Working safely with cut-off machines
Contents
1. which should release the starting throttle lock and allow the engine to slow down to idle A Warning When you pull the starter grip do not wrap the starter rope around your hand Do not allow the grip to snap back but guide the starter rope slowly back to permit the rope to rewind properly Fail ure to follow this procedure may result in injuries to hand or fingers and may dam age the starter mechanism Important Adjustments At correct idle speed the wheel should not turn For directions to adjust idle speed see the appropriate section of your instruction manual A Warning Do not use a cut off machine with incor rect idle speed adjustment The rotating wheel may cause injury If you cannot obtain the correct setting have your STIHL dealer check your cut off machine and make proper adjustments or repairs Working Conditions Operate the cut off machine under good visibility and daylight conditions only Wearing of hearing protection reduces sound perception Be alert not to miss voice signals from co workers Keep within calling distance to other persons who may assist in case of emergency A Warning As soon as the engine is running this product gen erates toxic exhaust fumes containing chemi cals such as unburned hydrocarbons including benzene and carbon monoxide that are known to cause respiratory prob lems cancer birth defects or other reproductive harm Some of the gases e g ca2. Particular care and precision are required for free hand cutting along such cutting lines Avoid side loading the wheel or causing it to bind English E o S e q a i o Cut a guiding groove along the marked cutting line starting at the top and moving out towards both sides Cut into the pipe or round object etc at the ends of the cutting line so that the material does not chip Cut deeper into the parting cut with uniform back and forth movements starting at the top and moving out towards the sides Advance the cutting wheel along the guiding groove at full cutting depth Always reposition the cutting wheel afresh taking care not to wedge it if the cutting direction has to be corrected slightly If necessary leave small ridges of uncut material to hold the severed part in position These ridges can subsequently be broken through 17 English Cutting wheels Cutting wheels are exposed to extremely high loads especially during freehand cutting The cutting wheels which have been developed by STIHL in cooperation with renowned manufacturers of abrasive wheels are of high quality and tailored precisely to the respective intended use as well as the engine performance of the cut off machine They are of consistently outstanding quality Transport and storage Do not expose cutting wheels to direct sunshine or other thermal stresses during transport and storage Avoid jolting and imp
3. Carburetor Adjusting Screws For tuning the carburetor Fuel Filler Cap For closing the fuel tank Water Attachment For connection of water supply for wet cutting Tensioning Nut For tensioning the ribbed belt Adjusting Lever To adjust the wheel guard in a way that sparks dust cutting debris or wheel fragments are directed away from the operator Abrasive Wheel Can either be a composite abrasive wheel or a diamond abrasive wheel Working safely with cut off machines 12 13 14 15 16 17 18 19 20 21 Front Thrust Washer Distributes clamping pressure of mounting nut evenly over cutting wheel Guard Guards the wheel and deflects sparks dust cutting debris or wheel fragments Muffler Reduces engine exhaust noises and diverts exhaust gases away from operator Spark Arresting Screen Designed to reduce the risk of fire Front Handle Handlebar for the left hand of the power tool Decompression Valve Releases compression pressure to make engine starting easier when activated Cap for Spark Plug Boot The spark plug boot connects the spark plug with the ignition lead Choke Lever Eases engine starting by enriching mixture Fuel Pump Provides additional fuel feed for a cold start Filter Cover Covers and protects the air filter element Clutch Couples engine to the belt pulley when engine is accelerated beyond idle speed Not illustrated English Belt Pull
4. machine to cut or disturb asbestos asbestos containing products or prod ucts such as pipes which are wrapped or covered with asbestos insulation If you have any reason to believe that you might be cutting asbestos immediately contact your employer or a local OSHA representative Working safely with cut off machines en 002BA060 KN A Warning Your STIHL cut off machine is designed for hand held use or operation on a cut off machine cart Cutting with your cut off machine resting on the ground or other surface can cause excessive wear to the bracket designed to protect the bottom of the tank housing Loss of fuel and personal injury from fire may result Replace damaged or badly worn brack ets immediately Grip Never use the cut off machine with one hand Always hold the cut off machine firmly with both hands when the engine is running Place your left hand on front handle bar and your right hand on rear handle and throttle trigger Left handed users should follow this instruction too 002BA061 KN Wrap your fingers tightly around the handles keeping the handles cradled between your thumbs and forefingers English Make sure your cut off machine handles and grip are in good condition and free of moisture pitch oil fuel mix or grease Never touch a rotating wheel with your hand or any part of your body A Warning Clear the area where you are working Avoid stumbling
5. segments Built up edges can form Working safely with cut off machines when cutting extremely hard material such as granite asa result of incorrect handling such as applying excessive feed force if extremely large sections are cut without a pendulum movement back and forth in the cutting plane Built up edges increase vibrations reduce cutting performance and cause sparking Diamond cutting wheels must be dressed at the first sign of built up edges For this purpose briefly cut a more abrasive material such as sandstone aerated concrete or asphalt Wet cutting helps to prevent the formation of built up edges H z z rey o lt ao If you continue to use a cutting wheel with blunt segments the segments may soften as a result of excessive heat built up The wheel core will also overheat and lose its mechanical strength This can lead to considerable stress as clearly indicated by stress cracks and or a wobbling movement of the cutting wheel English A Warning Such cutting wheels may break apart or throw off segments during use causing serious or fatal injury Replace them immediately 21 English Maintenance and Care The following maintenance intervals apply in normal operating conditions The specified intervals must be shortened accordingly when working for longer than 5 3 n
