635 / 636 / 642 / 643IP

Instruction manual Chain saw

Important!
Read this instruction manual carefully before
first operation and strictly observe the safety
regulations!

9 636 111 english 0/2008

 Symbols
For USA only
Emissions Control Warranty Statement The following symbols are used in this manual and on
The Environmental Protection Agency and Solo are the product:
pleased to explain the emission control system on your Thoroughly read these operating instructions
small non-road power equipment engine. In the US before undertaking any maintenance,
new small non- road engines must be designed, built, installation and cleaning steps
and equipped to meet the Environmental Protection
Agency's standards. Solo must warrant the emission Before starting the engine, make sure that you
control system on your small non- road engine for the are wearing a helmet, ear defenders and face
period of time listed below provided there has been no protection.
abuse, neglect, or improper maintenance of your small
non-road engine. Switching off the engine
Your emission control system includes parts such as
the carburetor, the ignition system, and the exhaust
Choke flap:
system.
Cold start position ! pull the lever out
Where a warrantable condition exists, Solo will repair Operation and warm start ! press the lever in
your small non-road power equipment engine at no cost
to you including diagnosis, parts, and labor. Chain lubrication: symbol above the chain
Manufacturers Warranty Coverage lubrication tank cap
Solo's small non-road power equipment engines are
Fuel mixture: symbol above the fuel mixture
warranted for a period of two years. If any emission
tank cap
control related part on your engine is defective, the part
will be repaired or replaced by Solo. Danger! Failure to comply with the
Contact Information for Authorized Service Center instructions could cause accidents with
Locations, Replacement Parts, potentially life-threatening injuries.
Warranty and Technical Information
Always wear protective gloves when working
Warranty repairs must be completed by a SOLO
Authorized Service Center. with or on the device.
SOLO USA, Inc. 1-800-765-6462
5100 Chestnut Avenu techserv@solousa.com Always wear safety shoes with non-slip soles.
Newport News, VA 23605
Chain brake: To block the chain, press the
lever forwards towards the guide bar.
Preface
Dear Customer, To release the chain again, pull the lever back
towards the front handle.
Congratulations for choosing this SOLO quality
product.
Caution: Risk of kickback.
The models in this series are particularly high-grade Please refer to the notes in chapter
chainsaws, made in Germany, that are specifically 9.“Hazards caused by kickback“
designed for the multi-faceted demands of the hobby
and leisure market. A high-grade single cylinder two- Never smoke near the power tool or where
stroke engine with nickel-aluminium-silicon coated the equipment is refuelled!
cylinder, designed according to the proven four channel
technology for high performance and low fuel Keep open flames away from the power tool
consumption, guarantees you a high level of and the fuel can
serviceability from your machine.
- This equipment produces exhaust fumes
The automatic chain lubrication system (Ecomatic),
and
the maintenance-free electronic ignition, the Anti-
- fuel vapours are poisonous;
Vibration-System for protection at work, the excellent
never start or refuel in enclosed spaces
starting characteristics and the ergonomic design of the
entire machine ensure excellent user comfort and it Packaging and disposal
makes light of your work. The safety equipment is state-
Please keep the original packaging in order to protect
of-the-art and complies with all German and
the equipment against transport damage in case you
international safety regulations.
ever need to ship it or transport it. If the packaging
Prior to operating the unit, please read the owner’s materials are no longer required then they must be
manual carefully, and most importantly, observe all disposed of properly in accordance with applicable local
safety rules. regulations. Cardboard packaging materials are raw
Observe the maintenance guidelines closely to materials which can be recycled or reused.
ensure the long service life of your equipment. At the end of the equipment’s service life, please make
Your dealer will be glad to assist you with any sure that you dispose of it properly, in accordance with
questions. the official directives and regulations that apply in your
area.

ENGLISH 2
 Index
Page
1. Safety regulations.....................................................................................................................................4
1.1 Correct use / General safety instructions 4
1.2 Working clothes 4
1.3 Fuelling 5
1.4 When transporting the equipment 5
1.5 Notes on assembly, cleaning, adjustment, maintenance and repairs 5
1.6 Before starting the tool 5
1.7 Starting the tool 6
1.8 When working with the saw 6
2. Specification .............................................................................................................................................7
3. Standard delivery......................................................................................................................................8
4. Designation of important controls and functional parts.......................................................................8
5. Preparing the equipment for use...........................................................................................................10
5.1 Assembly of the guide bar and chain 10
5.2 Adjusting the chain tension 10
6. Refuelling and adding oil to the chain lubrication system .................................................................11
6.1 Fuel information 11
6.2 Mixing ratio 11
6.3 Fuelling 11
6.4 Chain lubrication 11
7. Chain brake .............................................................................................................................................12
8. Starting / Stopping the engine...............................................................................................................12
8.1 Start-up settings 12
8.2 Starting up 13
8.3 Engine will not start: 13
8.4 Switching the engine off:: 13
9. Hazards caused by kickback .................................................................................................................14
10. Using the chainsaw ..............................................................................................................................15
10.1 Application areas 15
10.2 Sawing 15
11. Operating and maintenance information............................................................................................17
11.1 Maintenance and care of the cutting gear 17
11.2 Air Filter Maintenance 18
11.3 Carburettor settings 19
11.4 Maintenance of the chain brake 19
11.5 Vibration damping 19
11.6 Spark plug information 20
11.7 Shutdown and storage 20
11.8 Replacing the fuel filter 20
11.9 Self-help tips 20
11.10 Scheduled maintenance 21
12. Accessories...........................................................................................................................................21
13. Parts subject to wear and tear.............................................................................................................25
14. Guarantee ..............................................................................................................................................25
15. CE Declaration of conformity ..............................................................................................................25
* Permissible cutting gear.........................refer to the last two inside pages of this operating manual
(after the Dutch section)

Information regarding these operating instructions:

Some of the graphic depictions in these operating instructions are schematic illustrations which are not designed to
accurately reflect your specific chainsaw. However, the content is binding in every case.

ENGLISH 3
Safety regulations

1. Safety regulations
1.1 Correct use / General safety instructions
The chainsaw must only be used to cut wood and objects made of wood. The chainsaw must not be used for any
other purposes (chapter 10.1 "Application areas").
Before you start using the saw for the first time, please take the time to carefully read through these
operating instructions, and make sure you keep them in a safe place. At all times the instructions must be
kept available at the place where the saw is being used. The instructions must be read by anybody who works with or
on the device (including for maintenance, care and repairs).
Take special care when using this power tool. By handling the power tool recklessly or without the necessary care
and attention you can put yourself in grave danger. Always work with the utmost care and constantly remind yourself
of the potential dangers and hazards that could occur. Never undertake any work you are not fully comfortable with or
if you are not in a position to fully assess the risks involved. If you are still unsure after reading these operating
instructions, please consult a specialist or enrol in a training course for safe handling and use of the power tool (e.g.
at a specialist forestry training centre).
If you ignore these safety instructions you could be putting your life at risk. Please also make sure that you comply
with all of the health and safety requirements of the professional trade associations.
• When operating in highly flammable vegetation and in areas affected by drought, keep a fire extinguisher handy
(risk of fire).
• You should request and receive instructions from the vendor on the safe operation if you are using this type of
product for the first time.
• Children and young people under 18 years may not work with this power tool, with the exception of young people
over 16 years of age who are being trained under supervision.
• The power tool can be operated easily - even on start-up - by one person. Keep bystanders and animals away
from the working area. When working near thickets, be aware that children and animals may be hidden there.
Immediately stop the machine and the cutter if any person or animal comes close to the working area. The
operator is responsible for any accidents or damage caused to parties or property.
• This machine may only be passed on or lent to third parties if they are familiar with the safe use of this product
and with these instructions. Always supply the manual with the machine.
• Ensure you are rested and in good health when using this machine.
• Persons under the influence of alcohol or drugs, including prescription drugs, are not allowed to use this
machine, as their ability to quickly react to potential danger may be impaired.
• Never alter, change or modify any safety equipment or functional assemblies on this machine.
• Only use this machine if it is in good, safe condition. Always check the machine prior to use. Risk of accident!
• Only use those accessories and attachments that have been supplied by the manufacturer and that are
expressly approved for attachment.
• The reliability and safe operation of your machine depend on the quality of parts used with the machine. Only use
original spare parts. Original spare parts are identical with genuine production parts and guarantee best quality in
material, dimensions, function and safety. Original parts and accessories are available from your specialist
dealer. Your dealer has been supplied with appropriate documentation to determine the correct parts. Your
dealer is frequently supplied with updates about improvements to the equipment. Please note that the use of
non-original parts will void your warranty.
• Always store the machine in a safe place and in such a way that it will not pose any danger. Stop the engine
when the machine is not used.
Persons who disregard safety instructions, operating or maintenance instructions may be liable for any damage or
consequential losses.

