Stihl TS 410 User manual

TS 410, 420
2 - 36 Instruction Manual

Contents
1 Guide to Using this Manual.........................2
2 Safety Precautions and Working Techni‐
ques............................................................ 2
3 Sample Applications................................. 10
4 Cutting Wheels..........................................13
5 Composite Abrasive Wheels.....................13
6 Diamond Abrasive Wheels........................14
7 Electronic Water Control........................... 16
8 Assembling the cast arm and guard ........ 17
9 Tensioning the ribbed V‑belt..................... 21
10 Mounting an Abrasive Wheel.................... 22
11 Fuel........................................................... 23
12 Fueling...................................................... 24
13 Starting / Stopping the Engine.................. 25
14 Air Filter System........................................27
15 Adjusting the Carburetor........................... 28
16 Spark Arresting Screen in Muffler............. 29
17 Spark Plug................................................ 29
18 Replacing the V‑belt..................................30
19 Cut-off Machine Cart.................................31
20 Storing the Machine.................................. 31
21 Maintenance and Care..............................32
22 Main Parts.................................................33
23 Specifications............................................33
24 Maintenance and Repairs......................... 35
25 Disposal.................................................... 35
26 EC Declaration of Conformity................... 35
1 Guide to Using this Manual
1.1 Pictograms
Pictograms that appear on the machine are
explained in this Instruction Manual.
Depending on the machine and equipment ver‐
sion, the following pictograms may appear on the
machine.
Fuel tank; fuel mixture of gasoline
and engine oil
Actuate decompression valve
Actuate manual fuel pump
Water connection, shut-off cock
Tensioning nut for belt
Pull starter grip
1.2 Symbols in text
WARNING
Warning where there is a risk of an accident or
personal injury or serious damage to property.
NOTICE
Caution where there is a risk of damaging the
machine or its individual components.
1.3 Engineering improvements
STIHL's philosophy is to continually improve all
of its products. For this reason we may modify
the design, engineering and appearance of our
products periodically.
Therefore, some changes, modifications and
improvements may not be covered in this man‐
ual.
2 Safety Precautions and
Working Techniques
Special safety precautions must be
taken when working with the cut-off
machine, due to the very high rota‐
tional speed of the abrasive wheel.
It is important you read and under‐
stand the User Manual before com‐
missioning and keep it in a safe place
for future reference. Non-observance
of the safety precautions may result
in serious or even fatal injury.
Observe all applicable local safety regulations,
e.g. by trade organizations, social insurance
institutions, labor safety authorities etc.
As for employers within the European Commun‐
ity, the provision 2009/104/EC is binding – Safety
and health protection with the use of machines
and devices by employees at work.
If you have never used a power tool before: have
your STIHL dealer or other specialist show you
how to operate the machine – or attend one of
the special training courses.
Minors should never be allowed to use the
machine – except for apprentices over the age of
16 when working under supervision.
English
2 0458-370-8321-C
© ANDREAS STIHL AG & Co. KG 2022
0458-370-8321-C. VA2.E22.
Printed on chlorine-free paper Printing inks contain vegetable oils, paper can be recycled.
Original Instruction Manual 0000008292_007_GB

Children, animals and bystanders must not be
allowed near the machine.
When not using the machine, it must be laid
down in such a way that it does not endanger
anyone. Ensure that the machine cannot be
used without authorization.
The user is responsible for accidents or risks
involving third parties or their property.
Do not lend or rent your power tool without the
User Manual. Be sure that anyone using it under‐
stands the information contained in this manual.
The use of machines that emit noise may be limi‐
ted to certain hours of the day as specified by
national and/or regional or local regulations.
Anyone operating the machine must be well res‐
ted, in good physical health and in good mental
condition.
If you have any condition that might be aggrava‐
ted by strenuous work, check with your doctor
before operating a machine.
If you have a pacemaker: The ignition system of
your machine produces an electromagnetic field
of very low intensity. This field may interfere with
some pacemakers. STIHL recommends that per‐
sons with pacemakers consult their physician
and the pacemaker manufacturer to reduce any
health risk.
Anyone who has consumed alcohol or drugs or
medicines affecting their ability to react must not
operate a power tool.
Postpone the work if the weather is bad (snow,
ice, wind) – higher risk of accidents!
The machine may only be used for cutting. It is
not suitable for cutting wood or wooden objects.
Asbestos dust is extremely toxic - the machine
must therefore never be used to cut asbestos!
Other uses are not permitted and may lead to
accidents or damage to the machine.
Never attempt to modify your power tool in any
way since this may increase the risk of personal
injury. STIHL excludes all liability for personal
injury and damage to property caused while
using unauthorized attachments.
Only use abrasive wheels or accessories which
have been approved by STIHL for this machine
or which are technically equivalent. If you have
any questions in this respect, consult your
dealer. Only use high-quality abrasive wheels
and attachments. in order to avoid the risk of
accidents and damage to the machine.
STIHL recommends the use of genuine STIHL
abrasive wheels and accessories. They are spe‐
cifically designed to match the product and meet
your performance requirements.
Do not use a high-pressure washer to clean the
power tool. The solid jet of water may damage
parts of the unit.
Do not spray the power tool with water.
Never use circular saw blades, car‐
bide, rescue or wood cutting attach‐
ments or saws of any kind – these
may cause fatal injuries!Instead of
uniformly removing particles as when
cutting with an abrasive wheel, the
teeth of a circular saw blade may
snag in the material. This causes the
machine to react in a highly aggres‐
sive manner with uncontrolled and
extremely dangerous kickback.
2.1 Clothing and equipment
Wear proper protective clothing and equipment.
Clothing must be sturdy but allow
complete freedom of movement.
Wear close-fitting clothes such as a
boiler suit, not a work coat.
When cutting steel, always wear clothing made
of barely flammable material (e.g., leather or cot‐
ton with flame-retardant finish) – no man made
fibers – risk of fire due to flying sparks!
Clothing must be free from flammable deposits
(chips, fuel, oil, etc.).
Do not wear clothes that may be caught by mov‐
ing parts – no scarf, no tie, no jewelry. Tie up and
confine long hair above your shoulders.
Wear steel-toed safety boots with
non-slip soles.
WARNING
To reduce the risk of eye injuries,
wear close-fitting safety glasses in
accordance with European Standard
EN 166. Make sure the safety
glasses are a snug fit.
Wear a safety hard hat where there is a danger
of head injuries from falling objects.
Dust (e. g., crystalline material from the object
being cut), fumes and smoke may be produced
while cutting - health hazard!
2 Safety Precautions and Working Techniques English
0458-370-8321-C 3

