BCS 660HY WS Hydrostatic Commander User manual

Operating Instructions
Before commissioning the machine, read operating instructions
and observe warning and safety instructions.
PLEASE ALSO READ ORIGINAL
BCS INSTRUCTION MANUAL
BCS 660HY Hydrostatic Commander
Manufactured by BCS S.p.A.
Model 660HY WS

BCS 660HY Hydrostatic Commander
Page 2 BCS660HY/0819
No liability will be accepted for any damage caused to persons or property
through failure to observe the operating and safety instructions.
Contents
Page 3 Safety Symbols and Warnings
Page 5 Safety
Page 8 Identication and Stickers/Labels
Page 9 Stickers/Labels
Page 11 Controls Description
Page 13 Pre-Operation Checks
Page 14 Attaching Implements
Page 15 Making Adjustments
Page 16 Starting the Machine - Petrol Engine
Page 17 Starting the Machine - Diesel Engine
Page 18 Operating Test
Page 19 Operation
Page 21 After Work
Page 22 Maintenance
Page 23 Service Information
Page 24 Service Record
Page 25 Troubleshooting
Page 26 Manufacturer Information
IMPORTANT READ CAREFULLY

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BCS660HY/0819 Page 3
Safety Symbols and Warnings
SAFETY ALERT SYMBOL
This indicates important safety
messages. When you see
this symbol, be aware of the
possibility of injury, carefully
read the message that follows,
and inform other operators.
MANUAL OPEN
This means that you must
carefully read the user and
maintenance manual.
NO! DO NOT DO!
This means that you must
absolutely not carry out the
operations stated below this
symbol. It could involve a lethal
hazard.
IMPORTANT
You must pay particular attention
to the following information.
NOTE
Used to draw attention to
additional information given on
a specic topic.
Do not repair or lubricate the
machine when the parts are
moving or the engine is on.
Do not smoke. Do not light
matches or ames. Do not leave
naked ames around or make
sparks.
Take special care not to touch
hot parts of the engine.
Engine exhaust fumes can cause
sickness or death. If it is necessary
to run an engine in an enclosed area,
use an exhaust pipe extension to
remove the fumes. Always try to work
in a well ventilated area.
Caution! Never touch moving pulleys
or belts. They can be very dangerous.
Never undertake maintenance with
engine running.
A burst which separates the tyre from
the rim parts can cause serious injury
or death.
Prevent battery explosions: keep
sparks, lighted matches and open
ames away from the top of the
battery. Battery gas can explode.
Handle fuel with care, it is highly
ammable: do not refuel machine
while smoking, when machine is near
an open ame or sparks, or when the
engine is running. Stop the engine.
Sulfuric acid in battery electrolyte
is poisonous. It is strong enough to
burn skin, eat holes in clothing and
cause blindness if it gets in contact
with the eyes.
Rotating blades and moving
implements are dangerous. Protect
children and prevent accidents.
Avoid tipping. Do not drive where
machine could slip or tip. Stay alert
for holes and other hidden objects.

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Page 4 BCS660HY/0819
Before using the machine it is mandatory to put on the correct
personal protective equipment (PPE): body protection, protection
gloves, security shoes, and ear protection.
DANGER!
Machine rollover: don’t use this machine on slopes greater
than 30° (58%).
WARNING!
SHARP PARTS. Keep hands and feet away. Do not
operate with people near the machine, foreign
bodies may be ejected by blades or rotating
parts, generating a danger. Keep people away.
Remove the key and read the instruction manual
before attempting to carry out any maintenance
or repairs to the machine.
Safety Symbols and Warnings