1.2 Working clothes

To prevent injuries, always wear suitable clothing and safety equipment when working with this power tool. This
clothing should be practically oriented to the application (for example a tight fitting work suit), but should not be
confining.
We recommend: SOLO forest and countryside work jacket EN 340 Part no: 99 303 000 + size (2[s] - 6[xxl])
SOLO Outdoor Knee-breeches Part no: 99 020 95 + size
or SOLO Outdoor dungarees Part no: 99 020 94 + size
Never wear scarves, ties, jewellery or other items of clothing, which might get caught in the equipment, in brush or on
branches. Safely tie back long hair (use a cap, helmet or similar).
Wear safety shoes with a good tread.
We recommend: SOLO leather forest boots Part no: 99 305 10 + size (36 - 48)
Wear protective gloves with non-slip palms.
We recommend: SOLO Forst Part no: 99 390 13 + size (09 / 10 / 12)
Use personal hearing protection and a face protector (e.g. a visor on a safety helmet). Always wear a safety
helmet when working in woods or forests. Falling branches pose a serious risk.
We recommend the SOLO safety helmet with face and hearing protection, order no.: 99 390 1101 (one size)

ENGLISH 4
 Safety regulations

1.3 Fuelling
Petrol is very light and highly flammable. Keep away from open flames and never spill fuel. Do not
smoke at the operating site or at and near the refuelling site!
• Stop the engine prior to refuelling.
• Let the engine cool down before refuelling - fire risk!
• Open the tank lid slowly to allow any excess pressure in the tank to be reduced without the risk of petrol spraying
out.
• Fuel may contain substances similar to solvents. Prevent products made from mineral oil coming into contact
with skin and eyes. Wear protective gloves during filling with fuel. Frequently change and clean protective
clothing.
• Avoid breathing in fuel vapour.
• The refuelling site should be well ventilated.
• Avoid any soil spillage of fuel or oil (protection of the environment). Use a suitable mat.
• Immediately clean any spilled fuel on the machine. Change contaminated clothing without delay.
• Always tighten the fuel tank cap firmly by hand without using any tools. The fuel tank cap must not be able to
work itself loose as a result of the vibrations of the engine.
• Check for petrol leaks. Do not start the machine or work with the machine if there is a petrol leak. Life threatening
risk from burns!
• Store fuel and oil in approved and correctly labelled containers.

1.4 When transporting the equipment

• When carrying the chainsaw for short distances (from one working area to the next), always apply the chain
brake so that the chainsaw is blocked (preferably switch the engine off as well).
• Never carry or transport the power tool while the cutting tool is running.
• When transporting the device over longer distances, always switch the engine off and attach the chain guard.
• To prevent leakage of fuel or oil and damage in general, make sure that the device is secured so that it cannot
fall over when it is transported in vehicles. Check the fuel and chain lubrication tanks for leaks. Ideally you should
drain the tanks prior to transport.
• Always empty the tanks before dispatching the unit.

1.5 Notes on assembly, cleaning, adjustment, maintenance and repairs

• The power tool must not be assembled, maintained, repaired or stored in the vicinity of naked flames.
• The engine must be switched off and the stop switch set to "0“ for the duration of all work performed on the guide
bar and saw chain (for assembly, cleaning, maintenance and repairs) (ideally the spark plug connector should be
unplugged as well). Always use protective gloves.
• The power tool requires regular maintenance. Only perform maintenance or repairs yourself if the relevant
operations are covered in the operating instructions. All other work should be performed by an authorised
specialist workshop.
• During maintenance of the silencer or when checking that the silencer is firmly positioned, never touch the
silencer if it is still hot – risk of burns! The silencer gives off extremely large amounts of heat.
• Only genuine replacement parts supplied by the manufacturer must be used for any repairs.
• No changes must be made to the power tool, as this could affect the safety of the device and increase the risk of
accident or injury.

1.6 Before starting the tool

Check the tool every time before starting it to make sure that the complete power tool is operationally safe. The
following points should be checked in addition to the points listed in the operating and maintenance instructions
(chapter 11):
• The stop switch must be easy to switch.
• The throttle control must move freely and return automatically to the idle position. If the throttle control is
operated while the choke lever is pressed in then this must cancel any part throttle stop that is set.
• The guide bar must be firmly secured. Always check that the chain has the correct tension and adjust the tension
if required before starting the tool.
• Also check that the ignition cable and spark plug connector are firmly in place. If there is a loose connection this
can result is sparks which could ignite any escaping fuel/air mixture – fire hazard!
If anything is not as it should be, signs of damage are evident, settings are incorrect or the functional integrity of the
unit is compromised, do not start up the power tool. Instead, have it checked by a specialist workshop.

ENGLISH 5
Safety regulations

1.7 Starting the tool

• When starting the tool, keep a minimum distance of 3 metres to where the tool was refuelled. Never start the
device in an enclosed room.
• Make sure that you have a secure footing on firm ground when starting the tool. Always check that the ground is
level and keep a safe hold of the power tool.
• Perform the start-up routine as described in chapter 8. "Starting the engine / stopping the engine".
• Once the unit has been started, check the idle setting. The cutting blade must be stationary during idling.
• Once it has warmed up, switch the engine off and recheck the chain tension and adjust as required.

1.8 When working with the saw

• The power tool must only be started up if it is fully assembled.
• Work on windfall must only be performed by trained persons.
As soon as the engine is running, it produces toxic exhaust gases which may be colourless and odourless.
Never start up the tool in enclosed spaces. Always make sure that there is sufficient air exchange if you are
working under restricted conditions, such as in a dip or a ditch.
Do not smoke at the place of work or in the close vicinity of the power tool, as this would be an increased fire
hazard.
• Work carefully, deliberately and calmly and do not endanger the safety of others.
- Make sure that visibility and lighting conditions are good.
- Stay within calling distance of others who could help in the event of an emergency.
- Take breaks in good time.
- Be aware of potential sources of danger and take appropriate precautionary measures. Remember that the use
of ear defenders makes it more difficult to hear other sounds. This may also mask sounds warning of imminent
danger or shouts of warning etc.
- Remember that freshly debarked wood is very slippery (bark). Also take care in the wet, when the ground is
slippery, on slopes on uneven terrain.
- Look out for obstacles and hazards that could trip you up, e.g. tree roots, tree stumps and edges. Take special
care when working on slopes. Never work while standing on unstable ground.
- Always hold the power tool firmly with both hands and make sure you have a secure footing on stable ground
at all times.
- Never use the saw above shoulder height and avoid leaning too far forward. Never use the saw while standing
on a ladder, and never climb the tree holding the saw. The only safe way to reach greater heights is to use a
hydraulic lifting cabin.
- Move the chainsaw in such a way that no part of your body would be in the way if the arc of movement of the
saw chain was extended.
- Never touch the ground with the chainsaw while it is running.
- Do not use the saw to prise off or scoop away pieces of wood or other objects.
- Longitudinal cuts should be made at as flat an angle as possible. Special care is required here, as the bumper
spikes cannot engage.
- Be careful when cutting wood which has splintered, as sawn off pieces of wood can be torn off and fly off at
high speeds (risk of injury).
• Switch the engine off if you notice any significant changes in the behaviour of the power tool.
• Never touch the silencer while it is hot – risk of burns. Never set down the hot power tool in dried grass or on
other flammable objects. The silencer gives off extremely large amounts of heat (fire hazard).
• Never work with a defective silencer or without a silencer. You risk damaging your hearing and burning yourself
on the device.