Always wear a dust mask if dust is generated.
If fumes or smoke are anticipated (e. g., when
cutting composite materials), wear respiratory
protection.
Wear "personal" hearing protection – for exam‐
ple, ear defenders.
Wear sturdy protective gloves made
of a resistant material (e. g. leather).
STIHL can supply a comprehensive range of per‐
sonal protective equipment.
2.2 Transporting the machine
Always stop the engine.
Carry the device by the handlebar only – abra‐
sive wheel pointing to the rear – hot muffler away
from the body.
To avoid serious burn injuries, avoid touching hot
parts of the machine, especially the surface of
the muffler.
Never transport the engine-driven device with
attached abrasive wheel – risk of breakage!
By vehicle: When transporting in a vehicle, prop‐
erly secure your machine to prevent turnover,
damage and fuel spillage.
2.3 Refueling
Gasoline is highly flammable – keep
away from fire or flame – do not spill
any fuel – no smoking.
Always shut off the engine before refueling.
Do not fuel a hot engine – fuel may spill and
cause a fire.
Open the fuel cap carefully to allow any pressure
build-up in the tank to release slowly and avoid
fuel spillage.
Only refuel the machine in a well ventilated
place. If fuel has been spilled, immediately clean
the machine – do not allow your clothes to be
splashed with fuel. If that happens, change your
clothes at once.
Dust may collect on the engine unit, particularly
around the carburetor. If dust gets mixed with
fuel – risk of fire. For this reason, ensure that the
dust is always removed.
Check for fuel leakage! Never start
the engine if fuel has been spilled or
is leaking – Fatal burns may result!
Different cut-off machines may be equipped with
different fuel caps:
2.3.1 Bayonet-type fuel cap
Never use a tool to open or close the bayonet-
type fuel cap. This could damage the cap and
cause fuel to leak out.
Close the bayonet-type fuel cap carefully after
refueling.
2.3.2 Threaded fuel cap
After fueling, tighten down the screw-
type fuel cap as securely as possible.
This helps reduce the risk of unit vibrations caus‐
ing an incorrectly tightened fuel cap to loosen or
come off and spill quantities of fuel.
2.4 Cut-off machine, spindle bear‐
ing
Correct spindle bearings ensure the concentricity
and axial running of the diamond abrasive wheel
– if necessary, get it checked by an approved
dealer.
2.5 Abrasive cutting wheels
2.5.1 Selecting the abrasive cutting wheels
Abrasive cutting wheels must be approved for
freehand cutting. Do not use other cutting wheels
and attachments – risk of accident!
Abrasive cutting wheels are suitable for different
materials: Observe the identification of the abra‐
sive cutting wheels.
STIHL generally recommends wet cutting.
Observe the outer diameter of the
abrasive wheel.
English 2 Safety Precautions and Working Techniques
4 0458-370-8321-C

