STIHL GS 461 Owner's Manual
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STIHL GS 461
Instruction Manual
Contents
English
Guide to Using this Manual 2
Safety Precautions and Working
Techniques 2
Sample applications 9
Cutting Attachment 11
Mount guide bar and diamond
abrasive chain 11
Tension diamond abrasive chain 13
Check tension of diamond abrasive
Original Instruction ManualPrinted on chlorine-free paper
chain 13
Fuel 14
Fueling 15
Starting / Stopping the Engine 16
Operating Instructions 19
Air Filter System 20
Remove air filter 20
Cleaning the Air Filter 21
Adjusting the Carburetor 21
Spark Arresting Screen in Muffler 22
Spark Plug 23
Replacing the Starter Rope and
Rewind Spring 24
Printing inks contain vegetable oils, paper can be recycled.
Storing the Machine 26
Taking Care of the Guide Bar 26
Checking and Replacing the Chain
Sprocket 27
Maintain and sharpen diamond
abrasive chain 28
Maintenance and Care 29
Minimize Wear and Avoid Damage 31
Main Parts 32
Specifications 33
Special Accessories 34
Maintenance and Repairs 34
Disposal 34
EC Declaration of Conformity 35
Quality Certification 35
Dear Customer,
Thank you for choosing a quality
engineered STIHL product.
This machine has been built using
modern production techniques and
comprehensive quality assurance.
Every effort has been made to ensure
your satisfaction and troublefree use of
the machine.
Please contact your dealer or our sales
company if you have any queries
concerning your machine.
Your
Hans Peter Stihl
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© ANDREAS STIHL AG & Co. KG, 2012
0458-761-0121-A. VA3.J12.
0000006258_002_GB
GS 461
This instruction manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process
with electronic systems.
1
English
Guide to Using this Manual
Pictograms
Pictograms that appear on the machine
are explained in this Instruction Manual.
Depending on the machine and
equipment version, the following
pictograms may appear on the machine.
Fuel tank; fuel mixture of
gasoline and engine oil
Direction of chain travel
Tension diamond abrasive chain
Actuate decompression
valve
Water connection, shutoff cock
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.
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 manual.
Safety Precautions and
Working Techniques
Because the chain of a
concrete cutter runs at
very high speeds, special safety precautions
must be observed to
reduce the risk of personal injury.
It is important that you
carefully read the entire
Instruction Manual before
using the machine for the
first time and keep it in a
safe place for future reference. Non-compliance
with the Instruction Manual may cause serious or
even fatal injury.
Observe the national safety regulations
issued, e. g. by the employers' liability
insurance association, social security
institutions, occupational safety and
health authorities or other organizations.
If you have never used a power tool
before: Ask the salesperson or another
expert to explain how to use it safely – or
attend a training course.
Minors should never be allowed to use
the machine – except for young trainees
over the age of 16 when working under
supervision.
Children, animals and bystanders must
remain at a distance.
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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.
The machine should only be provided or
loaned to people familiar with this model
and its operation. The Instruction
Manual should always be handed over
with the machine.
Use of machines that emit noise may be
restricted in terms of time by national
and/or on-site, local regulations.
The machine may only be operated by
people who are fit, in good physical
health and in good mental condition.
If you have any condition that might be
aggravated 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. An effect on individual
pacemaker types cannot be excluded
entirely. STIHL recommends that you
consult your doctor and the
manufacturer of your pacemaker in
order to avoid health hazards.
Anyone who has consumed alcohol,
medicines affecting their ability to react
or drugs must not operate the machine.
Postpone the work if the weather is bad
(rain, snow, ice, wind) – higher risk of
accidents!
The machine may only be used for
cutting.
The machine must not be used for any
other purposes – risk of injury!
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!
Only use tools, guide bars, diamond
abrasive chains or accessories that
have been approved by STIHL for this
machine or which are technically
equivalent. Contact a servicing dealer if
in doubt. Only use high-quality tools or
accessories. Otherwise there may be a
risk of accidents or damage to the
machine.
STIHL recommends the use of genuine
STIHL guide bars, diamond abrasive
chains, chain sprockets and
accessories. These have been
optimized for the product and the user's
requirements.
Never modify the machine in any way,
as this could be extremely dangerous.