First Aid
A first aid box should always be available on-site. Immediately replace any materials you have used:
Note:
Over exposing persons with circulatory problems to vibrations can lead to damage to their nervous system or blood
vessels. The following systems may occur from vibrations to fingers, hands or the wrists: Numbness, itching, pain,
twinges, changes to the colour of the skin or the skin itself. Seek medical advice if you experience any of these
symptoms.

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 Specification

2. Specification

Chain saw 635 636 642 643IP

Engine type SOLO single cylinder two-stroke engine
3
Engine capacity cm 36,3 40,2
Bore / stroke mm 38 / 32 40 / 32
Max. power kW 1,4 1,5 1,8 2,0
1
at rpm /min 8.500 8.500 8.500 9.000
Max. torque Nm 1,8 1,8 2,1 2,5
at rpm / 1/min 7.000 7.000 6.500 6.200
1
Max. permissible speed /min 11.500 11.500 12.000 13.000
no load with cutter ± 200 ± 200 ± 200 ± 200
1
Medium idling speed /min 2.800± 150
1
Clutch engagement speed /min 4200± 150
Fuel tank capacity l 0,37
Fuel mix ratio: with SOLO 2T engine oil 1 : 50
with other two-stroke oils 1 : 25
Fuel consumption at max. power
kg
ISO 7293 /h 0,7 0,7 0,8 0,8
Specific consumption at max. power
g
ISO 7293 /kWh 500 490 470 410
Capacity of the chain lubrication oil tank l 0,19
Carburettor All-position diaphragm carburettor with primer and
integrated fuel pump
Air filter, two part Flow filter insert and large volume foam filter
Ignition Electronically controlled magneto ignition,
maintenance free
Sprocket teeth 6 7
In determining the following values regarding the acceleration of vibrations and sound, the different operating
conditions were weighted in accordance with the current standards
Sound pressure leve LPeq EN ISO 22868 dB(A) 100 100 101 101
Sound power level LWeq EN ISO 22868 dB(A) 105 105 107 107
Weighted effective acceleration ahv,eq DIN ISO 22867
Handle r.h. side / handle l.h. side m/s2 9,1 / 7,4 9,1 / 7,4 7,9 / 4,8 7,5 / 4,5
Dimensions Height/ Width/ Length
cutting length of the guide bar 35 cm (14’’) mm 250/ 220/ 720 ---
cutting length of the guide bar 38 cm (15’’) (643IP) mm --- 250/ 220/ 750
Weight without tank contents, guide bar and chain kg 4,2 4,2 4,1 4,1

Build year of the power tool ! refer to the type plate on the power tool (Chapter 4, " Designation of important
controls and functional parts ").
Permissible cutting gear and the corresponding cutting lengths ! refer to the last two inside pages of this operating
manual (after the Dutch section)

ENGLISH 7
Standard delivery ; Designation of important controls and functional parts

3. Standard delivery
• Chainsaw – basic unit (without guide bar and saw chain)
• Guide bar
• Saw chain
• Chain guard
• Tool: Combination tool (spark plug spanner with screwdriver), plus additional screwdriver
• These Operating Instructions

4. Designation of important controls and functional parts

Fig. 1a
(Depending on the version)
View: profile from the right

Fig. 1b
(Depending on the version)
View: profile from the left

ENGLISH 8
 Designation of important controls and functional parts

Fig. 1c 1. Chain
(Depending on the version)
2. Guide bar
View: rear
3. Hand protection

4*. Front handle

5. Cowl

6. Rear handle

7. Choke

8. Part throttle control pin

10. Throttle control lock

11. Throttle control

12. Retaining nuts for the rail cover

13a*. Chain tensioning bolt on the side

(636, 642, 643IP)

13b*. Chain tensioning bolt in front

(635)

14. Chain guard

15. Chain brake release spring

16. Hood fixing screw

17. Starter handle

Fig. 1d 18. Stop switch
(635)
19. Fuel tank cap
View: front-
20. Chain lubrication oil tank cap

21*. Primer (636, 642, 643IP only)

22*. Decompression valve (636, 642 only)

24. Idling stop screw T

25. Carburettor adjusting screws (H / L)

(for use by a specialist workshop only)

26a*. Bumper spikes metal (643IP)

26b*. Bumper spikes (635, 636, 642)

27. Exhaust
*
Depending on the version

Type plate:
Type designation
Serial number Build year (06 !2006).
.

ENGLISH 9
Preparing the equipment for use

5. Preparing the equipment for use • Ensure that the drive links grip correctly between the
teeth of the chain wheel and reversing wheel at the
tip of the guide bar.
5.1 Assembly of the guide bar and chain
• Fit the rail cover, but initially only tighten the retaining
nuts finger tight.
The chain brake must be released • After correctly adjusting the chain tension (refer to
when assembling the chain and adjusting the the next section), tighten the retaining nuts as
chain tension [pull back the hand protection (3) described below.
to the front handle (4)].
Fig. 2 5.2 Adjusting the chain tension
(643IP) • Loosen the retaining nuts on the rail cover (12), or if
you are assembling the chain, only tighten it finger-
tight.
• Place the rail tip on a suitable wooden support (e.g. a
tree stump) and press the guide bar upwards slightly
as a result.
• Use the chain tensioning bolt (13) to set the correct
chain tension. Turn the chain tensioning bolt
clockwise to increase the chain tension or anti-
clockwise to slacken the chain tension. The chain
has the correct tension if it makes full contact with
the guide bar but can still be lifted off the guide bar
by hand by around 2 - 4 mm.
*13a ! 636, 642, 643IP; *13b ! 635
• Undo the retaining nuts on the rail cover (12). Fig. 4
• Take off the rail cover (a).
• When setting up the tool for the first time, remove
the cardboard disc inserted at the factory as
transport protection underneath the rail cover before
installing the guide bar.
• On used saws, clean the rail contact surface and the
oil outlet.
• Use the chain tensioning bolt (13a / 13b) to move
the chain tensioning cam (b) to the left-hand end (schematic diagram)
stop. . • With the rail tip placed on a suitable surface and the
Note: Each time the guide bar is removed and guide bar pressed up slightly, tighten the retaining
installed, adjust the chain tension cam (b) up to the nuts with the enclosed combination tool. Then check
l.h. end stop. the chain tension again.
Fig. 3 Always check the chain tension before starting the
(643IP) device and adjust it as required. You should also check
the chain tension again and adjust it as required once
the power tool has warmed up and again intermittently
while working with the tool – but make sure the engine
is switched off first!
Important hint:
As the chain tightens again slightly when the device
cools off, slacken the chain tension a little once you
have finished work before putting the chainsaw into
storage.

• Position the guide bar; in the process, the chain

tensioning cam (b) must fully engage in the
designated hole in the guide bar.
Notes for new saw chains: Before installing a new chain
we recommend soaking it in a container (bowl) with
chain oil with anti-fling additives that help the oil adhere
to the chain.
• Fit the chain over the sprocket and into the guide
groove of the guide bar. The cutting elements of the
saw teeth must be on the upper side of the rail
facing towards the tip of the rail.