6. Clay pipes Diamond abrasive wheels cannot be used to cut metal Working safely with cut off machines Short names 798711 080978 180BA010 KN The short name is a combination of letters and numerals with up to four digits The letters indicate the main area of use for the cutting wheel Letter Main area of use A Asphalt B Concrete BA Concrete Asphalt S Stone rock SB Rock Concrete The numerals indicate the performance class of the STIHL diamond cutting wheel Radial and axial run out A correctly mounted spindle bearing on the cut off machine is essential for a long service life and efficient operation of the diamond cutting wheel Using a cutting wheel on a cut off machine with defective spindle bearing can lead to axial and radial run out Working safely with cut off machines z x e lt ao O 2 Excessive radial run out A causes individual diamond segments to be overloaded and to overheat This can in turn lead to stress cracking in the wheel core or to softening of individual segments Axial run out or wobble B results in higher thermal stress and wider cuts English 19 English Troubleshooting Cutting wheel Problem Cause Remedy Frayed edges or tears cut wanders out of line increased wear at the sides of the segments Radial or axial run out Consult a dealer Cutting wheel wobbles Use a new cutting wheel Frayed
7. Maintenance Repair and Storing of the Cut Off Machine Maintenance replacement or repair of the emission control devices and systems may be performed by any nonroad engine repair establishment or individual However if you make a warranty claim for a component that has not been serviced or maintained properly or if nonapproved replacement parts were used STIHL may deny warranty coverage Never operate a cut off machine that is damaged improperly adjusted or not completely or securely assembled Follow the maintenance and repair instructions in the appropriate sections of your instruction manual A Warning Use only STIHL replacement parts for maintenance and repair Use of parts manufactured by others may cause seri ous or fatal injury A Warning Always stop the machine make sure that the wheel is stopped and remove the spark plug boot from the spark plug before doing any maintenance or repair work or cleaning the cut off machine Do not attempt any maintenance or repair work not described in your instruction manual Have such work performed only at your STIHL servicing dealer 14 Clean off grinding dust after finishing work Tighten all nuts bolts and screws except the carburetor adjustment screws after each use Do not clean your machine with a pressure washer The solid jet of water may damage parts of the machine A Warning Never test the ignition system with spark plug boot removed from spark plu
8. STIHL i Working safely with cut off machines Contents Safety Precautions and Working Techniques Sample applications Cutting wheels Composite resin cutting wheels Diamond cutting wheels Maintenance and Care Main Parts Original Instruction Manual Printing inks contain vegetable oils paper can be recycled Printed on chlorine free paper ANDREAS STIHL AG amp Co KG 2010 0457 186 3021 M0 B10 xxx 0000000552_001_GB STIHL Working safely with cut off machines 15 18 18 18 22 24 English This manual contains the safety precautions and recommended cutting techniques outlined in STIHL instruction manuals for gasoline powered cut off machines Even if you are an experienced cut off machine user itis in your own interest to familiarize yourself with the latest instructions and safety precautions regarding your cut off machine Please note that the illustrations in the chapter Main Parts of the Machine in this manual show the cut off machine STIHL Cutquik TS 420 Other cut off machine models may have different parts and controls You should therefore always refer to the instruction manual of your particular cut off machine model Contact your STIHL dealer or the STIHL distributor for your area if you do not understand any of the instructions in this manual English Safety Precautions and Working Techniques The use of any cut off machine may be hazard ous Because a cut off machi
9. abrasive wheel approved for the type of material to be cut There are different types of abrasive wheels each specially marked With respect to composite wheels for example 1 Stone Also can be used for concrete masonry reinforced concrete and brick cutting 2 Steel Can be used for all ferrous metal cutting 3 Asphalt Also can be used for aggregate concrete cutting 4 Ductile iron Also can be used for certain grades of cast iron SG 17 24 bronze and copper cutting For cutting composite materials please ask your STIHL dealer Diamond Abrasive Wheels Diamond abrasive wheels have a much better cutting performance than composite abrasive wheels The diamond wheels are steel centered and diamond particles are imbedded in their cutting edges They can be used for concrete asphalt natural stone clay pipe brick and the like Working safely with cut off machines They are not normally suitable for cutting metal or other materials Wet or dry cutting is possible Water attachments are included with your STIHL cut off machine See the appropriate section of your instruction manual A Warning Do not remount a used diamond abra sive wheel without first inspecting for under cutting flatness core fatigue segment damage or loss signs of over heating discoloration and possible arbor hole damage See the chapter Diamond Cutting Wheels Check the wheel for cracks and make sure that no pieces ha
10. acts Stack cutting wheels flat on a level surface in the original packaging in a dry place where the temperature is as constant as possible Do not store cutting wheels in the vicinity of aggressive fluids Store cutting wheels in a frost free place 18 Composite resin cutting wheels z x e f lt ao f Economic benefit is improved and premature wear can be avoided by choosing and using the correct composite resin cutting wheel The short name e g asphalt concrete onthe label and on the packaging table with recommended uses can help to ensure the correct choice STIHL composite resin cutting wheels are suitable depending on the version for cutting the following materials Asphalt Concrete Stone Ductile cast pipes Steel STIHL composite resin cutting wheels cannot be used to cut railway tracks Diamond cutting wheels 180BA001 KN Economic benefit is improved and premature wear can be avoided by choosing and using the correct diamond cutting wheel The short name see following explanation onthe label and onthe packaging table with recommended uses can help to ensure the correct choice STIHL diamond cutting wheels are suitable depending on the version for cutting the following materials Asphalt Concrete Stone hard rock Abrasive concrete Green concrete Clay bricks
11. atter during operation and cause serious personal injury Fuel Your STIHL power tool uses an oil gasoline mixture for fuel see the chapter on Fuel of your instruction manual A Warning Gasoline is an extremely flammable fuel If spilled and ignited by a spark or other ignition source it can cause fire and seri ous burn injury or property damage Use extreme caution when handling gasoline or fuel mix Do not smoke or bring any fire or flame near the fuel or the power tool Note that combustible fuel vapor may escape from the fuel system A Warning Dust may collect on the powerhead especially around the carburetor and may absorb gasoline resulting in danger of fire Clean dust from the powerhead regularly Fueling Instructions A Warning Fuel your power tool in well ventilated areas outdoors Always shut off the engine and allow it to cool before refu eling Gasoline vapor pressure may build up inside the fuel tank depending on the fuel used the weather conditions and the tank venting system In order to reduce the risk of burns and other personal injury from escaping gas vapor and fumes remove the fuel filler cap on your power tool carefully so as to allow any pressure build up in the tank to release slowly Never remove the fuel filler cap while the engine is running Select bare ground for fueling and move at least 10 feet 3 m from the fueling spot before starting the engine Wipe off a
