Stihl Cutquik TS-420 User manual

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Working safely with cut-off machines
Warning!
Read and follow all safety precautions in
Instruction Manual – improper use can cause
serious or fatal injury.
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Original Instruction ManualPrinted on chlorine-free paper
Printing inks contain vegetable oils, paper can be recycled.
© ANDREAS STIHL AG & Co. KG, 2010 0457-186-3021. M0.B10.xxx. 0000000552_001_GB
Working safely with cut-off machines
English
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Contents
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, it is 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.
Safety Precautions and Working
Techniques 2
Sample applications 15
Cutting wheels 18
Composite resin cutting wheels 18
Diamond cutting wheels 18
Maintenance and Care 22
Main Parts 24
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Working safely with cut-off machines
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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 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.
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.
Safety Precautions and
Working Techniques
The use of any cut-off
machine may be hazard-
ous. Because a cut-off
machine 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.
Warning!
Careless or improper use of any cut-off
machine may cause serious or fatal
injury.
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.
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.
Warning!
Minors should never be allowed to use a
cut-off machine. Bystanders, especially
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.
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
known, 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:
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Working safely with cut-off machines
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–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.
Proper Clothing
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.
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.
Warning!
The ignition system of your unit pro-
duces an electromagnetic field of a very
low intensity. This field may interfere
with 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.
Warning!
To reduce the risk of
injury, the operator
should wear proper pro-
tective apparel.
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.
Always wear gloves
when handling the cut-off
machine. Heavy-duty,
nonslip 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.
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.
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Working safely with cut-off machines
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THE POWER TOOL
For illustrations and definitions of the
parts of the cut-off machine, see the
chapter "Main Parts."
Abrasive Wheels
Abrasive wheels for free-hand cutting
are subjected to particularly high
bending and compression stresses.
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
binding 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.
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
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.
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 models are authorized.
Although certain unauthorized attach-
ments are useable with the STIHL
powerhead, their use may, in fact, be
extremely dangerous.
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.
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.
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.
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.
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Working safely with cut-off machines
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Only use the 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.
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.
Always fit the wheel so that the arrow on
the wheel points in the direction of the
rotation of the spindle.
THE USE OF THE POWER TOOL
Transporting the STIHL Cutquik
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.
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
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.
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 have broken off the wheel before
use.
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.
Warning!
Always protect the cutting wheel from
hitting the ground or any other objects.
Damaged wheels may shatter and
cause serious or fatal injury.
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Working safely with cut-off machines
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during transportation may shatter 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.)
Fueling Instructions
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
any spilled fuel before starting your
machine.
Different cut-off machines may be
equipped with different fuel filler caps:
Bayonet Fuel Filler Cap
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.
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.
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.
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.
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.
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.
Warning!
An improperly tightened fuel cap can
loosen or come off and spill quantities of
fuel.
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Working safely with cut-off machines
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Fuel Filler Cap with Screw Thread
This reduces the risk of the cap working
loose due to engine vibrations and fuel
leaking out.
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.
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.
Starting
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
Tighten the fuel filler cap
as securely as possible
after refuelling.
Warning!
Never attempt to force the cap open by
using a tool. It may damage the cap and
allow fuel to leak.
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
cut material are deflected
away from the operator,
and cannot reach flam-
mable surroundings. See
section "Operating
Instructions" of your
instruction manual.
Warning!
Check 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.
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.
002BA058 KN
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Working safely with cut-off machines
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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,
which should release the starting throttle
lock and allow the engine to slow down
to idle.
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.
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.
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 rate 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
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.
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.
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. carbon 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.
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.
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Working safely with cut-off machines
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9
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.
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.
Wrap your fingers tightly around the
handles, keeping the handles cradled
between your thumbs and forefingers.
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.
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.
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
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.
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.
002BA060 KN
002BA061 KN
Warning!
Clear the area where you are working.
Avoid stumbling 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.)
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.
Warning!
Sparks from cutting
metal can burn or cause
clothing to catch fire.
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.
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Working safely with cut-off machines
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Operating Instructions
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. Do not cut 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 abrasive wheel.
This could result in high frictional forces
and thus greatly reduce the engine
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.
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.
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 particles 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.
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.
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.
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.
Warning!
Do not use abrasive wheels for rough
grinding. Large bending stresses occur
during such work, which may cause
abrasive wheels to shatter or break and
result in serious or fatal injury.
Warning!
