

  • Page 9: Safety

    BTS 630, 635 3 Safety Safety Principle State of the art This machine has been constructed with state-of-the-art technology according to the recognized rules of safety. Nevertheless, when used improperly, dangers to the life and limb of the operator or to third persons or damage to the machine or other materials cannot be excluded.
  • Page 10 Installation of accessories which are not from Wacker Neuson. 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 11 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 12: Qualification Of The Operating Personnel

    3 Safety BTS 630, 635 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.

  • Page 13: Protective Gear

    BTS 630, 635 3 Safety Work recommendations Please observe the recommendations below: Work only if you are in a good physical condition. Work attentively, particularly as you finish. Do not operate the machine when you are tired. Carry out all work calmly, circumspectly and carefully.

  • Page 14: Transport

    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 15: Operating Safety

    BTS 630, 635 3 Safety Transporting the machine Secure the machine on the transport device against tilting, falling or slipping. Restarting Machines, machine parts, accessories or tools that were detached for transport purposes must be re-mounted and fastened before restarting.
  • Page 16 3 Safety BTS 630, 635 Starting the machine Observe the safety information and warning notices located on the machine and in the operator's manual. Never attempt to start a machine that requires maintenance or repairs. Start the machine as described in the operator's manual.

  • Page 17: Safety During The Operation Of Hand Machines

    BTS 630, 635 3 Safety Storage location After operation, allow the machine to cool and then store it in a sealed-off, clean and dry location protected against frost and inaccessible to children. Vibrations When manually operated machines are intensively used, long-term damage caused by vibrations cannot be precluded.
  • Page 18 3 Safety BTS 630, 635 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 19 BTS 630, 635 3 Safety Operation in closed rooms In closed or partially closed rooms such as tunnels, drifts or deep trenches, ensure sufficient ventilation by, for example, providing a powerful exhaust air fan. Danger of poisoning! Do not inhale exhaust fumes. They contain toxic carbon monoxide that can lead to unconsciousness or death.

  • Page 20: Safety During Cut-Off Saw Operation

    3 Safety BTS 630, 635 Safety during cut-off saw operation Kickback If the upper quarter of the cutting blade is applied to a material, the machine can be flung back toward the operator with great force. The machine and the rotating cutting blade can cause severe injury.
  • Page 21 BTS 630, 635 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.
  • Page 22 3 Safety BTS 630, 635 Belt guard Never operate the machine without a belt guard! Exposed V-belts and belt pulleys are dangerous and can cause serious injuries if they pull in any part of your body or if parts are ejected.
  • Page 23 BTS 630, 635 3 Safety Do not stand in the machine's swing area Hold and guide the machine such that no body parts are in the machine's swing area. Securing the material Before cutting, secure the material so that it does not slide away or tip over. Do not ever secure the material with your foot.

  • Page 24: Maintenance

    Dispose of replaced or spilled operating fluids according to the applicable regulations for environmental protection. If operating fluids escape from the machine, cease operation of the machine and have it repaired immediately by your Wacker Neuson representative. Operator's manual...

  • Page 25: Safety And Information Labels

    BTS 630, 635 3 Safety 3.10 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.
  • Page 26 3 Safety BTS 630, 635 Item Label Description Wear personal protective gear to avoid injuries or health hazards: Hard hat. Ear protection. Eye protection. Breathing protection. Face protection. Work gloves made of durable material. Overalls made of durable material. Non-skid, hard-toed shoes.
  • Page 27 BTS 630, 635 3 Safety Item Label Description Danger of kickback. Machine kickback can cause severe injury. Do not use the upper quarter of the cutting blade to cut. Cutting blades can break, causing severe injuries. Only use undamaged cutting blades.