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BCS660HY/0819 Page 5
Read the user manual carefully
before starting up the engine.
The following warnings are
important for the safety of the
operator and any onlookers or
pets.
Caution and common sense are
the main factors in accident
prevention.
Do not use the machine on
slopes exceeding 30o(58% of
inclination).
Warning! The machine should
only be used for the purpose for
which it was designed. Do not
transport persons. Do not make
changes to it or tamper with it.
Do not race with it at all or use
it as a trailer, etc.
Pay particular attention to the
warnings and safety stickers on
the machine.
Caution! Danger! The battery
contains sulphuric acid. Fatal if
ingested! It can cause blindness
if it gets into contact with eyes.
It can also burn the skin and
dissolve clothing.
Danger! Keep the battery away
from sparks, matches, lighted
cigarettes and naked ames.
The battery gas is extremely
dangerous and lethal. Can
explode.
Caution! Danger! An exploded
tyre can cause serious injuries or
death.
Danger! The fuel is highly ammable.
Do not refuel when the engine is on.
Turn off the engine. Let the mufer cool
down. Do not refuel while smoking or in
the vicinity of naked ames or sparks.
Handle and store the fuel with care.
Danger! Never touch moving pulleys
and belts. Can cause serious accidents
to people.
Danger! Do not carry out maintenance
with the engine on. Turn off the engine
and remove the key.
Following the initial start-up, it is
recommended that you familiarize
yourself with the controls and the
machine.
Prior to starting work, learn how to turn
off the machine safely and quickly.
Danger! The movement of blade and
fork is verv dangerous. Never put your
hands and/or feet near the blade and
forks.
Before letting other people use your
machine, you must inform them about
the safety standards. Make them read
the user manual and teach them how
to use the machine.
Before turning on the machine, check
that there is nobody in the vicinity,
especially children.
Before reversing the machine, check for
people or obstacles.
Danger! Do not carry passengers on
the machine.
Safety

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Page 6 BCS660HY/0819
Danger! Do not use the machine
when tired. Do not drink alcohol.
Check the ground before to cut.
Check for stones, sticks or foreign
bodies, which could be catch from
blade or rotating parts and became
very dangerous.
Danger! Do not work on overly
sloping ground where the machine
could slide or tip over.
Before commencing work, wear
appropriate work clothing, gloves,
protective footwear and glasses.
Before getting down from the
machine, turn off the engine,
disable the PTO, remove the
ignition key and lower the
implement to the lowest position.
Travel slowly on bumpy roads.
Slow down on downhill slopes.
Danger! Must not be used by
people under the age of 18 years
and by non-experts.
Danger! Do not reverse with
accelerated engine.
When engine is at full power, it is
dangerous to turn suddenly.
Danger! Do not make sudden
movements with the forwards or
backwards lever.
To avoid the danger of toxic exhausts,
do not use the engine indoors when
turned on.
Fill the fuel tank before starting up the
engine. Only refuel outdoors. Always
turn off the engine. Stay away from
sparks or ames. Do not smoke. Do
not remove the fuel tank cap when the
engine is hot. Safely close the tank cap
and the fuel containers.
Avoid fuel leaks. After having lled
the tank dry all fuel resi-dues on the
machine before starting the engine.
Danger! Do not use the machine
near ditches or piers that may give
way under the weight of the machine,
especially when the surface is friable or
wet.
Always take downhill bends slowly.
Danger! Do not tamper with or disable
the safety devices.
Danger! Do not work with persons near
the machine, foreign objects they may
be launched by the blades or rotating
parts, making it very dangerous.
When the machine is not in use, remove
the keys from the panel and store them
in a place inaccessible to children.
Danger! Do not carry out any type
of adjustments or cleaning when the
engine is in operation.
Danger! Do not have the machine
checked by other people while seated
at the steering wheel with the engine
in operation.
Safety

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BCS660HY/0819 Page 7
The user is always responsible
for damage caused to third
parties.
All improper use will cause
the warranty to expire and the
manufacturer shall not be held
liable.
Broken blades and deformed
teeth must always be replaced,
never repaired.
Always use original spare parts
and accessories.
Only work in daylight or in good
articial light.
Danger! Do not stop on slopes
or when working uphill or
downhill.
If you have to empty the fuel
tank, do the operation out-doors.
CAUTION! To lower the risk of
re, keep the engine, mufer,
exhaust manifolds, battery, tank
area and fuel pipes free from
grass, leaves, dust, etc.
Danger! Do not store the
machine in buildings where
fuel fumes could come into
contact with ames. sparks and
unsheathed electrical wires.
Always replace the worn or
damaged mufers.
Keep the fuel in designated
containers. Never keep the fuel
in food-grade containers.
Pay particular attention to persons and
occasional passers-by when working
near roads.
Danger! Never work with persons
around the machine. Always maintain a
safety distance.
Danger! Do not tamper with the engine
settings, especially the maximum
number of revolutions.
If you hit a foreign body, disengage
the PTO, stop the engine, remove the
ignition key and inspect the machine.
If the machine vibrates, take it to
Tracmaster or an Authorised Dealer to
have it checked.
Let the engine and mufer cool down
before moving the machine indoors.
Safety