ENGLISH 10
 Refuelling and adding oil to the chain lubrication system

6. Refuelling and adding oil to the chain Place the machine with the fuel inlet pointing upwards.
lubrication system Unscrew the tank lid and fill the fuel mixture up to the
lower edge of the filler neck. Use a funnel with filter to
prevent tank contamination. After filling the tank replace
the tank lid and tighten firmly.
The tank caps for the fuel tank and the chain lubrication
oil tank are sealed by means of an O-ring. Both tank
6.4 Chain lubrication
closures should only be tightened finger-tight, without
the use of tools. Chainsaw oil with an anti-fling additive that helps
the oil adhere to the chain should be used for
Fig. 5 lubrication of the saw chain and guide bar.
Note: You should generally always add the chain oil
whenever topping up with fuel.
If the saw is used regularly we recommend the use of
biodegradable chainsaw oil.
The bio-chainsaw oil available from SOLO (order no. 00
83 107, 1 litre) has been awarded the German blue
angel symbol for eco friendliness (RAL UZ 48).
Biodegradable chainsaw oil only has a limited
lifespan and should be used within a period of 2
years from the printed date of manufacture.

Important: If you are planning to not use the saw for

6.1 Fuel information more than 2 months and are using bio-chainsaw oil then
you will need to drain the oil tank and then add a small
A high performance two-stroke engine operated quantity of engine oil (SAE 30). Then run the chainsaw
with a petrol:oil mixture (petrol + oil = fuel for a while to ensure that all bio-oil residue has been
mixture) or with a special fuel mixture for two-stroke flushed out from the tank, oil pickup hose and cutting
engines available from specialists powers this machine. device. Fill up with bio-chainsaw oil again when you are
The fuel mixture can be made up with standard lead- ready to take the saw back into operation again.
free petrol or with lead-free premium grade petrol. The
minimum octane rating for petrol is 92 ROZ. Fig. 6
Unsuitable petrol or deviations in the mixing ratio may
lead to serious engine damage!
Avoid direct skin contact with petrol and avoid
inhaling petrol fumes - health hazard!

6.2 Mixing ratio

Always use a fuel:oil ratio of 25:1 (4%) for the first five
tank fillings.
After that we recommend a ratio of 50:1 (2%) with the
use of special two-stroke oil "SOLO 2T engine oil"
which we can supply.
With the use of other brand two-stroke oils we (schematic diagram)
recommend a ratio of 25:1 (4%).
To check the chain lubrication, hold the guide bar above
Never store fuel mixture longer than 3 - 4 weeks. a lightly coloured object (e.g. a tree stump) and allow
Fuel mixture table the chainsaw to run in part throttle mode. A light oil trail
should form on the lightly coloured object.
Petrol in Oil in litres
litres Important: Never work without chain lubrication. Check
SOLO 2T engine oil Other two- the operation of the chain lubrication system and the
2% (50 : 1) stroke oils level of the oil in the oil tank every time before you start
4% (25 : 1) work. Never re-use old oil.
1 0,020 0,040
Notes for new saw chains: Before installing a new chain
5 0,100 0,200 we recommend soaking it in a container (bowl) with
10 0,200 0,400 chain oil with anti-fling additives that help the oil adhere
to the chain. Once the chain has been installed, do not
6.3 Fuelling start to cut wood straight away, but allow the machine to
run at part throttle for a while until a slight oil trail forms
While fuelling always follow all safety instructions and on a lightly coloured background.
take all safety precautions.
Handle fuel only with the engine turned off.
Carefully clean the area around the filler inlet.

ENGLISH 11
Chain brake ; Starting / Stopping the engine

7. Chain brake 8. Starting / Stopping the engine

When the chain brake is activated, it stops the saw

chain in a fraction of a second. Every time you pull the starter cord, observe the
Automatic engagement: correct position and the safe position of the
In an emergency, the chain brake engages instantly in chainsaw in accordance with the following chapter 8.2
response to the inertia caused by kickback. "Starting".
Please note that even the highly effective
automatic chain brake cannot offer complete 8.1 Start-up settings
protection against injury. Always work with
great care and always avoid working situations which Before starting the engine, apply the chain brake
would put you at risk of kickback. to immobilise the device.
Manual activation: • Set the stop switch (18) to "I".
Fig. 7 Type 636, 642 and 643IP:
• When starting the device for the first time, or after
having completely run down the fuel tank and
refuelled, press the primer (21) several times (at
least 5 x) until fuel can be seen in the plastic bubble.

Type 636 and 642:

• Before pulling the starter handle, press the
decompression valve (22) to make the starting
process easier. (Once the engine has started, the
decompression valve automatically jumps back to
the normal position.)
" To manually activate the chain brake, press Cold start:
the hand protection (3) forwards towards the Pull out the choke (7) [this also activates
guide bar. the part throttle setting, which can be seen
As well as providing a quick response in an emergency from the pulled-out part throttle control pin
situation, manual activation of the saw chain brake is (8)]
intended as a means for immobilising the tool in all Slowly pull the starter handle until a first
situations in which the operator cannot knowingly resistance is felt, then pull it through in a
control the position of the guide bar or in which the risk fast and strong motion.
of unintentional contact between the saw chain and a Repeat the starting process until the engine audibly and
foreign body or the user himself cannot be entirely briefly starts up (ignites).
excluded. This particularly applies to starting the engine
and carrying the tool, e.g. when assessing an object or Then immediately press the choke back
the surroundings before starting cutting work or when in again. When the engine is restarted
walking from one working area to the next. again it then keeps running at part throttle
(visible from the part throttle control pin).
In order to avoid excessive wear, the chain brake
should not be applied until the chainsaw has come to a
standstill – except of course in an emergency. During
start-up, once the engine has started the part throttle
setting should be cancelled as soon as possible by With the engine running, briefly operate
briefly pulling the throttle control. This ensures that the the throttle control to cancel the part
engine does not have to work against the blocked chain throttle setting (the part throttle control
for too long under part throttle. pin jumps back in again). The engine will
then continue to run at idle speedter.
# To release the chain drive (i.e. cancel the
Warm start:
chain brake), pull the hand protection (3) back to
the front handle (4) again Start the engine in idle setting with the choke not pulled
out, or start it in
Each time, before commencing your work, check part throttle setting:
the function of the chain brake as follows: by pulling the choke out and pressing it
• Start the engine (see chapter 8) back in again [the part throttle setting is
• trigger the chain brake at idle speed activated as a result, which is visible from
• then briefly accelerate to full throttle the pulled-out part throttle control pin (8)]
• the chain should then not move. Start the engine until it runs, then briefly operate the
Never operate the chainsaw if it is faulty; instead let a throttle control to cancel the part throttle setting (the part
service workshop check your power tool immediately throttle control pin jumps back in again). The engine
then runs on at idle speed.

ENGLISH 12
 Starting / Stopping the engine

8.2 Starting up • Always guide the starter handle back to its starting
position – do not just let go and allow it to speed
Please read the safety instructions before starting up back by itself.
the device. A damaged starter cable can be replaced by a
specialist.
Fig. 8
When the engine is running, lift up the power tool and
hold it safely with both hands, then briefly operate the
throttle control to cancel the part throttle setting.

8.3 Engine will not start:

If the engine fails to start after several attempts, check
whether all adjustments described above have been
correctly carried out, particularly that the stop switch is
not in the "0" position. Try starting once again. The
combustion chamber will be flooded, if the engine still
fails to start.

(schematic diagram) In that case we recommend you proceed as follows:

• Remove the cowl.
Take off the chain guard.
Place the power tool on level ground which is free of • Pull the spark plug cap off the spark plug.
obstructions and make sure that the cutting tool is not • Remove the spark plug and dry fuel mixture from the
touching anything. electrodes.
Place one foot in the rear handle to secure the saw on • Move the throttle lever up to full throttle. Pull the
the ground. Use one hand to firmly hold the saw by the starter handle several times (with removed spark
front handle. plug) to clear the combustion chamber.
Alternative way to hold the saw while starting it up • Move the throttle lever down to idling position, refit
(for experienced users only): the spark plug, the plug cap and the cowl.
• Repeat the starting process according to the starting
Fig. 9 settings for a warm start.