Spindle hole diameter of the abrasive
wheel and shaft of cut-off machine
must match.
Check the spindle hole for damage. Do not use
abrasive cutting wheels with a damaged spindle
hole – risk of accident!
The permissible speed of the abra‐
sive cutting wheel must be equal to or
greater than the maximum spindle
speed of the cut-off machine. – Refer
to the chapter "Specifications".
Before fitting a used abrasive cutting wheel,
check that it is not cracked, chipped, undercut or
uneven, and does not display any signs of core
fatigue or overheating (discoloration); check also
the spindle hole is not damaged.
Never use cracked, chipped or bent abrasive cut‐
ting wheels.
Substandard and/or unapproved diamond abra‐
sive wheels can shimmy during cutting. This
shimmying can cause such diamond abrasive
wheels to be abruptly braked or become stuck in
the cut – Danger of kickback! Kickback can result
in fatal injuries! Diamond abrasive wheels that
shimmy constantly or even only intermittently
must be replaced immediately.
Never straighten diamond abrasive wheels.
Do not use an abrasive cutting wheel which has
fallen to the ground – damaged abrasive cutting
wheels may break – risk of accident!
Observe the expiration date where composite
resin abrasive cutting wheels are concerned.
2.5.2 Fitting abrasive cutting wheels
Inspect the spindle of the cut-off machine. Do not
use a cut-off machine if the spindle is damaged –
risk of accident!
Note the arrows indicating the direction of rota‐
tion on diamond abrasive wheels.
Position the front pressure plate – tighten up the
tensioning screw – rotate the abrasive cutting
wheel by hand and take a sight check for con‐
centricity and axial running.
2.5.3 Storing abrasive cutting wheels
Store abrasive wheels in a dry and frost-free
place, on an even surface, at constant tempera‐
ture – risk of breakage and splintering!
Always protect abrasive cutting wheels against
sudden impact with the floor or objects.
2.6 Before starting
Inspect the cut-off machine for safe-to-operate
state – observe the respective chapters in the
User Manual:
–Check the fuel system for leaks, especially the
visible parts, e. g., fuel cap, hose connections,
manual fuel pump (only in machines with a
manual fuel pump). In case of leakage and
damage, do not start the engine – risk of fire!
Have the machine serviced by a dealer before
using it
–The abrasive wheel must be suitable for the
material to be cut. It must be in good condition
and fitted correctly (direction of rotation,
secure).
–Inspect the abrasive wheel guard for tight seat
– if loose, contact your specialist dealer.
–Smooth action of throttle trigger and throttle
trigger lockout – throttle trigger must return
automatically to idle position
–Slide control / master control lever / stop
switch must move easily to STOP or 0
–Check that the spark plug boot is secure – a
loose boot may cause sparking that could
ignite combustible fumes and cause a fire!
–Never attempt to modify the controls or safety
devices
–Keep the handles clean, dry and free of oil as
well as dirt – important for safe guiding of the
cut-off machine.
–For wet applications, provide sufficient water
To reduce the risk of personal injury, do not
operate your power tool if it is damaged or not
properly assembled!
2.7 Starting the engine
Start the engine at least 3 meters from the fuel‐
ing spot, outdoors only.
On even ground, ensure a firm and secure foot‐
ing and hold the engine-driven device firmly – the
abrasive cutting wheel must not touch any
objects or the ground and must not be in cutting
action.
The abrasive wheel may begin to rotate as soon
as the machine is started
The machine is operated by a single person only
– do not allow any person to stay within the work‐
ing area – nor with starting.
Do not drop start your machine – the correct
starting procedure is described in the User Man‐
ual.
2 Safety Precautions and Working Techniques English
0458-370-8321-C 5

After releasing the throttle trigger, the abrasive
wheel keeps on running for a while – danger of
injury due to coasting effect!
2.8 Holding and guiding the
machine
The cut-off machine may only be used for hand-
held cutting or when mounted on a STIHL Cut‐
quik cart.
2.8.1 Hand-held cutting
002BA549 AM
Always hold the machine firmly with both hands:
Right hand on the rear handle – even if you are
left-handed. To ensure safe control, wrap your
fingers tightly around both handles.
180BA022 KN
When a cut-off machine with an abrasive cutting
wheel rotating is moved in the direction of the
arrow, a force is produced which causes the
machine to tip sideways.
The object to be cut off has to be firmly suppor‐
ted. Always guide the machine towards the work‐
piece – never the other way round.
2.8.2 Cutquik cart
STIHL cut-off machines can be mounted onto a
STIHL Cutquik cart.
2.9 Deflector
The adjustment range of the guard is determined
by a stop pin. Never push the guard over the
stop pin.
002BA550 AM
Set the abrasive cutting wheel guard correctly:
Guide particles of material away from the user
and machine.
Note the direction of flight of the removed parti‐
cles of material.
2.10 While working
If there is imminent danger or in an emergency,
immediately stop the engine – set the slide con‐
trol / master control lever /stop switch to
STOP or 0.
Check for correct idling, so that the abrasive cut‐
ting wheel is no longer driven when the throttle
trigger is released and comes to a complete halt.
Check and correct the idle speed setting at regu‐
lar intervals. Have the machine repaired by a
STIHL dealer if the cutting wheel continues to
turn nevertheless.
Keep clear the working area – bear in mind
obstacles, holes and pitches.
Take special care in slippery conditions – damp,
snow, ice, on slopes or uneven ground.
Don not work while standing on a ladder – not on
an insecure support – not over your shoulder
height – not with one hand only – risk of accident!
Make sure you always have good balance and
secure footing.
Do not work alone – keep within calling distance
of others in case help is needed.
Keep out further persons from the working area –
maintain sufficiently large distance to additional
persons to protect them from noise and flying
objects.
Be particularly alert and cautious when wearing
hearing protection because your ability to hear
warnings (shouts, alarms, etc.) is restricted.
Take a break in good time before you get tired.
English 2 Safety Precautions and Working Techniques
6 0458-370-8321-C