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Page 8 BCS660HY/0819
Identication and Stickers/Labels
An identication label is applied to every machine in accordance with the EC Machinery Directive
(gs. 2a & 2c) and is located as per g. 2b.
1. Brand
2. Manufacturer
3. Model
4. Engine
5. Engine power (kW)
6. Weight (kg)
7. Year of manufacture
8. Serial number
Preservation of the Labels
IMPORTANT!
The labels must be kept clean from dust and mud.
Labels must always be clearly visible and legible.
Labels must be replaced if they are missing or illegible.
In the case of a replacement part or implement for the machine, or replacement of any
components that were originally equipped with labels, it is imperative that the labels are present,
so they must be replaced if they are missing or illegible.
The labels are available on the parts diagram specic to each machine model.
New labels may be obtained from the Spare Parts Department at Tracmaster Ltd or through your
Authorised Dealer.
Figure 2a
Figure 2b

BCS 660HY Hydrostatic Commander
BCS660HY/0819 Page 9
Stickers/Labels
The stickers/labels located on the machine are as follows:

BCS 660HY Hydrostatic Commander
Page 10 BCS660HY/0819
1. CE identication
2. Steering controls
3. Read the user manual
4. Engine on/off
5. Slow/fast speed
6. PTO engagement
7. Throttle control
8. PowerSafe®operation
9. Raise/lower handlebar
10. Foward/reverse indicator
11. Unlock the parking brake
12. Hot surfaces
13. Risk of explosion
14. Filter maintenance
15. Decompression
16. Engine operation
17. Made in Italy
18. BCS logo
19. 660HY WS model
Stickers/Labels
Figure 2c

BCS 660HY Hydrostatic Commander
BCS660HY/0819 Page 11
Controls Description
1. Wheel speed lever
2. PTO engagement lever
3. Handlebar height adjustment lever
4. Parking brake lock lever
5. Throttle lever
6. Engine stop lever
7. Red OPC stop lever
8. PowerSafe® clutch lever
9. Right steering lever (also on the right)
10. Left steering lever
11. Right steering lever
12. Handlebar lateral adjusting lever
13. Hydrostatic transmission control lever
14. Dipstick transmission oil level and lling
15. Support and lter oil transmission
16. PTO quick hitch
17. Oil radiator
18. Fuel tank cap
Figure 1a

BCS 660HY Hydrostatic Commander
Page 12 BCS660HY/0819
Controls Description
19. Support control rod
20. Recoil start device
21. Balancing plates
22. Dipstick engine oil level and lling
23. Engine oil drain plug
24. Engine electric switch (gasoline)
25. Engine dry air lter
26. Fuel tap
27. Hydro-transmission cooling fan
28. Quick coupling PTO knob
29. Plug (petrol)
30. Carburetor and drain screw (petrol)
31. Decompressor starting (diesel)
32. Magnetic cap
33. PowerSafe®unit clutch
34. Hydrostatic group
35. Hydraulic steering clutches
36. Quick coupling PTO knob
Figure 1b

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BCS660HY/0819 Page 13
Pre-Operation Checks
Refer to Figures 1a and 1b on pages 11-12
Before switching on the engine:
Check if the air intake grills for cooling the engine are clean.
Check the engine oil level
(g. 1a, 22) .
Check the gear oil level
(g. 1a, 14) .
Check that the PTO engagement lever is in neutral position
(g. 1a, 3) .
Chech that the air lter
(g. 1b, 25) is clean, if not then it must be cleaned.
Check that the safety equipment, including blade guards, is clean and free from obstructions,
and that the blade is sharp.
Check that the handlebar adjustment is working, by using the lever
(g. 1a, 3) and moving the
handlebars to the side position
(g. 1a, 12) .
Check that there is sufcient fuel in the tank.
IMPORTANT! Use clean fuel, fresh and stored in appropriate containers, otherwise the
injector, fuel pump, carburetor, or the plug could be damaged.
Remove the cap
(g. 1b, 18) and ll the fuel tank using a funnel with a ne lter.
Avoid the use of contaminated fuel, old or poorly preserved, the manufacturer and retailer
assume no responsibilities for damage to unit due to poor quality and poor preservation of the
fuel by the owner of the machine.
IMPORTANT! Diesel engines. Every 30-40 days start the engine and let it run for a few
minutes to keep the injector and the pump operating, and to prevent it from sticking.