  • Page 28: Safety And Information Icons

    3 Safety BTS 630, 635 3.11 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.

  • Page 29: Safety Devices

    BTS 630, 635 3 Safety 3.12 Safety devices WARNING Danger of injury due to open moving parts. Only operate the machine with properly installed and functioning safety devices. Do not modify or remove safety devices. Item Designation Protective hood Protective hood Never operate the machine without a protective hood.

  • Page 30: Scope Of Delivery

    4 Scope of delivery BTS 630, 635 Scope of delivery Item Designation Item Designation Machine 5 mm Allen wrench Operator's manual 6 mm Allen wrench Parts book Combination wrench 13/19 mm Operator's manual...

  • Page 31: Structure And Function

    BTS 630, 635 5 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.

  • Page 32: Components And Operator's Controls

    6 Components and operator's controls BTS 630, 635 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...
  • Page 33 BTS 630, 635 6 Components and operator's controls Water supply You can connect a water supply unit to the water supply connection. The water supply performs the following functions: Cools the cutting blade evenly. Causes dust particles to stick together.
  • Page 34 6 Components and operator's controls BTS 630, 635 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 entering the carburetor as a result of excessive pumping.

  • Page 35: Transport

    BTS 630, 635 7 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 36: Initial Start Up

    8 Initial start up BTS 630, 635 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.
  • Page 37 BTS 630, 635 8 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.
  • Page 38 8 Initial start up BTS 630, 635 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 completely.
  • Page 39 BTS 630, 635 8 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.
  • Page 40 8 Initial start up BTS 630, 635 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 necessary. Operator's manual...

  • Page 41: Use And Operation

    BTS 630, 635 9 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. Prior to starting the machine 9.1.1...
  • Page 42 9 Use and operation BTS 630, 635 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.

  • Page 43: Starting Up

    BTS 630, 635 9 Use and operation Starting up 9.2.1 Starting the engine Performing preparations Item Designation 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.
  • Page 44 9 Use and operation BTS 630, 635 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.
  • Page 45 BTS 630, 635 9 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 46 9 Use and operation BTS 630, 635 4. Pull the starter rope with force, but not suddenly. When you first hear the engine ignite, move the multifunction switch from the "Choke" position to the "I" position. If necessary, actuate the decompression valve once again.

  • Page 47: Operating The Machine

    BTS 630, 635 9 Use and operation Operating the machine Note: When cutting, lightly pressing the cutting blade against the cutting material produces a very pleasant vibration response as well as a particularly narrow cut. Holding and guiding the machine WARNING Injuries from insufficiently guided or uncontrolled machine.

  • Page 48: Decommissioning

    9 Use and operation BTS 630, 635 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".

  • Page 49: Maintenance

    BTS 630, 635 10 Maintenance 10 Maintenance 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 poisoning by exhaust fumes. Exhaust fumes contain toxic carbon monoxide that can lead to unconsciousness or death.

  • Page 50: Maintenance Schedule

    10 Maintenance BTS 630, 635 10.2 Maintenance schedule Task Daily Daily after Every Every before operation 50 hours 90 hours operation or every or once a year months Check fuel system for: Fuel tank fill level. Leaks in fuel tank and fuel cap.

  • Page 51: Maintenance Work

    * In case of loss in engine performance, shorten maintenance intervals. Note: For EPA machines (in the USA and Canada), have the exhaust port of the machine cleaned by the service team of your Wacker Neuson contact every 90 h.
  • Page 52 10 Maintenance BTS 630, 635 Topping up with fuel Item Designation Fuel cap 1. Slowly unscrew and 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.

  • Page 53: Tightening The V-Belt

    BTS 630, 635 10 Maintenance 10.3.3 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.

  • Page 54: Checking The Thrust Washers

    10 Maintenance BTS 630, 635 10.3.4 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.

  • Page 55: Cleaning/Changing The Air Cleaner

    BTS 630, 635 10 Maintenance 10.3.5 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...
  • Page 56 10 Maintenance BTS 630, 635 Changing the prefilter 1. Remove the prefilter. 2. Clean the air cleaner cover and the entire air cleaner housing with a brush and a clean cloth. Note: Use a vacuum cleaner to remove the dirt from the air cleaner housing.