12. ck that the spark plug boot is securely mounted on the spark plug a loose boot may cause arcing that could ignite combustible fumes and cause a fire Proper tensioning of the ribbed V belt is important In order to avoid an incorrect setting the tensioning procedure must be followed as described in your manual Always make sure the hexagonal collar nuts for the cast arm are tightened securely Check ribbed belt tension after one hour of operation and correct if necessary English Starting 002BA058 KN A Warning Your cut off machine is a one person tool Do not allow other persons to be near a running cut off machine Start and operate your cut off machine with out assistance For specific starting instructions see the appropriate section of your instruction manual Do not drop start This method is very dangerous because you may lose control of the cut off machine Place the cut off machine on firm ground or other solid surface in an open area Maintain good balance and secure footing Be absolutely sure that the cutting wheel is clear of you and all other obstructions and objects including the ground When the engine starts at starting throttle engine speed will be fast enough for the clutch to engage the belt pulley and turn English the wheel Never attempt to start the cut off machine when the abrasive wheel is in a cut Once the engine has started immediately blip the throttle trigger
13. ding of the wheel in the kerf that under certain circumstances can then result in serious or fatal injury from reactive forces See the section entitled Reactive Forces including Kickback Never use a wheel that wobbles or that has ever wobbled Even though such a wheel may temporarily cease to wobble e g if run without load it will always be prone to wobble again under certain conditions Replace it immediately before further use Composite abrasive wheels are heat sensitive Always store your cut off machine in a place where a composite wheel is not exposed to direct sunlight or other sources of heat Store spare composite wheels in a dry place where there is no risk of frost damage Failure to follow these directions may cause the wheel to shatter or crack in use causing serious or fatal injury A Warning Never use circular saw blades carbide tipped blades rescue blades wood cutting blades or toothed blades of any nature They can cause severe personal injury from blade con tact thrown objects and or reactive forces including kickback See section on Reactive Forces Your STIHL dealer stocks a range of special abra sive wheels for the many applications of the cut off machine Working safely with cut off machines A Warning Use of the wrong abrasive wheel or the cutting of material for which the wheel was not designed may cause the wheel to shatter causing serious or fatal injury Only use the
14. e binding that can lead to loss of control and or kickback If the wheel you are using begins to wobble or has ever wobbled discard it immedi ately Although such a wheel may temporarily cease to wobble e g if run without load it will always be prone to wobble again under certain conditions Some other unauthorized diamond wheels are manufactured with abrasive material on their sides Do not use such wheels since the abrasive material may lead to increased reactive forces in a pinch situation Working safely with cut off machines A Warning Never use chipped abrasive wheels or circular saw blades carbide tipped blades rescue blades or wood cutting or toothed blades of any nature on a cut off machine The use of such wheels or blades will greatly increase the risk of loss of control and severe personal injury or death from reactive forces since the chipped section of an abrasive wheel or the teeth of a saw blade may catch in the material being cut and gen erate substantially greater reactive forces including rotational kickback Cut off machines are designed for use with abrasive wheels in good condition only Machines designed for use with wood cutting or other toothed blades use different types of guarding systems that provide the protection necessary for those types of blades Machines such as a cut off machine that are designed for use with abrasive wheels require a different guarding system which is not de
15. e is not utilized the operator and any bystanders should always wear a respirator approved by NIOSH MSHA for the material being cut See the section on Respiratory Protection in the chapter Sample Applications in the instruction manual Even if wet cutting at the recommended flow rate an operator who is actively cutting for more than two hours in one Working safely with cut off machines day should wear at least a NIOSH approved disposable respirator Consult and follow any federal state or local laws or regulations with respect to dry and wet cutting A Warning Cutting masonry concrete and other materials with silica in their composition may give off dust containing crystalline silica Silica is a basic component of sand quartz brick clay granite and numerous other minerals and rocks Repeated and or substantial inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases including silicosis In addition California and some other authorities have listed respirable crystalline silica as a sub stance known to cause cancer When cutting such materials always follow the respiratory precautions mentioned above A Warning Breathing asbestos dust is dangerous and can cause severe or fatal injury respiratory illness or cancer The use and disposal of asbestos containing products have been strictly regulated by OSHA and the Environmental Protec tion Agency Do not use your cut off
16. e wheel This could result in high frictional forces and thus greatly reduce the engine Working safely with cut off machines power available for the actual cutting work It could also damage the abrasive wheel STIHL recommends the use of the cart for longer cuts in a straight line Wet Cutting with Abrasive Wheels Before wet cutting make sure water will not damage the floor or building A Warning To reduce the risk of electrocution to you or bystanders do not allow water or sludge to contact live electric wires A Warning To reduce the risk of injury from wheel breakage when wet cutting with any composite wheel 1 Make certain water does not flow on a wheel that is not running since the wheel will absorb water which will affect wheel balance 2 Be certain water is applied to both sides of wheel since uneven distribution can cause one sided wear 3 After finishing work run the cutting wheel at normal operating speed for about 3 to 6 seconds without water so that the remaining water is flung off Working safely with cut off machines A Warning To reduce the risk of injury from wheel breakage when wet cutting with a com posite wheel that is not specifically designed for wet cutting never store and reuse such a wheel that has been used with water Use these wheels up the same day Reactive Forces including Kickback A Warning Reactive forces may occur at any time the cut ting wheel