Work calmly and carefully – in daylight conditions
and only when visibility is good. Proceed with
caution, do not put others in danger.
As soon as the engine is running, the
power machine generates toxic
exhaust gas.As soon as the engine is
running, the power machine gener‐
ates toxic exhaust gas. These gases
may be odorless and invisible and
may contain unburned hydrocarbons
and benzene. Never run the engine
indoors or in poorly ventilated loca‐
tions, even if your model is equipped
with a catalytic converter.
Ensure proper ventilation when working in
trenches, hollows or similar locations – risk of
fatal injury from breathing toxic fumes!
Stop work immediately if you start suffering from
nausea, headaches, impaired vision (e.g. your
field of vision gets smaller), impaired hearing,
dizziness, or impaired concentration – these
symptoms may possibly be the result of too-high
exhaust gas concentration – Risk of accidents!
To reduce the risk of fire, do not smoke while
operating or standing near your power tool.
If your power tool is subjected to unusually high
loads for which it was not designed (e.g. heavy
impact or a fall), always check that it is in good
condition before continuing work – see also
"Before Starting". Check in particular that the fuel
system has no leaks and the safety equipment is
fully operative. Never use a power tool that is no
longer safe to operate. In case of doubt, contact
a dealer.
Do not operate your power tool in the starting
throttle position – engine speed cannot be con‐
trolled in this position.
Never touch a rotating abrasive cutting wheel
with your hand or any other part of your body.
Examine the workplace. Avoid all danger due to
damaged piping or electrical wiring.
The machine must not be used near inflammable
substances or gases.
Do not cut into pipes, metal tanks or other con‐
tainers if you are not sure that they do not con‐
tain any volatile or inflammable substances.
Never leave the machine unattended with the
engine running. Stop the engine before leaving
the machine unattended (e. g. for breaks).
Before putting the cut-off machine down on the
ground:
–Shut off the engine
–Wait until the abrasive cutting wheel has come
to a standstill or brake the abrasive cutting
wheel until it comes to a standstill by carefully
touching a hard surface (e.g., concrete slab)
Frequently inspect the abrasive cut‐
ting wheel – replace it right away if
there are visible cracks, buckling or
other damage (for example, overheat‐
ing) – risk of accident due to break‐
age!
In the event of changes in cutting behavior (e. g.,
increased vibration, reduced cutting perform‐
ance), stop work and eliminate the causes of the
changes.
2.11 Reactive forces
The most frequently occurring reactive forces are
kickback and pull-in.
Danger of kickback – Kickback can
result in fatal injuries.
002BA551 AM
Kickback occurs when the cut-off machine is
suddenly thrown up and back in an uncontrolled
arc towards the operator.
Kickback occurs if, for example, the abrasive cut‐
ting wheel
–gets jammed – primarily in its upper quarter, or
–is abruptly braked through friction contact with
a solid object
To reduce the risk of kickback
–Work cautiously and avoid situations which
could cause kickback.
–Hold the cut-off machine firmly with both
hands and maintain a secure grip
2 Safety Precautions and Working Techniques English
0458-370-8321-C 7

002BA552 AM
–If possible, avoid using the upper quarter of
the abrasive cutting wheel for cutting. Use
extreme caution when guiding the abrasive
cutting wheel into a cut, do not twist or push
into the cut
002BA555 AM
–Avoid any wedge effect - the severed part
must not brake the abrasive cutting wheel
–Always be aware that the object to be cut may
move and other factors may cause the cut to
close and jam the abrasive cutting wheel.
–The object to be cut must be secured and sup‐
ported so that the kerf remains open during
and after cutting
–Objects to be cut must therefore be fully sup‐
ported and must be secured against rolling
away, slipping off or vibrations
002BA556 AM
–Support an uncovered pipe stable and solid, if
necessary, use wedges – always bear in mind
a proper support and ground – material may
crumble away,
–Always work with water and wet cutting when
using diamond abrasive wheels
–Depending on the version, composite resin
abrasive cutting wheels are suitable only for
dry cutting or only for wet cutting. Always use
wet cutting with composite resin abrasive cut‐
ting wheels that are suitable only for wet cut‐
ting
2.11.1 Pull away from
002BA553 AM
The cut-off machine pulls forward, away from the
user, when the abrasive wheel touches the
object to be cut from above.
2.12 Working – cutting off
The abrasive cutting wheel must be
guided straight in the cut, without
wedging. Never exert lateral pressure
on the abrasive cutting wheel.
Do not use for lateral grinding or
scrubbing.
002BA554 AM
Do not stand in line with the abrasive wheel.
Ensure sufficient freedom of movement, espe‐
cially in construction trenches there must be suf‐
ficient space for the user and for the part being
cut to fall.
Do not lean too far forwards and never bend over
the abrasive wheel when the guard has been
pulled back.
Do not work above shoulder height.
The cut-off machine may only be used for cut‐
ting. It must not be used as a lever or shovel.
English 2 Safety Precautions and Working Techniques
8 0458-370-8321-C