  • Page 57: Checking/Cleaning/Replacing The Spark Plug

    BTS 630, 635 10 Maintenance 10.3.6 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.
  • Page 58 10 Maintenance BTS 630, 635 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 59: Replacing The V-Belt

    BTS 630, 635 10 Maintenance 10.3.7 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.
  • Page 60 10 Maintenance BTS 630, 635 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.
  • Page 61 BTS 630, 635 10 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.

  • Page 62: Replacing The Fuel Filter

    10 Maintenance BTS 630, 635 10.3.8 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.

  • Page 63: Setting The Idle Speed

    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. Operator's manual...

  • Page 64: 10Cleaning The Spark Arrestor

    10 Maintenance BTS 630, 635 10.3.10 Cleaning the spark arrestor Note: Only EPA machines (in the USA and Canada) have a spark arrestor. Item Description Item Description Muffler Guide plate Spark arrestor grid Screw (2 pieces) Cleaning the spark arrestor 1.

  • Page 65: 11Cleaning The Exhaust Port

    10 Maintenance 10.3.11 Cleaning the exhaust port Note: For EPA machines (in the USA and Canada), have the exhaust port of the machine cleaned by the service team of your Wacker Neuson representative every 90 h. CAUTION Improper handling can severely damage the machine.
  • Page 66 10 Maintenance BTS 630, 635 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 outside. Operator's manual...

  • Page 67: Troubleshooting

    1. Set multifunction switch to multifunction switch is "Choke". The engine will defective. switch off after a few seconds. 2. Have the machine repaired. * * Have these tasks carried out by the service department of your Wacker Neuson representative. Operator's manual...

  • Page 68: Accessories

    12 Accessories BTS 630, 635 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.wackerneuson.com. Operator's manual...

  • Page 69: Storage

    BTS 630, 635 13 Storage 13 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.

  • Page 70: Technical Data

    14 Technical data BTS 630, 635 14 Technical data 14.1 BTS 630, 635, 635s Machine Designation Unit BTS 630 BTS 635 BTS 635s Item no. 0610186, 0610190, 0610192, 0610187 0610191 0610193 Length x Width x Height mm (ft) 800 x 315 x 400...
  • Page 71 BTS 630, 635 14 Technical data Designation Unit BTS 630 BTS 635 BTS 635s Total vibration value of the 4.4 (14.4) 4.2 (13.8) 4.2 (13.8) acceleration a * at the (ft/s front handle Total vibration value of the 4.5 (14.8) 4.8 (15.7)

  • Page 72: Fuel Mixture Table

    14 Technical data BTS 630, 635 14.2 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)

  • Page 73: Emission Control Warranty

    30 days. If a warrantable condition exists and there is no Authorized Dealer within 100 miles, Wacker Neuson will pay to ship the unit to the nearest authorized Operator´s manual...
  • Page 74 How will a covered part be corrected? If there is a defect in a part covered by this warranty, any Wacker Neuson Autho- rized Service Dealer will correct the defect. You will not have to pay anything to have the part adjusted, repaired or replaced.
  • Page 75 BTS 630, 635 15 Emission control warranty Specific emission related warranted parts Electronic Ignition System Spark Plug Catalytic Converter / Muffler Assembly Carburetor (complete assembly or replaceable components) Choke Fuel Tank Fuel-injection Assembly (or replaceable components) Fuel Cap Assembly Air Filter...
  • Page 76 15 Emission control warranty BTS 630, 635 Operator´s manual...

  • Page 77: Ec Declaration Of Conformity

    EC Declaration of Conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München Product Product BTS 630 BTS 635s Product category Cut-off saw Product function Cutting materials Item number 0610186 0610192 Net installed power 4,3 kW 4,3 kW...

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