17. eaking out A Warning Never attempt to force the cap open by using a tool It may damage the cap and allow fuel to leak Before use make sure that the fuel cap has been properly tightened and any spilled fuel wiped away Check for fuel leakage while refueling and during operation If a fuel leak is suspected do not start or run the engine until the leak is fixed and spilled fuel has been wiped away Before Starting For assembly follow the procedure described in the appropriate section of your instruction manual Never operate a cut off machine that is damaged improperly adjusted or not completely and securely assembled Check machine that it is ready for proper operation Keep the handles dry clean and free of oil and fuel Working safely with cut off machines A Warning Before operation of your cut off machine be sure the controls e g throttle trigger throttle trigger lockout stop switch and the safety devices are working properly the carburetor idle and maximum speed are correctly adjusted the wheel is properly mounted and the wheel guard is in place and securely fastened to your unit All wheels should be carefully inspected for good condition before mounting Adjust the wheel guard so that sparks dust and AN cut material are deflected Z away from the operator and cannot reach flam mable surroundings See section Operating Instructions of your instruction manual A Warning Che
18. edges cut wanders out of line lit tle or no cutting performance sparking Cutting wheel is blunt built up edges on cut ting wheels for stone Dress the cutting wheel for stone by briefly cutting in abrasive material use a new cutting wheel for cutting asphalt Poor cutting performance high level of segment wear Cutting wheel rotates in the wrong direction Mount the cutting wheel with correct direction of rotation Chipping or cracking in the wheel core and segments Overload Replace immediately with a new cutting wheel Undercutting Cutting in a material for which the wheel is not rated Use a new cutting wheel note the differ ent cutting layers in different materials 1 STIHL recommends that a STIHL servicing dealer be consulted 20 Working safely with cut off machines Undercut z a a o lt fea e Undercutting is a wearing away of the steel core at or just below the diamond segments When cutting road surfaces do not cut through into the more abrasive ballast gravel crushed rock below as indicated by a light colored dust This can cause excessive undercutting resulting in wheel breakage and or thrown segments A Warning Immediately replace a diamond wheel if the core has been severely undercut Built up edges dressing Built up edges are identified by a pale grey deposit on the top of the diamond segments that clogs and blunts the
19. el in the kerf English 11 Use your cut off machine for cutting only It is not designed for prying or shoveling away any objects 12 Be especially alert for reactive forces including kickback when cutting with the front and upper quadrant of the wheel Never pull the top of the wheel guard back beyond the limit stop 13 Be alert to shifting of the workpiece or anything that could cause the cut to close and pinch the wheel especially in the upper quadrant Support the workpiece in such a way that the cut remains open Never make a cut that results in a binding of the wheel 14 Use wet cutting whenever feasible Ina pinch situation the water can act as a lubricant and reduce the energy of reactive forces 15 Release the pressure on the cut off machine as you reach the end of the cut Too much pressure may cause the operator to lose control of the cut off machine when the abrasive wheel completes the cut The abrasive wheel may contact the operator or strike some foreign object and shatter 16 Use extreme caution when reentering a cut and do not turn the wheel at an angle or push the wheel into the cut as this may result ina binding of the wheel Gyroscopic Forces Be alert for gyroscopic forces that are caused by the rapid spinning of the cut off wheel These forces result in 13 English opposition to directional change e g when the operator attempts to move the machine in a sideways direction
20. ess and when the cut is finished see illustration Never make a cut that results in a binding of the wheel If you cannot properly support the workpiece do not use a cutting off machine to make the cut select another tool or cutting technique that is not subject to kickback A Warning Be particularly alert when cutting a workpiece such as a pipe with a belled end ora pipe in a trench that if not prop erly supported can sag upon completion of the cut creating a pinch not where you are actually cutting but rather at or near the top of the work piece If the pinch is in the upper quadrant of the abrasive wheel kick back can result A Warning Use wet cutting whenever feasible since the water can act as a lubricant in a pinch situation and thus reduce the likelihood of reactive forces occurring and the energy of any such forces that do occur making it easier to maintain control of the machine A Warning Use only cutting attachments author ized by STIHL Use of non STIHL authorized wheels may be extremely dangerous Many substandard diamond wheels for instance are available in the market If they are not manufactured with the proper quality steel in their core if they are not properly tensioned or if other design or manufacturing defects exist they may e g begin to wobble during use If a diamond wheel begins or ceases to wobble within the kerf the change in the behavior of the wheel may cause a sever
21. ey The wheel that drives the ribbed belt and the abrasive wheel Not illustrated Anti Vibration System The anti vibration system includes a number of anti vibration elements designed to reduce the transmission of vibrations created by the engine to the operator s hands Not illustrated 25 Z WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A WARNING Some dust created by power grinding and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e lead from lead based paints and e crystalline silica from bricks and cement and other masonry products Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as those dust masks that are specially designed to filter out microscopic particles 0457 186 3021 englisch USA 0457 186 3021
22. g or with unseated spark plug since uncon tained sparking may cause a fire A Warning To reduce the risk of fire and burn injury use only spark plugs authorized by STIHL Always press spark plug boot snugly onto spark plug terminal of the proper size Note If terminal has a detachable SAE adapter nut it must be attached A loose connection between spark plug terminal and ignition wire connector in the boot may create arcing that could ignite combustible fumes and cause a fire Keep spark plug clean and make sure ignition lead is in good condition A Warning Do not operate your cut off machine if the muffler is damaged missing or mod ified An improperly maintained muffler will increase the risk of fire and hearing loss Never touch a hot muffler or spill fuel or other flammable liquid over it Burn injuries or fire will result If your muffler was equipped with a spark arresting screen to reduce the risk of fire e g in the USA Canada and Aus tralia never operate your cut off machine if the screen is missing or damaged For any maintenance please refer to the maintenance chart and to the warranty statement near the end of the instruction manual Store wheels on a flat surface in a dry place preferably at a constant temperature where there is not a risk of frost Do not store a cut off machine with a wheel mounted on the machine Store cut off machine in a high or locked place away from children Emp