STIHL excludes all liability for personal
injury and damage to property caused
while using unauthorized attachments.
Do not use high-pressure cleaners to
clean the machine. The hard water jet
can damage parts of the machine.
Clothing and equipment
Wear proper protective clothing and
equipment.
Clothing must be sturdy
and snug-fitting, but allow
complete freedom of
movement. Wear snug
fitting clothing – an overall, not a loose-fitting
jacket.
Do not wear clothing that could become
trapped in moving parts of the machine
– no scarves, no neckties, no jewelry.
Long hair must be tied up and covered.
Wear safety boots with
steel toe caps and nonslip soles.
Wear a hard hat wherever there is any risk of
falling objects. Wear goggles to protect the eyes
against flying objects.
Wear "personal" hearing
protection – e. g., ear
defenders.
A face mask alone is not sufficient to
protect the eyes.
Dust (e. g., crystalline material from the
object being cut), fumes and smoke may
be produced while cutting - health
hazard!
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 sturdy gloves.
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English
STIHL can supply a comprehensive
range of protective clothing and
equipment.
Transporting the machine
Always stop the engine and attach the
chain scabbard.
Carry the machine only by the top
handle – guide bar towards the rear –
with the hot muffler facing away from the
body.
Avoid touching hot parts of the machine,
especially the surface of the muffler –
risk of burns!
In vehicles: Properly secure your
machine to prevent turnover, damage
and fuel spillage.
Refueling
Gasoline is an extremely
flammable fuel – keep
clear of naked flames and
fire – do not spill any fuel
– no smoking.
Switch off the engine before refueling.
Never refuel the machine while the
engine is still hot – the fuel may spill over
– risk of fire!
Open the fuel filler cap carefully so that
any excess pressure is relieved
gradually and fuel does not splash out.
The machine may only be refueled in a
well ventilated place. Clean the machine
immediately if fuel is spilled. Change
your clothes immediately if they are
contaminated with fuel.
Dust may collect on the engine unit,
particularly around the carburetor. If the
dust is soaked with gasoline, it may
catch fire. For this reason, ensure that
the dust is always removed.
Check for fuel leakage
while refueling and during
operation. Never start the
engine if fuel has been
spilled or is leaking –
Fatal burns may result!
Bayonet filler cap
Never use a tool to open or close the
bayonet filler cap. This could damage
the cap and cause fuel to leak out.
Secure the bayonet filler cap tightly after
refueling.
Diamond abrasive chain
The diamond abrasive chain, guide bar
and chain sprocket must match each
other and your concrete cutter.
Use only approved diamond abrasive
chains. If unauthorized chains are used,
aggressive cutting cannot be ruled out.
This may lead to uncontrolled and
exceedingly dangerous reaction forces
(kickback) in the machine – risk of fatal
injuries!
Only use diamond abrasive chain for the
specified materials, observe diamond
abrasive chain codes.
Always cut with water.
Before fitting used diamond abrasive
chains, check that they are not cracked,
chipped, check also that there are no
damaged or missing segments, signs of
overheating (discoloration).
Never use diamond abrasive chains that
are cracked or have chipped segments.
Visit your servicing dealer.
Before starting
Check that concrete cutter is properly
assembled and in good condition – refer
to appropriate chapters in the Instruction
Manual:
– Check fuel system for leaks,
especially the visible parts, e. g.,
filler cap, hose connections, fuel
pump. Do not start the engine if
there are leaks or damage – risk of
fire! Have the machine repaired by a
servicing dealer before using it
– functional, front hand guard
– Check chain sprocket
– Sprocket nose moves easily
– Correctly mounted guide bar
– The diamond abrasive chain must
be suitable for the material to be cut.
It must be in good condition and
fitted correctly (direction of running).
– Correctly tensioned diamond
abrasive chain
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2411BA046 KN
– The throttle trigger and throttle
trigger lockout must move easily –
throttle trigger must return
automatically to the idle position
when released
– Master control lever can be moved
to STOP or 0
– Check that the spark plug boot is
secure. A loose boot can lead to
flying sparks which may ignite the
escaping fuel/air mixture – risk of
fire!
– Never attempt to modify the controls
or safety devices
– Keep the handles dry and clean,
free from oil and dirt – important for
safe control of the concrete cutter
The concrete cutter should only be used
if it is in full working order – risk of
accident!