Do not press down on the cut-off machine
Always decide the cutting direction before posi‐
tioning the cut-off machine. After that, do not
change the cutting direction. Never push or hit
with the device into the cutting gap – do not let
the concrete cutter fall into the cutting depth –
risk of breakage!
Diamond abrasive cutting wheels: If cutting per‐
formance begins to deteriorate, check the sharp‐
ness of the diamond abrasive wheel, resharpen
as needed. To do this, briefly cut through abra‐
sive material, e. g., sandstone, aerated concrete
or asphalt.
At the end of the cut, the cut-off machine is no
longer supported by the abrasive wheel in the
cut. The user has to absorb the weight force –
risk of loss of control!
When cutting steel: glowing metal
particles may cause fires!
Keep water and sludge away from alive electrical
cables – risk of electric shock!
Drag the abrasive wheel into the workpiece – do
not push it into the material. Do not correct
severing cuts with the cut-off machine. Do not re-
cut – remove left webs or breaking edges (for
example, with a hammer).
When applying diamond abrasive wheels, take a
wet cut – for example, use the STIHL water con‐
nector.
Depending on the version, composite resin abra‐
sive cutting wheels are suitable only for dry cut‐
ting or only for wet cutting.
When using composite resin abrasive cutting
wheels which are suited for wet cuts only, take
such wet cuts only – for example, use the STIHL
water connector.
When using composite resin abrasive cutting
wheels which are suited for dry cuts only, take
such dry cuts only. If however composite resin
abrasive cutting wheels of this type become wet,
their cutting performance is reduced and they
become dull. If composite resin abrasive cutting
wheels of this type become wet while working
(e. g., due to puddles or water in pipes), do not
increase the cutting pressure, but continue work‐
ing with the same pressure – risk of breakage!
Use up such composite resin abrasive cutting
wheels immediately.
2.12.1 Cutquik cart
Clear a path for the Cutquik cart. If the Cutquik
cart is pushed over objects, the abrasive wheel
may become wedged in the cut and shatter!
2.13 Vibrations
Prolonged use of the power tool may result in
vibration-induced circulation problems in the
hands (whitefinger disease).
No general recommendation can be given for the
length of usage because it depends on several
factors.
The period of usage is prolonged by:
–Hand protection (wearing warm gloves)
–Work breaks
The period of usage is shortened by:
–Any personal tendency to suffer from poor cir‐
culation (symptoms: frequently cold fingers,
tingling sensations).
–Low outside temperatures.
–The force with which the handles are held (a
tight grip restricts circulation).
Continual and regular users should monitor
closely the condition of their hands and fingers. If
any of the above symptoms appear (e.g. tingling
sensation in fingers), seek medical advice.
2.14 Maintenance and repairs
The machine must be serviced regularly. Do not
attempt any maintenance or repair work not
described in the Instruction Manual. All other
work should be carried out by a servicing dealer.
STIHL recommends that maintenance and repair
work be carried out only by authorized STIHL
dealers. STIHL dealers receive regular training
and are supplied with technical information.
Use only high-quality replacement parts, in order
to avoid the risk of accidents or damage to the
machine. Contact a dealer if in doubt.
STIHL recommends the use of genuine STIHL
spare parts. Such parts have been optimized for
the machine and the user's requirements.
Before starting any maintenance or repair work
and before cleaning the machine, always stop
the engine and disconnect the spark plug boot –
risk of injury if the engine starts up inadvertently!
– Exception: adjustment of carburetor and idle
speed.
To reduce the risk of fire due to ignition outside
the cylinder, move the slide control / stop switch
to STOP or 0 before turning the engine over on
2 Safety Precautions and Working Techniques English
0458-370-8321-C 9

the starter with the spark plug boot removed or
the spark plug unscrewed.
Do not service or store the machine near a
naked flame – risk of fire due to the fuel.
Check fuel cap regularly for tightness.
Use only spark plugs that are in perfect condition
and have been approved by STIHL – see Specifi‐
cations.
Inspect ignition lead (insulation in good condi‐
tion, secure connection).
Check that the muffler is in perfect working con‐
dition.
Do not use the machine if the muffler is damaged
or missing - risk of fire! – Hearing damage!
Never touch a hot muffler – risk of burns!
Check the rubber buffers underneath the
machine - the housing must not rub against the
ground - risk of damage!
The condition of the antivibration elements influ‐
ences vibration behavior – inspect antivibration
elements periodically.
3 Sample Applications
3.1 Water must always be used for
wet cutting when working with
diamond abrasive wheels
3.1.1 Extend service life and increase cut‐
ting speed
Always ensure a supply of water to the abrasive
wheel.
3.1.2 Binding dust
The abrasive wheel must be supplied with at
least 0.6 liters of water per minute.
3.1.3 Water attachment
–Water attachment on the machine for all types
of water supplies
–Pressurized water tank 10 l for binding dust
–water tank usable on the cut-off machine cart
for binding dust
3.2 Use composite resin abrasive
wheels with or without water –
depending on version
Depending on the version, resin abrasive wheels
are only suitable for dry cutting or only for wet
cutting.
3.2.1 Composite resin abrasive wheels suit‐
able only for dry cutting
During dry cutting, wear a suitable dust mask.
If fumes or smoke are anticipated (e. g., when
cutting composite materials), wear respiratory
protection.
3.2.2 Composite resin abrasive wheels suit‐
able only for wet cutting
Use abrasive wheel only with water.
To bind dust, the abrasive wheel must be sup‐
plied with at least 1 liter of water per minute. To
avoid a reduction in cutting performance, the
abrasive wheel must be supplied with not more
than 4 liters of water per minute.
After using the abrasive wheel, the wheel should
be allowed to continue spinning at operating
speed for approx. 3 to 6 seconds without water in
order to spin off the water remaining on it.
–Water attachment on the machine for all types
of water supplies
–Pressurized water tank 10 l for binding dust
–water tank usable on the cut-off machine cart
for binding dust
3.3 Observe with diamond and
composite resin abrasive
wheels
3.3.1 Objects to be cut
–Must be fully supported
–Must be secured so it cannot roll or slip off
–Must be prevented from vibrating
3.3.2 Severed parts
With openings, recesses, etc., the sequence of
the cuts is important. Always make the last cut
so that the abrasive wheel does not become jam‐
med and so that the operator is not endangered
by the severed or separated part.
If necessary, leave small ridges that hold the part
that is to be separated in position. Break these
ridges later.
Before finally separating the part, determine:
–how heavy the part is
–how it can move after separation
–whether it is under tension
When breaking out the part, do not endanger
assistants.
English 3 Sample Applications
10 0458-370-8321-C