23. icles of the material being cut sparks or pieces of damaged wheels either directly or by ricochet Failure to follow this instruction could result in serious or fatal injury A Warning Your cut off machine is equipped with a wheel guard limit stop that restricts the opening of the wheel guard To reduce the risk of injury from wheel contact and or reactive forces and to avoid damag ing the guarding system never attempt to pull the adjusting lever past the limit stop 10 A Warning Always check the wheel before use and after unintentionally striking any object frequently check it during use when it is stopped Look for cracks and make sure that it is undamaged and in good condi tion and that no pieces have broken off See sections on Abrasive Wheels and Reactive Forces in this manual Check the wheel guard for cracks If you dis cover any breaks or cracks fit a new guard before further use A Warning It is essential to determine the exact direction of the cut before applying the abrasive wheel to the work Wheels are constructed for radial pressure only Lateral pressure must be avoided Hold the cut off machine steady To reduce the risk of serious or fatal injury do not change the direction of the cut during the cut as this may produce a high tor sional load on the abrasive wheel and may cause it to break or shatter A Warning Do not use abrasive wheels for rough grinding Large bending stresses occ
24. lip gloves improve your grip and help to pro tect your hands Good footing is important in cut off machine work Wear sturdy boots with nonslip soles Steel toed safety boots are recommended A Warning Loose objects may be thrown toward the operator by the cutting tool To reduce the risk of injury to your eyes never operate a cut off machine unless wearing goggles or properly fitted safety glasses with adequate top and side protection complying with ANSI Z 87 1 Proper eye protection is a must wep Wear an approved safety hard hat to protect your head Cut off machine noise may damage your hearing Always wear sound barriers ear plugs or ear mufflers to help protect your hearing Regular users should have their hearing checked regularly English A Warning When wet cutting at the recommended flow rate is not utilized the oper ator should always wear a respirator approved by NIOSH MSHA for U the material being cut to reduce the risk of serious or fatal respiratory illness For additional details and warnings on this subject see information under Working Conditions in this instruction manual THE POWER TOOL For illustrations and definitions of the parts of the cut off machine see the chapter Main Parts A Warning Never modify a cut off machine in any way Only attachments supplied by STIHL or expressly approved by STIHL for use with the specific STIHL cut off machine mode
25. ls are authorized Although certain unauthorized attach ments are useable with the STIHL powerhead their use may in fact be extremely dangerous Abrasive Wheels A Warning Before mounting the cutting wheel make sure that the maximum operating wheel speed is above or equal to the spindle speed of your cut off machine as provided in the specifications of this manual A wheel that is not so rated may shatter or break and poses a threat of serious or fatal injury to the operator and other nearby persons Abrasive wheels for free hand cutting are subjected to particularly high bending and compression stresses A Warning Unauthorized wheels may be more likely to shatter or break Use only STIHL wheels or other authorized wheels with approved RPM ratings Read and follow any addional safety precautions that accompany the wheel A Warning Inspect the abrasive wheel frequently and replace immediately if the abrasive wheel is cracked or warped Cracked or warped wheels may shatter or break and cause serious or fatal personal injury Out of round or unbalanced abrasive wheels increase vibration and reduce the serv ice life of the cut off machine Unauthorized diamond abrasive wheels that utilize poor quality steel cores that are not properly tensioned or that have other design or manufacturing defects may begin to wobble during use which can cause wheel breakage Such wobbling can also lead to a severe bin
26. m back and forth In which direction can it move after movements being severed Is it under tension Cut through the slab at the ends so Helpers must not be put at risk of injury the material does not chip when the part is broken off or out e Then break the slab z x o f lt L fea f Thick walled workpieces should be cut with a uniform swinging movement back and forth 16 Working safely with cut off machines 180BA020 KN Curves must be cut in several straight passes taking care to ensure that the cutting wheel does not become wedged Cutting round and hollow workpieces Zz Es lt ao Pipes and round objects etc must be secured so that they cannot roll Avoid reinforcing elements especially in the direction of the cut when deciding on the cutting line Cut a guiding groove along the marked line Cut deeper into the parting cut with uniform back and forth movements Advance the cutting wheel along the guiding groove at full cutting depth Always reposition the cutting wheel taking care not to wedge it if the cutting direction has to be corrected slightly If necessary leave small ridges of uncut material to hold the Working safely with cut off machines severed part in position These ridges can subsequently be broken through Cutting shapes on pipes z x ke lt ao e io Mark the cutting line A Warning
27. n operator who is actively cut ting for more than two hours a day should wear at least a NIOSH approved disposable respirator 15 English Points to be noted with diamond and Cutting in several passes Cutting slabs composite resin cutting wheels e Place the slab securely on a non Object to be cut slip surface Must be fully supported Must be secured so that it cannot A roll or slip away Must be protected against vibration 180BA017 KN The cutting sequence Mark cutting line A The cutting sequence is important when cutting openings and recesses etc The last cut must always be made in such a way that the cutting wheel cannot become bound and so that the user is not at risk of being injured by the part that has been cut off or out Cuta guiding groove A along the marked line If applicable leave small ridges of uncut material to hold the severed part in position These ridges can subsequently be broken through Work along the cutting line If corrections are necessary always reposition the cutting wheel taking care to ensure that it is not wedged How heavy is the part The cutting depth per pass should not exceed 5 to 6 cm 2 to 2 1 2 Thicker material must be cut in several passes Leave a ridge C of uncut material z a D 3 lt a O A number of points must be decided before the part is finally severed Cut deeper into the parting cut B with unifor