8.4 Switching the engine off::

Release the throttle control and move the stop switch to
the "0" position.
Always make sure that the cutting tool has come
to a complete standstill before placing the machine
down.
Tip: As it can sometimes happen that, after a
brief/intermediate stop, the starting settings are not set
up correctly before the machine is restarted (in
particular, the stop switch may still be set to "0" and the
(schematic diagram) chain brake may not have been applied), we
recommend that users should get in the habit of
Firmly grasp the rear handle between your thighs. Use immediately applying the chain brake whenever the
one hand to firmly hold the saw by the front handle. machine is temporarily switched off and the engine
You must make absolutely sure that there is no comes to a complete standstill and of setting the stop
risk of contact between the guide bar and any part switch back to the "Operating“ position.
of your body. As a general rule, you should always check the starting
settings before every start.
The following instructions are intended to extend the
service life of the starter cable and the starter
mechanism: Switching the engine off in the event of a malfunction:
• To start with, pull the cable carefully until a first If – due to a malfunction of the stop switch – it is not
resistance is felt, then pull it through in a fast and possible to switch the engine off, you can also close the
strong motion. choke flap (choke pulled out) to bring the engine to a
• Always pull the cable in a straight direction. standstill. In this case do not restart the tool – have it
• Do not allow the cable to chafe on the edge of the checked out immediately by a specialist workshop
cable eyelet. instead!
• Avoid pulling the cable all the way out – risk of
breaking the cable.

ENGLISH 13
Hazards caused by kickback

9. Hazards caused by kickback 3. Contact point in the lower part of the guide bar
(bumper spikes (26a / 26b) as the point at which the
chainsaw is positioned on the cutting object):
When working with the chainsaw, careless
or incorrect working methods can cause a Fig. 12
dangerous situation which is referred to as
"kickback". Kickback forces can occur when the running
saw chain comes into contact with solid objects or if the
saw chain suddenly gets stuck in the cut. In the
process, the chainsaw is accelerated violently and
uncontrollably.
Depending on the contact point of the running saw
chain, the forces acting on the chainsaw are directed as
follows, resulting in the corresponding acceleration of
the tool:
1. Contact point at the tip of the guide bar:
Safe application: The chainsaw is pulled towards the
Fig. 10 object being sawn. As the bumper spikes (26a / 26b) on
the engine housing are positioned on the object being
sawn, the chainsaw cannot be accelerated away. The
operator is able to control the tool safely.
The following general guidelines should be followed in
order to avoid kickback:
• Always hold the chainsaw firmly with both hands.
Position your right hand on the rear handle and
your left handle on the front handle.
• Before positioning the saw for the cut, apply the
throttle and, with the saw chain running, start the cut
on the underside of the guide bar as close as
(schematic diagram) possible to the engine housing.
Danger: The guide bar is kicked up suddenly and • Never cut more than one branch at a time. When
quickly. As the user is holding the chainsaw by removing branches, bear in mind that other branches
the handles, this results in a rotational acceleration of may inadvertently come into contact with the saw
the chainsaw, during which the guide bar is accelerated chain. When cutting to length, look out for other
towards the head of the operator. Although this trunks which may be close nearby.
rotational acceleration instantly activates the chain • Special care is required when continuing cuts which
brake, the magnitude of the acceleration and the have already been started.
uncontrolled response of the operator can result in • Carefully watch the guide bar during the cut.
serious accidents. • Look out for forces which could compress the cut
gap and cause the saw chain to become trapped,
2. Contact point in the upper part of the guide bar: particularly on objects which are under tension.
Fig. 11 • Always follow the correct procedure for sharpening
the saw chain. In the process, pay particular
attention to the correct height of the depth limiter.
Professional users can use special working techniques
which must only be carried out by experienced users.
We recommend that anyone who wishes to safely learn
about the more difficult techniques which are not
described here should attend a special course (e.g. at
specialist forestry training centre).

Danger: The chainsaw is kicked suddenly in the

direction of the operator. The magnitude of the
acceleration and the uncontrolled response of the
operator can result in serious accidents.
Experienced users can perform a so-called "backhand
cut". This can only be done by anticipating the sudden
acceleration of the tool and supporting the chainsaw in
a rearward direction with your thigh before positioning
the tool for the cut and while performing the cut.
Inexperienced users must not use the
"backhand cut"!

ENGLISH 14
 Using the chainsaw

10. Using the chainsaw Trunk under tension on the

upper side.
Danger: The tree will spring
back in an upward direction.
10.1 Application areas
The chainsaw must only be used to cut wood and
objects made of wood. Trunk under tension on the
Any loose wooden objects must be safely secured (e.g. underside:
on a sawhorse). When cutting down overgrown trees Danger: The tree will spring
and branches please refer also to the notes on cutting back in a downward direction
down trees and removing branches.
The chainsaw must not be used for any other purpose,
for example to cut plastics or metals. Thick trunks and high tension:
Danger: The tree will spring
back suddenly and with
10.2 Sawing considerable force. Also watch
Always follow the safety instructions when performing out for the root clump tipping
any kind of work with the saw. Always hold the back.
chainsaw firmly with both hands. Position your right
hand on the rear handle and your left handle on the Trunk under lateral tension:
front handle. Danger: The tree will spring
Cutting to length: back to one side
Make sure that you have a secure footing.
Clean the area which is to be cut of any foreign bodies Note: Always stand on the compression side if the tree
like sand, stones, nails etc. Foreign bodies can cause is under lateral tension.
dangerous kickback. If the saw becomes pinched in the cut, stop the engine
Loose wooden objects must be firmly and lift the trunk with a bar or other lever, or change its
secured, ideally with a sawhorse. The position to open up the cutting gap.
wood must nut be held in place with a Removing branches:
foot or by another person. Round Do not cut through free-hanging branches from
timber must be secured so that they underneath.
cannot rotate.
Do not remove branches while standing on the trunk.
Remove any obstructing branches before you start
Fig. 13
sawing.
If you change your standing point, remember that the
guide bar must always be on the side of the trunk facing
away from your body.
Always keep an eye on tree and branch movement –
plan ahead and proceed with care!
When removing branches on thick hardwood trees,
follow the correct procedure described below to prevent
the chainsaw from becoming pinched:
1. Remove any obstructing
branches.
2. Cut off any branches
Apply full throttle and move the chainsaw close to the which are creating tension.
cutting point, position and press the bumper spikes onto 3. Cut off the main branch
the object you wish to saw (a), then – and not before – (note which side is the
use a pivoting movement (around the point at which the compression side and which the tension side).
bumper spikes have been positioned) to move the If it is important that the wood does not tear, make a
guide bar downwards (b) and start the cut. relieving cut.
Important note on cutting branches which are under Start this cut on the
tension (e.g. in the forest): compression side ", then
• Always make the first cut on the compression side finish the cut from the
", but be careful as there is a risk of pinching. tension side #.
• Then proceed carefully and make a cut at the The remainder of the branch
which is left standing is now
tension side. #
no longer under tension and
• On thick trunks which are under a lot of tension can be cut off close to the
offset the cut to one side. trunk $.

ENGLISH 15
Using the chainsaw

Felling: Making the felling notch:

Felling trees is dangerous and requires training. If The felling notch determines the direction in which the
you are a novice then you must not fell any trees. tree falls and helps to control the fall. It is made
You can attend a training course to learn how to fell perpendicular to the fall direction with a cut through 1/5 -
trees. 1/3 of the trunk diameter. The cut should preferably be
Before felling a tree, make sure that: made close to the ground.
• No persons other than those involved in the felling of Fig. 15
the tree are in the felling area.
• Everybody involved in the felling has an
unobstructed path of escape. The path of escape
should be opposite to the planned direction of the
fall of the tree at an angle of around 45°.
• The nearest working area should be at least 2½ tree
lengths away.