BCS 660HY Hydrostatic Commander
Page 14 BCS660HY/0819
Attaching Implements
Implements are mounted directly to the machine
coupler
(g. 5a, 1) by attaching the coupler (g.
5b, 3)
that is xed to the implement.
The tting and removal of attachments is
achieved by rotating the knob
(g. 5b, 2) .
The the device is locked by turning the knob
(g. 5b, 3) clockwise and unlocked by the knob
anti-clockwise.
It is important that nuts
(g. 5b, 4) which
fasten the implement and the bushing are well
tightened. 1
Figure 5b
Figure 5a
4
2
3

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BCS660HY/0819 Page 15
Making Adjustments
The machine is delivered with the correct
adjustments, however, if it is necessary to make
adjustments, then this should be done via the
adjusting screws below or on the handlebar:
PowerSafe®clutch cable adjustment
(g. 6a, 1).
Steering brakes/clutches cable adjustment
(gs. 6a & 6b, 2).
Throttle cable adjustment (g. 6c, 3).
Forward/reverse knob cable adjustment (g.
6d, 4).
Engine stop cable adjustment (g. 6c, 5).
Engine RPM adjustment (g. 6c, 6) (see engine
manual).
Figure 6d
4
Figure 6b
2
Figure 6a
1
2
Figure 6c
6
3
5

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Page 16 BCS660HY/0819
Starting the Machine - Petrol Engine
IMPORTANT! Before start-up read the Pre-Operation
Checks and the Safety information.
Petrol engines
1. Check that the stop lever (g. 7a, 1) is at the green ON [I]
position.
2. Check that the engine stop switch
(g. 7b, 2) is in the ON
[I] position.
3. Apply half throttle using lever
(g.7c, 3) .
4. Turn the fuel tap
(g. 7d, 4) to ‘ON’ position, and if the
engine is cold set the choke lever to ‘ON’ position (g. 7d,
5).
5. Pull the recoil rope
(g. 7e, 6) gently until it engages then
give it a good strong pull to start the engine.
6. Once the engine has started, release the choke lever after
a few seconds and return the throttle lever to idle position.
Figure 7a
1
Figure 7b
2
Figure 7c
3
Figure 7e
6
Figure 7d
5
4

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BCS660HY/0819 Page 17
Starting the Machine - Diesel Engine
IMPORTANT! Before start-up read the Pre-Operation
Checks and the Safety information.
Diesel engines
1. Check that the stop lever (g.7f, 7) is at the green ON [I]
position.
2. Set the fuel tap to ‘O’ position
(g. 7g, 8) .
3. Apply full throttle
(g. 7h, 9) .
4. Pull the recoil handle out slowly
(g.7i, 10) until resistance/
compression is felt and then let it back in.
5. Press down, but DO NOT HOLD, the decompression lever
(g. 7i, 11) . It will stay down if the engine is on compression.
6. Grip the recoil handle
(g. 7i, 10) with both hands and pull
rmly and positively, making sure you use the entire length
of the rope.
7. Once the engine has started, return the throttle to the IDLE
position.
If the engine does NOT start then go back to step 4 and repeat
the procedure.
Figure 7f
7
Figure 7g
8
Figure 7h
9
Figure 7j
11
Figure 7i
10