28. ne is a high speed fast cutting power tool special safety precau tions must be observed to reduce the risk of per sonal injury and fire It is important that you read fully understand and observe the following safety precautions and warnings Read the instruction manual and the safety precautions periodically A Warning Careless or improper use of any cut off machine may cause serious or fatal injury Have your STIHL dealer show you how to operate your cut off machine Observe all applicable national state and local safety regulations standards and ordinances A Warning Your cut off machine is for professional use only Do not lend or rent your cut off machine without the instruction manual Be sure that anyone using it under stands the information contained in this manual A first time operator should obtain practical instruction before using the machine Employers should establish a training program for operators of gasoline powered hand held portable cut off machines to assure safe operation of these machines These safety precautions and warnings apply to the use of all current STIHL Cutquiks A Warning Use your cut off machine only for authorized uses For instance it is not suitable for cutting wood or wooden objects Misuse may result in personal injury or property damage including damage to the machine A Warning Minors should never be allowed to use a cut off machine Bystanders es
29. ny spilled fuel before starting your machine A Warning Check for fuel leakage while refueling and dur ing operation If fuel leakage is found do not start or run the engine until the leak is fixed and any spilled fuel has been wiped away Take care not to get fuel on your cloth ing If this happens change your clothing immediately A Warning If fuel gets spilled on clothes especially trousers it is very important to change clothes immediately Do not rely upon evaporation Flammable quantities of fuel may remain on clothes after a spill for longer than expected Cutting metal with a cut off machine when clothes are wet or damp from gasoline is extremely dangerous as the operator s clothes might catch fire and cause serious or fatal injury A Warning An improperly tightened fuel cap can loosen or come off and spill quantities of fuel Different cut off machines may be equipped with different fuel filler caps Bayonet Fuel Filler Cap 376BA014 KN Never use a tool to open or close the bayonet fuel filler cap as this could damage the cap and cause fuel to leak out The bayonet fuel filler cap must be closed with care after refuelling Working safely with cut off machines Fuel Filler Cap with Screw Thread Tighten the fuel filler cap as securely as possible K Cont after refuelling This reduces the risk of the cap working loose due to engine vibrations and fuel l
30. on a cut off machine is rotating The powerful force used to cut through a workpiece can be reversed and work against the operator If the wheel is slowed or stopped by frictional contact with any solid object or by a pinch or binding reactive forces can occur instantly and may result in the operator losing control of the cut off machine which in turn may result in serious or fatal injury An understanding of the causes of these reactive forces may help you avoid loss of control Reactive forces are exerted in a direction opposite to the direction in which the wheel is moving at the point of contact or of pinching binding If the wheel is slowed solely by frictional contact with a solid object such as the workpiece the resulting reactive forces are normally moderate and readily controllable by an operator who is holding the machine properly If however the wheel is abruptly slowed or stopped by a pinch or severe bind the reactive forces may be substantially English greater The greater the force generated the more difficult it will be for the operator to control the cut off machine Loss of control can result in severe personal injury or death Pull away Climbing Pinching and Rotational Kickback Forces The most common reactive forces are pull away and climbing If the contact is at the bottom of the wheel a cut off machine will try to pull away from the operator pull away If the contact is at the front of
31. on obstacles and watch out for holes or ditches Be extremely cautious when working on slopes or uneven ground Take extreme care in wet and freezing weather rain snow ice A Warning Never operate the cut off machine with the starting throttle lock engaged as this does not permit proper control of the speed of the unit and may lead to seri ous injury A Warning Sparks from cutting metal can burn or cause y clothing to catch fire Z Always direct sparks away from the operator or any flammable sur roundings Never cut metal while standing on a flammable surface such as wood or tar paper Where there is a risk of fire have appropriate fire extin guishing equipment readily available English A Warning To reduce the risk of injury from fire do not cut into any pipe drum or other con tainer without first ensuring that it does not contain a volatile or flammable substance A Warning When cutting into existing walls floors or similar structures be alert for hidden hazards such as electrical cables water and gas pipes and flammable sub stances Make sure that power water and gas have been shut off and pipes drained before starting to cut Operating Instructions A Warning The wheel guard is adjustable It is extremely important that the wheel guard is in place and set to suit the type of work and your stance The guard should always be adjusted so that the user is not endangered by part
32. ormal or under difficult cutting conditions extensive dust etc 2 x 5 fe x o _ 2 2 5 o s ne no amp 5 D o 3 5 lsz Il alz 2 3 S s2 G f z 2 D o 2 o ka Q 2 oO gt lt Visual inspection condition leaks X X Complete machine Clean X Operating elements Check operation X XxX test check X Fuel pick up body in fuel tank Replace X X XxX Fuel tank Clean x Clean retension Ribbed V belt Replace X Air filter all filter components Replace Only if there is a noticeable loss of engine power Cooling air intake slits Clean X Cylinder fins Have them cleaned by a specialist x dealer test check xX Spark arresting screen in muffler Clean or replace x test check x x Water attachment Have them maintained by a specialist dealer Check idle adjustment abrasive Xx Xx Carburetor wheel must not rotate Readjust idle speed X Adjust electrode gap X Spark plug Replace after 100 hours operation All accessible screws nuts and bolts not Retighten x x adjusting screws 22 Working safely with cut off machines English The following maintenance intervals apply in normal operating conditions The specified intervals must be shortened accordingly when working for longer than S 3 normal or under difficult cutting conditions extensive dust etc 3 2 x 5 fo x z 5 S a 3 S ka 5