3.4 Cut in several passes
► Mark cutting line (A)
180BA027 AM
► Work along the cutting line. When making cor‐
rections, do not tilt the abrasive wheel, but
always set the abrasive wheel against the
workpiece anew – the cutting depth for each
operation should not exceed 5 to 6 cm. Cut
thicker material in multiple operations
3.5 Cutting plates
► Secure the plate (e. g. on a non-slip surface,
sandbed)
► Grind a guide groove (A) along the line
marked
180BA028 AM
► Make the cut (B) deeper
► Leave a "hinge" (C)
► First sever the plate at the cut ends so that no
material breaks away
► Break plate
► Make curves in multiple operations – make
certain that the abrasive wheel does not tilt
3.6 Cutting pipes, round and hollow
bodies
► Secure pipes, round and hollow bodies
against vibrations, slipping and rolling away
► Note direction of fall and weight of the severed
part
► Determine and mark the cutting line, avoid
reinforcement, especially in the direction of the
severing cut
► Determine sequence of severing cuts
► Grind a guide groove along the line marked
► Make cut deeper along the guide groove –
observe the recommended cutting depth for
each operation – for small corrections of direc‐
tion, do not tilt the abrasive wheel, but always
position it anew instead – if necessary, leave
small ridges that hold the part that is to be
separated in position. Break these ridges after
the last planned cut
3 Sample Applications English
0458-370-8321-C 11

3.7 Cutting concrete pipe
A
002BA557 AM
The procedure is dependent on the outer diame‐
ter of the pipe and the maximum possible cutting
depth of the abrasive wheel (A).
► Secure pipe against vibrations, slipping and
rolling away
► Note weight, tension and direction of fall of the
part to be severed
002BA528 AM
► Determine and mark direction of cut
► Determine sequence of cuts
Outer diameter is smaller than the maximum cut‐
ting depth
002BA558 AM
► Make one cut from the top to the bottom
Outer diameter is greater than the maximum cut‐
ting depth
Plan first, then cut. Several cuts are needed –
correct sequence is important.
► Turn guard at rear stop
002BA560 AM
► Always start at the bottom, use the upper
quarter of the abrasive wheel for cutting
002BA561 AM
► Use the upper quarter of the abrasive wheel
for cutting the opposite lower side.
002BA562 AM
► First lateral cut on the top half of the pipe
002BA563 AM
► Second lateral cut in the marked area – never
cut into the area of the last cut, to ensure a
firm hold on the part of pipe to be cut
Only make the last top cut once all bottom and
lateral cuts have been made.
English 3 Sample Applications
12 0458-370-8321-C

002BA559 AM
► Last cut always from the top (approx. 15 % of
the pipe circumference)
3.8 Concrete pipe – cut recess
Sequence of cuts (1 to 4) is important:
► First, cut hard-to-reach areas
12
180BA024 AM
► Always make severing cuts so that the abra‐
sive wheel is not pinched
180BA025 AM
► Use wedges and/or leave ridges that are bro‐
ken after cutting
180BA026 AM
3
4
► If the severed part remains in the recess after
cutting (due to wedges, ridges used), do not
make any further cuts – break the severed part
4 Cutting Wheels
Abrasive wheels are exposed to extremely high
loads especially during freehand cutting.
Therefore only for use of approved and corre‐
spondingly labeled abrasive wheels with hand-
held machines as per EN 13236 (diamond) or
EN 12413 (composite resin). Note maximum per‐
missible speed of the abrasive wheel – risk of
accident!
The abrasive wheels, which have been devel‐
oped 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.
4.1 Transport and storage
–Do not expose abrasive wheels to direct sun‐
shine or other thermal stresses during trans‐
port and storage
–Avoid jolting and impacts
–Stack abrasive 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 abrasive wheels in the vicinity of
aggressive fluids
–Store abrasive wheels in a frost-free place
5 Composite Abrasive
Wheels
Types:
–for dry applications
–for wet applications
The proper selection and use of composite resin
cutting wheels ensures economical use and
4 Cutting Wheels English
0458-370-8321-C 13

avoids accelerated wear. The product code
which appears
–on the label and
–on the packaging (table with recommendations
for use) is an aid to selection
STIHL composite resin cutting wheels are suita‐
ble, depending on the version, for cutting the fol‐
lowing materials:
–Asphalt
–Concrete
–Stone
–Ductile cast iron pipes
–Steel; STIHL composite resin cutting wheels
are not suitable for cutting railway tracks
Do not cut any other materials – risk of accident!
6 Diamond Abrasive Wheels
For wet applications.
The proper selection and use of diamond abra‐
sive wheels ensures economical use and avoids
accelerated wear. The product code which
appears
–on the label and
–on the packaging (table with recommendations
for use) is an aid to selection
STIHL diamond abrasive wheels are suitable,
depending on the version, for cutting the follow‐
ing materials:
–Asphalt
–Concrete
–Stone (hard stone)
–Abrasive concrete
–Fresh concrete
–Clay brick
–Clay pipe
–Ductile cast iron pipe
Do not cut any other materials – Risk of accident!
Never use diamond abrasive wheels with side
plating as they jam in the cut and can result in
extreme kickback – Risk of accident!
6.1 Product Codes
0000-GXX-1235-A0
D-B10
The product code is a combination of letters and
numbers, consisting of up to four characters:
–the letters denote the main field of application
of the abrasive wheel
–the numbers denote the performance class of
the STIHL diamond abrasive wheel
6.2 Axial and radial run-out
A faultless spindle bearing of the cut-off machine
is necessary for a long service life and efficient
functioning of the diamond abrasive wheel.
Using the abrasive wheel on a cut-off machine
with a faulty spindle bearing can lead to devia‐
tions in radial and axial run-out.
An excessively high radial run-out deviation (A)
overloads individual diamond segments, which
overheat in the process. This can lead to stress
cracks in the parent wheel or to annealing of indi‐
vidual segments.
Deviations in axial run-out (B) result in higher
thermal loading and wider cuts.
English 6 Diamond Abrasive Wheels
14 0458-370-8321-C