Fig. 14

" Start with the upper cut (roof of the felling notch).
# Then make the lower cut (bottom of the felling
Before felling a tree you need to carefully check the notch). The lower cut should meet the upper cut
direction of fall and make sure that no persons, animals precisely.
or objects are within 2½ tree lengths. Check the direction of fall.
If the felling notch needs to be corrected, always re-
Then consider the general condition of the tree: cut it across the full width. In exceptional cases it is
Hanging direction – loose or dry branches – height of also possible to slope the lower cut upwards to
the tree – natural overhang – is the tree diseased? obtain a more open felling notch. If the tree is
You also need to take into account the wind speed and situated on a slope this gives longer control over the
wind direction. Do not fell a tree under heavy, gusting fall.
winds. $ The felling cut is made higher % than the bottom of
The foot of the trunk must be free of all foreign objects, the felling notch #. This cut must be exactly
roots, undergrowth and branches. horizontal. In front of the felling notch around 1/10 of
Ensure that you have a secure footing and remove any the trunk diameter needs to be left as a hinge &.
objects which could cause you to trip. & The hinge must not be cut through, as this could
Cutting into the buttress roots: result in loss of control over the fall of the tree.
Start with the largest Wedges need to be positioned in good time. The felling
buttress root first. cut must only be secured with plastic or aluminium
Make a vertical cut into the wedges, and steel wedges must never be used.
root ", followed by a During felling, always keep to the side of the tree.
horizontal cut #. When walking back after the felling cut has been made,
watch out for falling branches.
Never cut into diseased trunks before felling them. When working on a slope, the operator of the saw
Note: Leave the buttress root intact as a wedge on the should stand above or to the side of the trunk or tree
side opposite the direction of fall. being worked on.
Stand back when the tree falls. Observe the crown of
the tree.
Wait for the crown to swing out.
Do not continue work under branches or trees which
have become caught.

After work ! slacken the chain tension

ENGLISH 16
 Operating and maintenance information

11. Operating and maintenance information Sharpening the saw chain:

A special round chain file with the correct diameter
With modern equipment and safety-relevant should be used for sharpening. Normal round files are
components, maintenance and repairs must only be not suitable.
carried out by persons with suitable specialist
Pitch Files Ø Filing Depth limiter Filing
qualifications in a workshop equipped with the
in inches mm/zoll angle α spacing b direction
necessary special tool and testing equipment. As a mm/zoll
result, the manufacturer recommends that all work
5
which is not described in these operating instructions 3/8’’ Spez. 4,0/ /32 30° 0,64 / .025 0° horizon
should be performed by a specialist workshop. The 3
.325’’(21BP) 4,8/ /16 30° 0,64 / .025 10° upw.
experts have access to the training, experience and
equipment which is required in order to provide you with
the most cost-effective solution. An expert can also
offer invaluable advice.
Always follow all of the safety instructions when
performing maintenance work. A file holder makes guidance of
After the device has been run in for around 5 operating the file easier, as it has
hours, all accessible nuts, bolts and screws (except the markings for the correct
carburettor adjusting screws) should be checked for sharpening angle (align the
tightness and retightened as required. markings parallel to the saw
It is best to store the device in a dry and safe location chain) and limits the penetration
with a full fuel tank. There must not be any naked depth (4/5 of the file diameter)
flames or similar nearby. If you plan to not use the
chainsaw for a longer period (i.e. more than four
weeks), please refer to the information in chapter 11.7
"Taking the chainsaw out of operation and putting it into
storage. Position the file holder on the
roof of the tooth. The file should
only engage during the forward
11.1 Maintenance and care of the cutting gear stroke. Lift the file off when
α moving it back.

Saw chain: The shortest cutting tooth is

sharpened first. The length of
Just like any other cutting tool, the saw chain is subject this tooth is then the target size
to natural wear. Your chainsaw will only be able to for all the other teeth on the
deliver its full potential if the saw chain is correctly saw chain. All of the cutting elements must have the
sharpened. Every saw chain is matched to the relevant same length.
chainsaw type in terms of its form, cutting performance To start with, file all of the cutting elements on one side
and design. Only use the genuine SOLO saw chain from the inside outwards, then file all of the cutting
which is approved for your chainsaw / guide bar type. elements on the other side.
The key distinguishing factors for the saw chain are: Always fully file out any damage from the side plate or
The form of the cutting elements, the roof of the tooth.
a) Solid bit (rectangular cutting tooth, Correction of the depth limiter:
professional chainsaws) The distance b between the depth limiter (round nose)
b) Half bit (half-round cutting tooth, and the cutting edge defines the
semi-professional / hobby chainsaws) thickness of the chips. The best
cutting results are obtained with the
The pitch
prescribed depth limiter spacing,
This is the distance s (from one
which should be checked every
rivet to the next but one) divided
time the saw chain is sharpened.
by 2.
The pitch is quoted in inches Lay the depth limiter gauge on the
cutting element. If the depth
The driving link thickness limiter protrudes, file off the
This is the thickness of the part protruding part with a flat file.
of the driving link which Round off the front edge of the depth
protrudes in the guide groove of limiter. The original shape must be
the rail. restored. CAUTION: If the spacing is
too large then there is a greater risk of
Pitch Driving link kickback.
in inches in mm thickness in in inches For your safety: If you would like to pull the chain
mm through while filing, pull the chain forwards with a
3/8’’ Spez. 9,32 mm 1,3 mm .050’’ screwdriver towards the tip of the rail. This will reduce
the risk of slipping.
.325’’ 8,25 mm 1,5 mm .058’’

ENGLISH 17
Operating and maintenance information

Before you can fit a new saw chain you must check the 11.2 Air Filter Maintenance
condition of the sprocket. Worn sprockets will damage
your new saw chain. If necessary, replace the sprocket
with the new chain. Grease the bearing with lithium-
based grease whenever the sprocket is replaced. Contaminated air filters cause a reduction in engine
Tip: We recommend the use of two saw chains per performance and increase fuel consumption with more
sprocket, and that both chains should be replaced as pollutants in the exhaust gas. Engines are less likely to
frequently as possible so that all of the components start readily with a contaminated air filter.
wear evenly. Once a certain wear limit is reached, When using the power tool all day, clean the air filter
replace all of the parts together again. daily; under very dusty conditions, even several times a
day.
Fig. 16
Carry out the following maintenance jobs regularly.

Fig. 17

To replace the chain wheel (after dismantling the guide

bar cover and the guide bar with chain), push the chain
wheel with its washer down slightly and lift off the
locking ring with a small screwdriver.
To refit the locking ring after fitting the new chain wheel
push the chain wheel, with its washer, down again
slightly. To prevent dirt from entering the carburettor inlet,
Guide bar: always pull out the choke lever (7) prior to removing the
hood (5). To make the hood removal easier (and the
The guide bar of your
subsequent replacement), it is recommended to push
chainsaw requires just as
the hand guard (3) forward (chain brake activated).
much care as the saw
Undo the fixing screw (16) completely (screw is retained
chain. The running surfaces
inside the hood) and remove the hood (5).
must be flat and level, and
the groove must not be Fig. 18
widened.
In order to prevent one-sided wearing of the guide bar,
we recommend that the guide bar be reversed
whenever the chain is sharpened.
On guide bars with a guide
sprocket, the bearing of the
guide sprocket should
preferably be lubricated with
ball bearing grease (through
the lubricating hole on the side with a grease gun)
every time the chainsaw is refuelled. Rotate the guide
sprocket while doing this.
Important: The guide bars are only designed to guide Remove the foam filter (5) and the flow filter insert (b).
the saw chain and must not be used as a levering tool. The best way to clean the filter is to simply tap out any
Any twisting or turning or use of the guide bar to gain dirt or blow it out with a blast of air.
leverage in the wood shortens the service life of the If they are more heavily contaminated, both filters can
guide bars. be cleaned with non-flammable cleaning fluid (warm
soapy water). Both filters must be absolutely dry before
they are refitted to the device.
The corresponding parts should be replaced
immediately if the filter material is damaged. No
warranty claims can be accepted for engine damage
arising as a result of inadequate care.
Dry out the area surrounding the filter and remove all
dust residues. First introduce the flow filter insert, then
the foam filter.
When positioning the hood, ensure that it fully locks all-
round into the groove of the main casing.