To reduce the risk of injury from shat-
tered abrasive wheels:
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Working safely with cut-off machines
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11
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.
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.
Reactive Forces including Kickback
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
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 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
an improper 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 in a
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.
Warning!
To reduce the risk of electrocution to
you or bystanders, do not allow water or
sludge to contact live electric wires.
Warning!
To reduce the risk of injury from wheel
breakage when wet cutting with any
composite wheel:
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.
Warning!
Reactive forces may
occur at any time the cut-
ting wheel 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.
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Working safely with cut-off machines
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12
Reducing the Risk of Kickback Injury
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
pinching, support the workpiece in such
a way that the cut remains open during
the cutting process 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.
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.
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.
002BA242 KN
002BA146 KN
Warning!
Be particularly alert when cutting a
workpiece such as a pipe with a belled
end or a 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.
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.
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 severe 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.
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Working safely with cut-off machines
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13
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
designed 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.
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.
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.)
4. Do not cut above shoulder height.
5. 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 wheel in the kerf.
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.
In a 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 in a
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
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.
Warning!
To reduce the risk of injury from loss of
control from reactive forces, including
kickback:
002BA059 KN
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Working safely with cut-off machines
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14
opposition to directional change, e.g.,
when the operator attempts to move the
machine in a sideways direction.
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.
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.
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.
Empty 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.
Warning!
Use only STIHL replacement parts for
maintenance and repair. Use of parts
manufactured by others may cause seri-
ous or fatal injury.
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.
Warning!
Never test the ignition system with spark
plug boot removed from spark plug or
with unseated spark plug, since uncon-
tained sparking may cause a fire.
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.
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.
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Working safely with cut-off machines
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15
Most diamond cutting wheels are
suitable for wet cutting
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.
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
precautions of this manual. Wet cutting
is generally not suitable for cutting
metals.
Composite resin wheels designed for
wet cutting
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
4L/min.
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
Sample applications
Adjust water flow rate
during cutting so it is suf-
ficient to bind all the dust
that occurs (at least
0.6 L/min).
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, an operator who is actively cut-
ting for more than two hours a day
should wear at least a NIOSH-approved
disposable respirator.
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Working safely with cut-off machines
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16
Points to be noted with diamond and
composite resin cutting wheels
Object to be cut
–Must be fully supported
–Must be secured so that it cannot
roll or slip away
–Must be protected against vibration
The cutting sequence
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.
If applicable, leave small ridges of uncut
material to hold the severed part in
position. These ridges can subsequently
be broken through.
A number of points must be decided
before the part is finally severed:
–How heavy is the part?
–In which direction can it move after
being severed?
–Is it under tension?
Helpers must not be put at risk of injury
when the part is broken off or out.
Cutting in several passes
NMark cutting line (A).
NWork along the cutting line. If
corrections are necessary, always
reposition the cutting wheel, taking
care to ensure that it is not wedged.
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.
NThick-walled workpieces should be
cut with a uniform swinging
movement, back and forth.
Cutting slabs
NPlace the slab securely on a non-
slip surface.
NCut a guiding groove (A) along the
marked line.
NCut deeper into the parting cut (B)
with uniform back-and-forth
movements.
NLeave a ridge (C) of uncut material.
NCut through the slab at the ends so
the material does not chip.
NThen break the slab.
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Working safely with cut-off machines
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NCurves must be cut in several
straight passes, taking care to
ensure that the cutting wheel does
not become wedged.
Cutting round and hollow workpieces
NPipes and round objects, etc. must
be secured so that they cannot roll.
NAvoid reinforcing elements,
especially in the direction of the cut,
when deciding on the cutting line.
NCut a guiding groove along the
marked line.
NCut 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
severed part in position. These
ridges can subsequently be broken
through.
Cutting shapes on pipes
NMark the cutting line.
NCut a guiding groove along the
marked cutting line, starting at the
top and moving out towards both
sides.
NCut into the pipe or round object,
etc. at the ends of the cutting line so
that the material does not chip.
NCut 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.
Warning!
Particular care and precision are
required for free-hand cutting along
such cutting lines. Avoid side-loading
the wheel or causing it to bind.
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Working safely with cut-off machines
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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 impacts
–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
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“)
–on the 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.
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)
–on the label and
–on the 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
–Clay pipes
Diamond abrasive wheels cannot be
used to cut metal.
Cutting wheels Composite resin cutting
wheels
Diamond cutting wheels
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