6.3 Undercut
Do not cut into the base course (frequently chip‐
ped stones and gravel) when cutting roadway
pavement – cutting in chipped stones and gravel
is revealed by light-colored dust – excessive
undercut may occur as a result – Danger of shat‐
tering!
6.4 Built-up edges, sharpen
Built-up edges take the form of a light gray
deposit on the tops of the diamond segments.
This deposit on the segments clogs the dia‐
monds and blunts the segments.
Built-up edges can form:
–when cutting extremely hard materials, e. g.,
granite
–with incorrect handling, e. g., excessive feed
effort
Built-up edges increase vibration, reduce cutting
performance, and cause formation of sparks.
At the first signs of built-up edges, immediately
"sharpen" the diamond abrasive wheel – to do
this, briefly cut through abrasive material such as
sandstone, aerated concrete or asphalt.
Addition of water prevents the formation of built-
up edges.
If work continues with dull segments, these may
soften due to the high heat generated – the
parent wheel is annealed and its strength is com‐
promised – this can lead to stresses that are
clearly recognizable by gyrations of the abrasive
wheel. Do not continue to use the abrasive wheel
– Risk of accident!
6.5 Troubleshooting
6.5.1 Abrasive wheel
Defects Cause Remedy
ragged edges or cut surfaces,
crooked cut
Deviation in radial or axial run-out Contact a servicing dealer1)
heavy wear on the sides of the
segments
Abrasive wheel gyrates use a new abrasive wheel
ragged edges, crooked cut, no
cutting performance, generation
of sparks
Abrasive wheel is dull; built-up
edges with abrasive wheels for
stone
Sharpen abrasive wheels for
stone by briefly cutting through
abrasive materials; replace
1) STIHL recommends STIHL servicing dealers
6 Diamond Abrasive Wheels English
0458-370-8321-C 15

Defects Cause Remedy
abrasive wheel for asphalt with a
new one
poor cutting performance, high
segment wear
Abrasive wheel is turning in the
wrong direction
Mount abrasive wheel so that it
turns in the right direction
Breakdowns or tears in the
parent wheel and segment
Overloading use a new abrasive wheel
Undercut Cutting in the wrong material use new abrasive wheel;
observe separating layers of
various materials
7 Electronic Water Control
STIHL cut-off machines may be equipped with
an electronic water control system.
The electronic water control makes it possible to
feed the optimum amount of water to the abra‐
sive wheel. No water is fed to the abrasive wheel
during idling.
7.1 Before starting work
► Familiarize yourself with the sequence of
motions while the engine is switched off
1307BA001 KN
► All of the control panel buttons can be oper‐
ated with the thumb of the right hand – the
right hand always remains on the rear handle
while doing so
► The left hand always remains on the handle‐
bar
7.2 Control panel
When the engine is running, it is possible to acti‐
vate / deactivate the electronic water control and
adjust the water flow.
2
1
370BA085 KN
3
1 Button (+):
activate the electronic water control or
increase water flow to abrasive wheel
2 Button (–):
activate the electronic water control or
decrease water flow to abrasive wheel
3 Deactivate electronic water control; no water
is fed to the abrasive wheel
7.3 Using the electronic water con‐
trol
► Start engine, see "Starting / Stopping the
Engine"
► Tap on the (+) button or (–) button with the
thumb of the right hand – the right hand
always remains on the rear handle while doing
so, the left hand always remains on the han‐
dlebar – no water is fed to the abrasive wheel
yet during idling
During use, the set amount of water is fed to the
abrasive wheel.
► Adjust water flow if necessary – to do so, tap
on the (+) button or (–) button with the thumb
of the right hand until the correct water quan‐
tity is attained – the right hand always remains
on the rear handle while doing so, the left
hand always remains on the handlebar
If the cut-off machine is idling after use, no more
water will be fed to the abrasive wheel – the elec‐
1) STIHL recommends STIHL servicing dealers
English 7 Electronic Water Control
16 0458-370-8321-C