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Page 18 BCS660HY/0819
Operating Test
After starting the engine, check that the levers and controls
are all functioning correctly.
If you have tted an implement to the power unit, then
read the relavent user manual. For information on how to
connect an implement to the power unit see page 14.
Follow the steps below to check correct function of machine:
1. Open the brake unlock lever
(gs. 8a & 8b, S) by
pushing it in the direction indicated by arrow 1;
2. Use the wheel speed lever
(g. 8b, A) in the direction
indicated by arrow 2, to check that the lever
(g. 8a,
R)
moves along the position indicated by arrow 3 (gear
position/lock activated);
IMPORTANT! The area indicated by arrow 4
(g.8a) is the brake unlock position (see image
of label -
g. 8f ) which enables the machine to
be pushed when the engine is off.
3. Pull (arrow 1) the clutch lever
(g. 8c, F) .
4. Lower (arrow 2) the red PowerSafe®lever
(g. 8c, P) .
5. Select the low or fast range with the control rod
(A, g.
8b)
.
6. Move the red lever
(g. 8d, T) slowly forwards and
backwards to verify that the machine moves.
7. By mean of the clutch insert the PTO with the control
rod
(g. 8b, B) and verify if the applied implement
turns regularly.
8. After the verify, switch off the engine by moving the
stop lever
(g. 8e, G) in position (0).
Figure 8a
1
2
S
R
R
A
34
Figure 8f
Figure 8b
B
S
A
Figure 8d
T
Figure 8e
G
Figure 8c
F
P

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BCS660HY/0819 Page 19
Operation
IMPORTANT!
Inspect the area before work to ensure that there are no stones, sticks, pipes for irrigation or
foreign objects.
When working adjust the speed accordingly based on the work being undertaken.
Engage the PTO few feet before entering the work area.
Caution! During the RUNNING check the oil daily, and change the engine oil after the
rst 30 hours of operation.
Always follow the maintenance program information provided with the machine.
If the engine keeps stopping, it may be due to the density or quantity of vegetation. In this case
reduce the forward speed to slow the machine. If the problem persists, then check the engine
and/or the implement.
Whilst working, be careful near trees and bushes, and near curbs that could damage the
implement, particularly blades and the transmission.
After nishing the work, switch off the engine, and check that the machine is locked.
Using the machine on slopes
Caution! If the wheels slip while operating on a slope, correct the working angle using
the steering levers
(g.1a, 9/10/11) .
You should always work across the face of the slope, never up and down.
For extra traction when cutting on slopes we recommend using either the twin 5.0x10 wheels or
the wide 8.0x10 lug wheels, or t the steel bank wheels.
When changing direction be careful that the wheels do not hit obstacles (stones, branches,
roots, etc.) that could cause you to lose control of the machine.
Be careful when operating on loose soil or wet grass because the machine could slip.
To descend the slope, use a slow speed and avoid passing over dry or cut grass because the
wheels could lose traction.
Working on slopes, in case of use of the clutch an automatic brake will lock the machine in every
condition of stationery work, also with engine off.

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Page 20 BCS660HY/0819
Operation
Caution! Do not unlock the automatic brake (gs. 1a & 1b, 4) whilst on the slope. To
change the speed from 1st to 2nd and vice-versa, hold the hydro-control lever
(g. 1a,
13)
at the minimum speed, never put into neutral.
Hydrostatic transmission / Gearbox
The transmission is composed of a hydrostatic unit and gears in an oil bath with 2 ranges of
speed forward and reverse.
The 2 speeds are adjustable; the low range should be used for working.
There is a neutral position for moving the machine with a safety lock to avoid accidental
engagement of the implement.
There is also a stationery brake (auto-hold) that locks the machine with the engine off.
Hydraulic steering Brakes - Clutches (work / service)
The machine has 2 integrated steering brakes/clutches. They have multiple discs, automatic
adjustment of the play, and are independent for each wheel. They are controlled by a lever on
the handlebar, with a double lever for right steering.
Mechanic stationery brake
The automatic brake (auto-hold), locks the machine in any working situation and also with
engine off
(g. 1a, 28) .
Checking the oil levels
Check the engine and gearbox oil levels daily and ensure there is no leakage. See pages 24-25
for more information on how to change the oil.
Clean the air lter daily.
Greasing
The machine and implements are equipped with a geasing point (identied in the specic user
manual). Daily general lubrication extends the life of the machine, so it is strongly recommended
that the instructions in the relevant user manuals are followed.