ENGLISH 18
 Operating and maintenance information

Fig. 19 The saw chain must never be driven while the

engine is idling.
If the idling speed cannot be set correctly with the idling
end-stop screw "T", request an authorised service
centre to tune the carburettor.

The following instructions are for authorised service

shops
D-CUT carburettors:
Use the D-CUT carburettor key to adjust the idle mixture
screw "L" and the full load mixture screw "H".
Carburettors with limiter caps:
Initially, it is best to set the hood down at the back The regulating screws for idle mixture and full load
recess for the primer and the choke lever. For this, it mixture can only be adjusted in a limited range.
may prove beneficial to push the rear handle back Clean the air filter before adjusting the low speed screw!
slightly - but never use force! Let the engine run warm before adjusting the engine
speed.
Fig. 20
The carburettor is tuned for optimum engine
performance. Use a rev counter to tune the carburettor
correctly!
Do not adjust the engine to a higher speed. Excessive
engine speed can lead to major engine damage!

11.4 Maintenance of the chain brake

Check for ease of movement and correct operation on a

daily basis. Remove any resin, sawdust and dirt.
Push the hood together gently to fit it accurately into the
front groove at the hand guard on the starter side of the
Fig. 21
casing. If necessary, hold the hand guard with activated
chain brake in its play position. Before tightening the
fixing screw (16), check that the hood fully engages in
the groove of the main casing.

11.3 Carburettor settings

The carburettor is preset to the optimum settings for the

device at the factory. Depending on the particular
location where the chainsaw is used (mountains, flat Visible joints and bearings should be lubricated with
country) it may be necessary to adjust the idling grease or temperature-resistant engine oil.
settings via the idle stop screw "T" (24).
• Chain brake function test (chapter 7.).
The adjusting screws for the idling mixture "L" and the
full-load mixture "H" (25) must only be adjusted by an
authorised workshop. 11.5 Vibration damping
When the idling settings are correct the engine should If you find that vibrations on the handles worsen
run smoothly at idle without the saw chain being driven. significantly with time in comparison to when the
Corrective adjustments to the average idle speed chainsaw was new, check the damping elements
indicated in the technical data can be made as follows (rubber-bonded metal mountings) for damage and
via the idle stop screw "T" – ideally with the aid of a replace them as required.
tachometer: Working with the chainsaw while the vibration
• If the idle speed is too high (particularly if the saw damping system is not working properly can
chain is already driven without the throttle being cause health problems.
operated), slightly open up the idle stop screw "T"
by turning it anti-clockwise.
• If the idle speed is too low (i.e. the engine keeps
stopping at idle), slightly close the idle stop screw
"T" by turning it clockwise until the engine runs
evenly.
•

ENGLISH 19
Operating and maintenance information

11.6 Spark plug information A trained mechanic can carefully remove the fuel filter
via a wire loop through the fuel tank filler. Ensure that
the thicker part of the fuel hose on the tank wall is not
drawn into the fuel tank.
The spark plug should be regularly checked every 50
operating hours.
11.9 Self-help tips
• Take off the cowl from the chainsaw.
• Disconnect the spark plug connector which is located Possible malfunctions:
underneath.
• Unscrew the spark plug and dry it thoroughly. • The engine will not start.
In the event of severe burn-off of the electrodes the o Correct starting settings? (E.g. the stop switch)
spark plug should be replaced immediately, otherwise o Spark plug?
every 100 hours. ' Clean or replace
The engine must not be moved if the spark plug is o Combustion chamber oversaturated
removed or the ignition cable is disconnected.
' Unscrew the spark plug, dry, vent the
Otherwise there is a risk that sparks could form which
combustion chamber
might cause a fire.
Interference-suppressed replacement spark plugs o Old fuel?
(calorific value: 200) are available for example under ' Drain and clean the tank, refuel with fresh
the following trade names: fuel
BOSCH WSR6F • The chain will not run
CHAMPION RCJ-6Y or equivalent.
o Chain brake?
The prescribed electrode gap is 0.5 mm.
Before starting work, check the ignition cable to make • The chain is driven at idle
sure the connections are in good working order and the o Idle speed set too high
insulation is intact.
o Defective clutch
• Screw the spark plug back in again.
' Service workshop
• Always press the spark plug connector firmly onto
the spark plug. • Poor engine performance
• Refit the cowl to the chainsaw. o Air filter clogged
' Clean both filters
11.7 Shutdown and storage o Choke not fully open
The chainsaw should be thoroughly cleaned and ' Press the choke lever right in.
checked for damage after every use. The most o Carburettor settings ("L" / "H“ settings)
important areas are the chain brake, the cooling air ' Service workshop
intake area, the cylinder cooling fins and the air filter.
Only use the eco-friendly cleaning agents available • The saw chain is not cutting well
from a specialist retailer. Do not use fuel to clean the o Chain is blunt / incorrectly sharpened.
chainsaw. ' Sharpen the chain correctly
The chainsaw should be stored in a dry room and fitted
with a chain guard. There must be no naked flames or
similar in the vicinity. Measures must be taken to
prevent unauthorised use of the chainsaw, particularly Important operating instructions (summary):
by children.
If you plan to stop using the saw for more than four • Before starting:
weeks then you should also drain the fuel tank and the o Have you filled up with fuel and oil?
chain lubrication oil tank in a well vented area and clean o Is the chain tension set correctly?
them. Start the engine with the fuel tank empty and run
o Are the starting settings and the chain brake
it until the carburettor is empty and the engine goes out.
OK?
Otherwise oil residue from the fuel mixture could block
the carburettor nozzles and make subsequent starts ' Primer (636, 642, 643IP)
more difficult. ' Choke - part throttle
Important: If you are using bio-chainsaw oil and ' Decompression valve (636, 642)
planning to stop using the chainsaw for at least 2 ' Stop switch
months then you should run the chainsaw for a while
with the oil tank filled with engine oil (SAE 30), so that • While working:
all residue of the bio-oil is flushed from the tank, oil o Is the chain tension set correctly?
pickup hose and cutting device. o Is the chain lubrication OK?
o Are the idle settings OK?
11.8 Replacing the fuel filter o Chain brake function test
• After work ! slacken the chain tension
We recommend having the fuel filter changed annually
by a specialised service centre.

ENGLISH 20
 Operating and maintenance information; Accessories

Daily, before and/or after work and also in

11.10 Scheduled maintenance

Yearly before or after the season

The following information is based on standard operating conditions.
For special conditions, such as prolonged daily use, the recommended maintenance
intervals should be reduced accordingly.

after every 100 hours

after the first 5 hours

after every 50 hours

Implement all maintenance jobs regularly. If required, authorise a specialist service
centre to maintain the machine for you. The owner of the machine is responsible for:
• Any damage caused by a lack of maintenance, incorrect or late maintenance and

as required
repairs

between
weekly
• Consequential losses - including corrosion - from incorrect storage

Complete machine Visual inspection X

Clean (incl. air inlet, cylinder cooling fins) X X X
Guide bar Visual inspection X
Reverse the blade X
Lubricate the guide sprocket X
Clean the chain groove / oil bore X
Clean the blade cover on the inside X
Saw chain Visually inspect condition, check sharpness X
Re-sharpen X X
Renew, possibly renew the sprocket as well and X
lubricate the sprocket bearing
Chain brake Functional test, check for ease of operation X
Clean, lubricate joints X X
Chain lubrication Check X
Silencer Visual inspection of condition – check tightness X
of screws/bolts
Carburettor Check idling speed X
Adjust idling speed X
Air filter Clean X
(pre-filter and main air filter)
Replace X
Spark plug Check the electrode gap and adjust, if required X X
Replace X X
Fuel tank, oil tank Clean X X
Fuel filter Replace X
All accessible screws Retighten X X X
(except for adjusting screws)
Other control elements Check function X
[stop switch, throttle control, throttle
control lock, choke part throttle
stop, starter]

12. Accessories

The next three pages are abbreviated extracts from our general 2007 catalogue. If you require a copy of the full
catalogue, please contact your specialist SOLO dealer or visit our website at www.solo-germany.com.