33. own but cold weather smoking and diseases or physical conditions that affect blood vessels and blood trans port as well as high vibration levels and long periods of exposure to vibration are mentioned as factors in the develop ment of whitefinger disease In order to reduce the risk of whitefinger disease and carpal tunnel syndrome please note the following Working safely with cut off machines STIHL cut off machines are equipped with an anti vibration AV system designed to reduce the transmission of vibrations created by the machine to the operator s hands An AV system is recommended for those persons using cut off machines on a regular or sustained basis Wear gloves and keep your hands warm Keep the AV system well maintained A cut off machine with loose components or with damaged or worn AV elements will tend to have higher vibration levels Maintain a firm grip at all times but do not squeeze the handles with constant excessive pressure Take frequent breaks All the above mentioned precautions do not guarantee that you will not sustain whitefinger disease or carpal tunnel syndrome Therefore continual and regular users should monitor closely the condition of their hands and fingers If any of the above symptoms appear seek medical advice immediately A Warning The ignition system of your unit pro duces an electromagnetic field of a very low intensity This field may interfere wi
34. pecially children and animals should not be allowed in the area where a cut off machine is in use Never let the cut off machine run unattended Different models may have different parts and controls See the appropriate section of your instruction manual for a description of the controls and function of the parts of your model cut off machine Safe use of a cut off machine involves 1 the operator 2 the power tool 3 the use of the power tool THE OPERATOR Physical Condition You must be in good physical condition and mental health and not under the influence of any substance drugs alcohol etc which might impair vision dexterity or judgment Do not operate a cut off machine when you are fatigued Be alert if you get tired while operating your cut off machine take a break tiredness may result in loss of control Working with any cut off machine can be strenuous If you have any condition that might be aggravated by strenuous work check with your doctor before operating a cut off machine A Warning Prolonged use of cut off machines or other machines exposing the operator to vibrations may produce whitefinger disease Raynaud s phenomenon or carpal tunnel syndrome These condi tions reduce the hand s ability to feel and regulate temperature produce numbness and burning sensations and cause nerve and circulation damage and tissue necrosis All factors which contribute to whitefinger disease are not kn
35. precautions of this manual Wet cutting is generally not suitable for cutting metals Composite resin wheels designed for wet cutting Adjust water flow rate during cutting so it is suf ficient to bind all the dust that occurs at least 0 6 L min If the water flow rate is too high the cutting wheel may skim on the water surface in the cut and greatly reduce cutting performance To avoid this do not exceed a water flow rate of about 4 L min English Use water properly 1 Be certain water is applied to both sides of wheel since uneven distribution can cause one sided wear with possible wheel breakage 2 Make certain water does not flow on wheel that is not running since the wheel will absorb water and that will affect wheel balance 3 After finishing work run the cutting wheel at normal operating speed for about 3 to 6 seconds without water so that the remaining water is flung off Water connection A water attachment kit is mounted on the machine for use with all types of water supply A pressurized 10 liter water tank is available from STIHL for dust suppression A water tank for mounting on the Cutquik cart is also available for dust suppression Respiratory protection A Warning When wet cutting at the recommended flow rate is not utilized the operator and any bystanders should always wear a respirator approved by NIOSH MSHA for the material being cut Even if wet cutting a
36. rbon monoxide may be color less and odorless To reduce the risk of serious or fatal injury illness from inhal ing toxic fumes never run the machine indoors or in poorly ventilated locations Ensure proper ventilation when working in trenches or other confined areas A Warning Use of this product to cut masonry con crete metal and other materials can generate dust and fumes containing chemicals known to cause serious or fatal injury or illness such as respiratory disease cancer birth defects or other reproductive harm If you are unfamiliar with the risks associated with the partic ular material being cut review the material safety data sheet and or con sult your employer the material manufacturer supplier governmental agencies such as OSHA and NIOSH and other sources on hazardous materi als California and some other authorities for instance have published lists of substances known to cause can cer reproductive toxicity etc Control dust and fumes at the source where possible In this regard use good work practices and follow the recommendations of the manufacturer supplier OSHA NIOSH and occupational and trade associations A water attachment kit is provided with your cut off machine and should be used to reduce dust whenever wet cutting is feasible For dust suppression purposes the flow rate should be at least 0 6 liters 20 fl oz of water per minute If wet cutting at the recommended flow rat
37. s D no ele 3 gt AE o o gt 2 F amp z 8 S F amp 5 P a wS gt lt test check X Xx X Antivibration elements Have them replaced by a specialist x dealer test check xX X Abrasive wheel Replace X X Supports rubber buffers underneath the test check X machine Replace X Safety information sticker Replace X 1 STIHL recommends STIHL servicing dealers 2 present only in some countries 23 Working safely with cut off machines English Main Parts Rear Handle Throttle Trigger Lockout Throttle Trigger Slide Control Starter Grip Carburetor Adjusting Screws Fuel Filler Cap Water Attachment 9 Tensioning Nut 10 Adjusting Lever 11 Abrasive Wheel 12 Front Thrust Washer 13 Guard 14 Muffler 15 Spark Arresting Screen 16 Front Handle 17 Decompression Valve 18 Cap for Spark Plug Boot 19 Choke Lever 20 Fuel Pump 21 Filter Cover Serial Number ONOaARWHND z a o 3 lt a O i oO 24 Working safely with cut off machines Definitions 10 11 Rear Handle The support handle for the right hand Throttle Trigger Lockout Must be depressed before the throttle trigger can be activated Throttle Trigger Controls the speed of the engine Slide Control For starting throttle run and stop Keeps the throttle partially open during starting and switches off the ignition to stop the engine Starter Grip The grip of the pull starter for starting the engine
38. signed to provide protection against all dangers presented by circular saw blades carbide tipped blades rescue blades or wood cutting or toothed blades of any nature A Warning To reduce the risk of injury from loss of control from reactive forces including kickback 1 Hold the cut off machine firmly with both hands 2 Maintain good balance and footing at all times Never cut while standing on a ladder Working safely with cut off machines gt N 3 Position the cut off machine in such a way that your body is clear of the cutting attachment Avoid standing in direct line with the wheel Never bend over the cutting attachment especially when the guard is pulled back towards the top and there is a risk of reactive forces See illustration Do not cut above shoulder height Use only STIHL branded diamond and composite abrasive wheels Never work with a diamond wheel that wobbles or that has ever wobbled or that is manufactured with abrasive material on its sides 6 Do not cut wood or any other material for which the abrasive wheel is not authorized 7 Never use circular saw blades carbide tipped blades rescue blades wood cutting blades or toothed blades of any nature Their use increases the risk of injury from blade contact thrown tips and reactive forces including kickback 8 Begin cutting and continue at full throttle 9 Do not overreach 10 Never sideload a whe
