Solo 635, 636, 642, 643IP Instruction Manual
9 636 111 english 0/2008
635 / 636 / 642 / 643IP
Instruction manual
Important!
Read this instruction manual carefully before
first operation and strictly observe the safety
regulations!
Chain saw
ENGLISH 2
For USA only
Emissions Control Warranty Statement
The Environmental Protection Agency and Solo are
pleased to explain the emission control system on your
small non-road power equipment engine. In the US
new small non- road engines must be designed, built,
and equipped to meet the Environmental Protection
Agency's standards. Solo must warrant the emission
control system on your small non- road engine for the
period of time listed below provided there has been no
abuse, neglect, or improper maintenance of your small
non-road engine.
Your emission control system includes parts such as
the carburetor, the ignition system, and the exhaust
system.
Where a warrantable condition exists, Solo will repair
your small non-road power equipment engine at no cost
to you including diagnosis, parts, and labor.
Manufacturers Warranty Coverage
Solo's small non-road power equipment engines are
warranted for a period of two years. If any emission
control related part on your engine is defective, the part
will be repaired or replaced by Solo.
Contact Information for Authorized Service Center
Locations, Replacement Parts,
Warranty and Technical Information
Warranty repairs must be completed by a SOLO
Authorized Service Center.
SOLO USA, Inc. 1-800-765-6462
5100 Chestnut Avenu techserv@solousa.com
Newport News, VA 23605
Preface
Dear Customer,
Congratulations for choosing this SOLO quality
product.
The models in this series are particularly high-grade
chainsaws, made in Germany, that are specifically
designed for the multi-faceted demands of the hobby
and leisure market. A high-grade single cylinder twostroke engine with nickel-aluminium-silicon coated
cylinder, designed according to the proven four channel
technology for high performance and low fuel
consumption, guarantees you a high level of
serviceability from your machine.
The automatic chain lubrication system (Ecomatic),
the maintenance-free electronic ignition, the AntiVibration-System for protection at work, the excellent
starting characteristics and the ergonomic design of the
entire machine ensure excellent user comfort and it
makes light of your work. The safety equipment is stateof-the-art and complies with all German and
international safety regulations.
Prior to operating the unit, please read the owner’s
manual carefully, and most importantly, observe all
safety rules.
Observe the maintenance guidelines closely to
ensure the long service life of your equipment.
Your dealer will be glad to assist you with any
questions.
Symbols
The following symbols are used in this manual and on
the product:
Thoroughly read these operating instructions
before undertaking any maintenance,
installation and cleaning steps
Before starting the engine, make sure that you
are wearing a helmet, ear defenders and face
protection.
Switching off the engine
Choke flap:
Cold start position ! pull the lever out
Operation and warm start ! press the lever in
Chain lubrication: symbol above the chain
lubrication tank cap
Fuel mixture: symbol above the fuel mixture
tank cap
Danger! Failure to comply with the
instructions could cause accidents with
potentially life-threatening injuries.
Always wear protective gloves when working
with or on the device.
Always wear safety shoes with non-slip soles.
Chain brake: To block the chain, press the
lever forwards towards the guide bar.
To release the chain again, pull the lever back
towards the front handle.
Caution: Risk of kickback.
Please refer to the notes in chapter
9.“Hazards caused by kickback“
Never smoke near the power tool or where
the equipment is refuelled!
Keep open flames away from the power tool
and the fuel can
- This equipment produces exhaust fumes
and
- fuel vapours are poisonous;
never start or refuel in enclosed spaces
Packaging and disposal
Please keep the original packaging in order to protect
the equipment against transport damage in case you
ever need to ship it or transport it. If the packaging
materials are no longer required then they must be
disposed of properly in accordance with applicable local
regulations. Cardboard packaging materials are raw
materials which can be recycled or reused.
At the end of the equipment’s service life, please make
sure that you dispose of it properly, in accordance with
the official directives and regulations that apply in your
area.
ENGLISH 3
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.
Safety regulations
ENGLISH 4
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-bree ches 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)
Safety regulations
ENGLISH 5
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.
Safety regulations
ENGLISH 6
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.
Specification
ENGLISH 7
2. Specification
Chain saw 635 636 642 643IP
Engine type SOLO single cylinder two-stroke engine
Engine capacity cm3 36,3 40,2
Bore / stroke mm 38 / 32 40 / 32
Max. power kW
at rpm
1
/
min
1,4
8.500
1,5
8.500
1,8
8.500
2,0
9.000
Max. torque Nm
at rpm /
1
/
min
1,8
7.000
1,8
7.000
2,1
6.500
2,5
6.200
Max. permissible speed
1
/
min
no load with cutter
11.500
± 200
11.500
± 200
12.000
± 200
13.000
± 200
Medium idling speed
1
/
min
2.800± 150
Clutch engagement speed
1
/
min
4200± 150
Fuel tank capacity l 0,37
Fuel mix ratio: with SOLO 2T engine oil
with other two-stroke oils
1 : 50
1 : 25
Fuel consumption at max. power
ISO 7293
kg
/
h
0,7
0,7
0,8
0,8
Specific consumption at max. power
ISO 7293
g
/
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 L
Peq
EN ISO 22868 dB(A) 100 100 101 101
Sound power level L
Weq
EN ISO 22868 dB(A) 105 105 107 107
Weighted effective acceleration a
hv,eq
DIN ISO 22867
Handle r.h. side / handle l.h. side m/s
2
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
cutting length of the guide bar 38 cm (15’’) (643IP) mm
250/ 220/ 720
---
---
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)
Standard delivery ; Designation of important controls and functional parts
ENGLISH 8
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
View: profile from the right
View: profile from the left
Fig. 1a
(
Depending on the version
)
Fig. 1b
(Depending on the version)
Designation of important controls and functional parts
ENGLISH 9
View: rear
View: front
-
Type plate:
Type designation
Serial number Build year (06 !2006).
.
Fig. 1c
(Depending on the version)
Fig. 1d
(635)
1. Chain
2. Guide bar
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
18. Stop switch
19. Fuel tank cap
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
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