tronic water control, however, remains activated.
With continued use, the last quantity of water set
will be fed to the abrasive wheel again automati‐
cally.
If the engine is stopped and restarted, the elec‐
tronic water control is switched off.
7.3.1 For installation on the STIHL FW 20
cut-off machine cart
If the cut-off machine is mounted on the STIHL
FW 20 cut-off machine cart in combination with
the water tank, feed the maximum amount of
water.
7.4 Maintenance and care
If too little water or no water is fed to the abrasive
wheel during use although the electronic water
control has been activated:
2
370BA086 KN
1
► Remove the coupling sleeve (1)
► Unscrew "water connection with screen" (2)
and rinse under running water – the screen
remains on the water connection
If too little water or no water is fed to the abrasive
wheel although the screen has been cleaned,
visit your servicing dealer.
8 Assembling the cast arm
and guard
The "cast arm with guard" is mounted on the
inboard side by the manufacturer.
The "cast arm with guard" can also be mounted
on the outboard side depending on require‐
ments.
Assembly on the inboard side is recommended
for freehand cutting on account of the better bal‐
ance.
8.1 Outboard mounting
► Disassemble the cutting wheel (see “Fitting /
replacing an cutting wheel”)
8.1.1 Remove water attachment
1
1
2
370BA068 KN
3
► Unscrew the banjo bolt (1) with the combina‐
tion wrench – in the process, remove the
square nut from the inside of the guard from
the guide
► Remove the water hose (2) with connector
from the adjusting lever (3)
► Pull the water hose (2) out of the
guide (arrows) in the V‑belt guard
8.1.2 Removing the adjusting lever
2
370BA069 KN
1
3
► Unscrew the banjo bolt (1) with the combina‐
tion wrench and remove it together with the
seal – in the process, remove the square nut
from the inside of the guard from the guide
► Remove screw (2)
► Turn the adjusting lever (3) upwards and
remove
8.1.3 Slackening the V-belt
11
1
2
370BA070 KN
0
► Unscrew the nuts (1) – do not remove them
8 Assembling the cast arm and guard English
0458-370-8321-C 17

► Turn the tensioning nut (2) counterclockwise
with the combination wrench –
approx. 1/4 turn, as far as it will go = 0
8.1.4 Removing the V-belt guard
2
1
370BA071 KN
► Remove screw (1)
► Raise the V‑belt guard (2) slightly and pull it
off to the front
3
370BA079 KN
4
► Remove the V-belt (3) from the front pulley (4)
8.1.5 Remove the "cast arm with guard"
370BA072 KN
1
2
3
1
1
► Unscrew the nuts (1)
► Remove the "starter cover with rewind
starter" (2)
► Remove the "cast arm with guard" (3) from the
studs
8.1.6 Preparing the "cast arm with guard" for
outboard mounting
1
370BA073 KN
► Unscrew stop pin (1)
1
370BA074 KN
4 5 32
A
English 8 Assembling the cast arm and guard
18 0458-370-8321-C

► Turn the guard so that it is in the position
shown (see picture)
► Screw in and tighten the stop pin (1)
► Move the adjusting lever (2) to position A
► Screw in the bolt (3) and tighten up
► Unscrew the bolt (4) of the limit stop (5)
► Remove the limit stop (5)
45
370BA075 KN
6
► Turn the "cast arm with guard" so that the
guard is on the outboard side
► Insert limit stop (5) – align the hole in the limit
stop with the hole in the cast arm
► Screw in the bolt (4) and tighten up
► Insert the square nut into the guide in the
guard and hold it in place
► Screw in the shorter banjo bolt (6) and washer
at the adjusting lever and tighten up with the
combination wrench
8.1.7 Mount "cast arm with guard" – guard
on the outboard side
1
12
2
370BA008 KN
12
43
► Press the oblong holes (1) in the "cast arm
with guard" on to the studs (2), guiding the rib‐
bed V‑belt over the front pulley
NOTICE
The belt action must run smoothly.
► The belt tensioner (3) must sit close to the
lug (4)
6
6
2
2
2
370BA051 KN
6
5
► Fit the "starter cover with rewind starter" (5)
over the studs (2)
► Tighten up the nuts (6) by hand
8
370BA077 KN
7
► Push the V‑belt guard (7) into place
► Screw in the bolt (8) and tighten up
8.1.8 Connect water connection
1
1
370BA078 KN
2
3
► Insert the longer banjo bolt (1) through the
connector (2) of the water attachment –
observe the position of the connector
► Insert the square nut into the guide in the
guard and hold it in place
8 Assembling the cast arm and guard English
0458-370-8321-C 19

► Fit the support with the longer banjo bolt on
the adjusting lever (3) – screw in the banjo bolt
and tighten with the combination wrench
► Insert the water hose into the guide in the
V‑belt guard (arrow) from the shut-off cock
towards the guard – avoid tight radiuses
8.1.9 Checking the adjustment range of the
guard
370BA076 KN
A
► Rotate the guard forwards and backwards as
far as possible – adjustment range (A) must be
limited by the stop pin
Continue as described in the chapter “Tensioning
the V‑belt”.
8.2 Inboard mounting
► Disassemble the cutting wheel (see “Fitting /
replacing an cutting wheel”)
► Remove water attachment
► Remove the adjusting lever
► Slacken the V-belt
► Remove the V-belt guard
► Remove the "cast arm with guard"
8.2.1 Preparing the "cast arm with guard" for
inboard mounting
12
370BA080 KN
► Unscrew the screw (1) of the limit stop (2)
► Remove the limit stop (2)
3
370BA081 KN
12
► Turn the "cast arm with guard" so that the
guard is on the inboard side
► Insert limit stop (2) – align the hole in the limit
stop with the hole in the cast arm
► Screw in the bolt (1) and tighten up
► Unscrew stop pin (3)
3
370BA082 KN
► Turn the guard so that it is in the position
shown (see picture)
► Screw in and tighten the stop pin (3)
► Install the adjusting lever
► Mount "cast arm with guard" – guard on the
inboard side
► Install the V-belt guard
► Connect water connection
English 8 Assembling the cast arm and guard
20 0458-370-8321-C