39. th some pacemakers To reduce the risk of serious or fatal injury persons with a pacemaker should consult their physician and the pacemaker manufac turer before operating this tool Working safely with cut off machines Proper Clothing A Warning To reduce the risk of injury the operator should wear proper pro tective apparel Clothing must be sturdy and snug fitting but allow complete freedom of movement Avoid loose fitting jackets scarfs neckties jewelry flared or cuffed pants unconfined long hair or anything that could become caught on any obstacles or moving parts of the unit Wear overalls or long pants to protect your legs Do not wear shorts A Warning When cutting metal a cut off machine generates sparks that can ignite cloth ing Most fabrics used in clothing are flammable even flame retardant fab rics will ignite at higher temperatures To reduce the risk of burn injury STIHL recommends wearing clothing made of leather wool flame retardant treated cotton or a tightly woven heavier cotton such as denim Some flame retardant synthetic fabrics are also suitable but others such as polyester nylon rayon and acetate can melt during a fire into a tar like matter that burns into the skin Check the clothing manufacturer s instructions Keep clothing free of oil fuel grease and other flammable substances English Always wear gloves when handling the cut off machine Heavy duty nons
40. the wheel the wheel may attempt to climb the object being cut climbing Pinching occurs when the piece being cut closes on the wheel A severe binding may also occur if the wheel is substantially sideloaded in the kerf or if animproper or damaged diamond wheel begins or ceases to wobble in the kerf If the wheel is severely pinched or bound in the upper quadrant the wheel may be instantly thrown up and back towards the operator with great force ina rotational kickback motion Such kickback situations can and should always be avoided Pinching of the wheel can be prevented by proper support of the workpiece See below Severe binding of the wheel can be prevented by proper cutting techniques e g not sideloading the wheel and by the use of properly designed manufactured and maintained wheels 11 English Reducing the Risk of Kickback Injury 002BA242 KN A Warning To reduce the risk of kickback injury avoid cutting with the upper quadrant of the wheel where possible Be especially cautious for a pinching or binding of the wheel in this area which can cause severe reactive forces in a rotational kickback motion 002BA146 KN Be alert to potential movement of the workpiece or anything else that could cause the cut to close and pinch the wheel In order to reduce the risk of 12 pinching support the workpiece in such a way that the cut remains open during the cutting proc
41. ty the fuel tank before storing for longer than a few days Store fuel only in correctly labeled and approved containers Avoid direct skin contact and do not inhale the gas vapors Working safely with cut off machines Sample applications Most diamond cutting wheels are suitable for wet cutting z x o lt ao f i Wet cut whenever feasible It increases the service life and cutting speed of diamond cutting wheels Ensure that the cutting wheel is generously supplied with water Wet cutting helps to suppress dust The water binds the dust The cutting wheel must be supplied with at least 0 6 liters water per minute Wet cutting can reduce the energy of reactive forces In a pinch situation the water can act as a lubricant Working safely with cut off machines Water connection A water attachment kit is mounted on the machine for use with all types of water supply A pressurized 10 liter water tank is available from STIHL for dust suppression A water tank for mounting on the Cutquik cart is also available for dust suppression Composite resin wheels can be used for dry cutting of metals or for wet or dry cutting of concrete stone or masonry Composite resin wheels designed for dry cutting Special procedures must be followed when wet cutting with a composite non diamond wheel designed for dry cutting See the section entitled Wet Cutting with Abrasive Wheels in the safety
42. ur during such work which may cause abrasive wheels to shatter or break and result in serious or fatal injury A Warning To reduce the risk of injury from shat tered abrasive wheels 1 Do not exceed the maximum operating speed marked on the wheel 2 Do not use a wheel that has been dropped 3 Test each new wheel immediately after installation for approximately one minute at maximum speed without cutting making sure to keep bystanders away 4 Donotcut any material for which the abrasive wheel is not authorized 5 Do not grind on the side of the abrasive wheel 6 Do not twist thrust knock or drop the machine This can cause damage to the wheel To achieve a clean and efficient cut pull the abrasive wheel across the work or move it to and fro in the cutting direction Do not use force to push the abrasive wheel into the work Insert the wheel into the material only as deep as necessary to make the cut To reduce the amount of dust created do not cut all the way through stone and concrete materials leave a thin piece uncut For most such materials this piece can be easily broken afterwards Do not cock jam or wedge the wheel in the cut Always stop the engine and be sure the wheel has stopped rotating before setting down the cut off machine If a cut off machine cart is used sweep debris from the path of the wheels as debris under one of the cart s wheels may cause flexing of the abrasiv
43. ve broken off the wheel before use Always fit the wheel so that the arrow on the wheel points in the direction of the rotation of the spindle English THE USE OF THE POWER TOOL Transporting the STIHL Cutquik A Warning To reduce the risk of injury from unin tended activation and or contact with a moving wheel always stop the engine before putting a cut off machine down or carrying it The abrasive wheel contin ues to rotate coast down for a short while after the throttle trigger is released flywheel effect Bring the wheel to a stop by lightly contacting the bottom of the wheel with a hard surface or wait until the wheel comes to a complete stop on its own Carrying a cut off machine with the engine running is extremely dangerous Accidental accel eration of the engine can cause the wheel to rotate Avoid touching the hot muffler By hand When carrying your cut off machine by hand the engine must be stopped and the cut off machine must be in the proper position Grip the front handle and place the muffler at the side away from the body A Warning Always protect the cutting wheel from hitting the ground or any other objects Damaged wheels may shatter and cause serious or fatal injury By vehicle Properly secure your cut off machine to prevent turnover fuel spillage and damage to the cut off machine Never transport with cutting wheel mounted A wheel damaged English during transportation may sh
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