ENGLISH 21
Accessories

ENGLISH 22
Parts subject to wear and tear ; Guarantee ; CE Declaration of conformity

ENGLISH 23
Accessories

ENGLISH 24
 Parts subject to wear and tear ; Guarantee ; CE Declaration of conformity

13. Parts subject to wear and tear 15. CE Declaration of conformity

Various parts are subject to application-specific or
normal wear and must be replaced in good time, when In accordance with EG Directives 98/37/EC, 2000/14/EC
required. The following parts are subject to normal wear and RL - 2004 - 108 EG, SOLO Kleinmotoren GmbH,
and are not covered by the manufacturer's guarantee: Stuttgarter Strasse 41, D-71069 Sindelfingen, being
solely responsible, states that the product referred to in
• Air filter this declaration complies with the requirements of the
• Fuel filter Machinery Directive.
• All rubber parts which come into contact with fuel Description of product: chain saw
• Clutch
Model/type description / Sound power level:
• Spark plug
635ECO 636 642 643IP
• Starter
• Cutting tools Guaranteed sound 109 109 110 110 dB(A)
• Operating materials Actual sound 108 108 109 109 dB(A)
• Cutting tools: guide bar / saw chain (EN ISO 3744, EN ISO 22868)
• Vibration damping elements made of rubber
Applied standards: DIN EN ISO 11681,
DIN EN ISO 14982
14. Guarantee
Conformity assessment procedures
The manufacturer guarantees trouble-free quality and (98/37/EG)! Appendix IV, (2000/14/EG)! Appendix V
will cover the cost of replacing parts which are found to
be faulty in material or workmanship within the Nominated location acc. to 98/37/EC:
prescribed guarantee period after the date of purchase.
Intertek Deutschland GmbH
Please note that specific guarantee conditions may vary Nikolaus-Otto-Str. 13
from country to country. If in doubt, ask your equipment D 70771 Leinfelden-Echterdingen
vendor. He is responsible for guarantee matters.
Registration number: 0905
We hope you will understand that we cannot be liable for
damage resulting from the following causes: Storage location for the technical documentation
according to 2000/14/EC and 89/336/EC:
• Non-compliance with the operating instructions.
Solo Kleinmotoren GmbH
• Neglecting essential maintenance and repair work. Stuttgarterstr. 41
• Damage caused by incorrect carburettor D-71069 Sindelfingen
adjustment.
This declaration of conformity loses its validity, if the
• Wear in normal use.
equipment is converted or modified without the
• Obvious overload by continuously exceeding the manufacturer's consent.
maximum performance limit of the product.
• Using non-authorised tools.
Sindelfingen,
• Use of force, incorrect treatment, misuse and 1st August 2007
accidents. SOLO Kleinmotoren GmbH Wolfgang Emmerich
• Damage from excessive heat due to dirt build-up Executive Director
around the cooling fan housing.
• Attempted adjustments and repairs by unqualified
persons.
• Use of unsuitable spare parts or third party parts, if
these are the cause of the defect.
• Use of unsuitable or stale fuel.
• Damage caused by using the product in the hire or
rental industry.
Normal cleaning, adjustments or maintenance work fall
outside the guarantee provisions.
A service centre authorised by the manufacturer must
carry out all guarantee work.

In the best interest of continued technological progress

we reserve the right to change the design and
configuration of any product without prior notice.
For that reason, no claims can be accepted with
reference to text and illustrations in this manual.
ENGLISH 25
 Zulässige Schneidgarnituren
Permissible cutting gear
Jeux de coupe autorisés
Conjuntos de corte autorizados
Accessori da tagli permessi
Toegelaten snijgarnituren

Symbole / Symbols / Symboles / Símbolos / Simboli / Symbolen

Kettenrad
Sprocket
Pignon de chaîne
Rueda de cadena
Rocchetto della catena
Kettingwiel
Teilung
Pitch
Pas
División
Passo
Steek
Schnittlänge
Cutting length
Longueur de coupe
Longitud de corte
Lunghezza di taglio
Snijlengte
Anzahl Treibglieder
Number of driving links
Nombre d'éléments d'entraînement
Cantidad de elementos de accionamiento
Numero elementi di trasmissione
Aantal aandrijfschakels
Treibgliedstärke
Driving link thickness
Epaisseur d'élément d'entraînement
Grosor del elemento de accionamiento
Spessore elementi di trasmissione
Dikte van aandrijfschakels
Sägenkette Bestell.-Nr.
Saw chain order no.
Chaîne de tronçonneuse, réf.
Cadena de sierra, no. pedido
Catena di taglio numero di ordine
Zaagketting bestelnr.
Führungsschiene Bestell.-Nr.
Guide railorder no.
Guide-chaîne, réf.
Riel de guía, no. pedido
Barra di taglio numero di ordine
Geleidingsrail bestelnr.
635, 636, 642 - Code: 91VG… - 3/8’’ spez.

.3/8’’ - 6 3/8’’ 30 cm / 12’’ 45 .050’’ / 1,3 mm 69 00 132 69 00 133

No.: 35 00 433 3/8’’ 35 cm / 14’’ 52 .050’’ / 1,3 mm 69 00 136 69 00 744
25
3/8’’ 40 cm / 16’’ 57 .050’’ / 1,3 mm 69 00 600 69 00 900

643IP - Code: 21BP… - .325’’

.325’’ - 7 .325’’ 33 cm / 13’’ 56 .058’’ / 1,5 mm 69 00 704 69 00 342
No.: 35 00 414 .325’’ 38 cm / 15’’ 64 .058’’ / 1,5 mm 69 00 875 69 00 343

Wichtig: Kettenrad, Sägekette und Führungsschiene ausschließlich in der angegebenen

Kombination verwenden. Niemals Bauteile zu unterschiedlicher Teilung zusammen verwenden!

Important: Only use the specified combination of sprocket, saw chain and guide rail. Never
combine components with a different pitch!

Important : Utiliser le pignon de chaîne, la chaîne et le guide-chaîne uniquement avec la

combinaison indiquée. Ne jamais utiliser de composants avec des pas différents !

Importante: Utilizar la rueda de cadena, el riel de guía y la cadena de sierra exclusivamente en

la combinación indicada. ¡Nunca utilizar conjuntamente componentes con diferente división!

Importante: Rocchetto della catena, Catena di taglio e Barra di taglio usare esclusivamente nella
combinazione fornita. Non usare mai insieme pezzi di componentistica diversa!

Belangrijk: Gebruik het kettingwiel, de zaagketting en de geleidingsrail uitsluitend in de

opgegeven combinatie. Combineer nooit componenten met een verschillende steek!
 Made in Germany

SOLO SOLO
Postfach 60 01 52 P.O.Box 60 01 52
D 71050 Sindelfingen D 71050 Sindelfingen
Germany
Tel. 07031-301-0 Phone+49-7031-301-0
Fax 07031-301-130 Fax +49-7031-301-149
info@solo-germany.com export@solo-germany.com