Starting the engine
Move at least 3 meters away from the
place at which the machine was refueled
and never start the machine in enclosed
spaces.
The machine may only be used on level
ground. Ensure a firm and secure
footing and hold the machine firmly. The
diamond abrasive chain must not touch
any objects or the ground and must not
be in the cut, because it may begin to
rotate when the machine is started.
The machine is operated by only one
person. There should not be any other
person within the working area, not even
when starting the machine.
Do not drop-start the engine – start as
described in the Instruction Manual.
Before starting, open the shut-off valve
completely and ensure a supply of water
to the diamond abrasive chain – do not
allow diamond abrasive chain to run dry.
Holding and guiding the machine
Always hold the machine firmly with both
hands: Right hand on the rear handle –
even if you are left-handed. To ensure
reliable control, wrap your thumbs tightly
around the handlebar and handle.
The object that is to be cut must be
positioned firmly; always guide the
machine to the workpiece – never vice
versa.
During work
Ensure you always have a firm and safe
footing.
In the event of impending danger or in
an emergency, switch off the engine
immediately by moving the master
control lever to STOPor0.
The machine is operated by only one
person. There should not be any other
person within the working area.
Use extreme caution with openings,
recesses, etc., someone could be
standing behind them – look
beforehand.
Never let the machine run unattended.
When the engine is running: The
diamond abrasive chain continues to run
for some time after the throttle trigger
has been released – Risk of injury due to
coasting effect!
Beware of slipping on ice, water, snow
or uneven ground!
Never work on a ladder or on any other
unsteady support. Do not work above
shoulder height and never operate the
machine with one hand - risk of
accidents!
Ensure that the working area is clear –
watch out for obstacles, holes and pits.
Do not work alone – keep within calling
distance of others in case help is
needed.
More care and attention than usual are
required when wearing ear protection –
warning sounds (shouts, alarms, etc.)
cannot be heard properly.
Take breaks in due time in order to
prevent tiredness and exhaustion – risk
of accidents!
Keep easily combustible materials away
from hot exhaust gases and hot mufflers
– risk of fire! Mufflers with catalytic
converters can become especially hot.
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2411BA001 KN
A
2411BA002 KN
B
Your power tool produces
toxic exhaust fumes as
soon as the engine is
running. These gases
may be colorless and
odorless and may contain
unburnt hydrocarbons
and benzene. Never run
the engine indoors or in
poorly ventilated areas,
even if your model is
equipped with a catalytic
converter.
Ensure proper ventilation when working
in trenches, hollows or other confined
areas. Toxic fumes can kill!
If you feel sick, if you have a headache,
vision problems (e.g., your field of vision
gets smaller), hearing problems,
dizziness or inability to concentrate, stop
work immediately. Such symptoms may
be caused by an excessively high
concentration of exhaust emissions –
risk of accident!
No smoking when working with or near
the machine - risk of fire! Combustible
fuel vapor may escape from the fuel
system.
Examine the diamond abrasive chain
periodically at short intervals, check that
they are not cracked, chipped, check
also that there are no damaged or
missing segments, signs of overheating
(discoloration).
Never use diamond abrasive chains that
are cracked or have chipped segments.
Visit your servicing dealer.
In the event of noticeable changes in
cutting behavior (e. g., increased
vibration, reduced cutting performance),
stop work and eliminate the causes of
the changes.
– Switch off the engine and wait until
the diamond abrasive chain is
stationary
– Check condition and correct tension
of diamond abrasive chain
– Ensure that the cutting blades are
sharp
Never touch the diamond abrasive chain
when the motor is running. If the
diamond abrasive chain becomes
jammed by an object, switch off the
engine immediately before attempting to
remove the object – risk of injury!
To change the diamond abrasive chain,
switch off the engine – risk of injury!
If the machine 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 – refer also to the
section "Before starting". Check the fuel
system for leaks and make sure the
safety devices are working properly.
Never continue using a power tool that is
not in perfect working order. Consult a
servicing dealer if in doubt.
Check for correct idling, so that the
diamond abrasive chain stops moving
when the throttle trigger is released.
Check and/or correct the idle setting
regularly. Have the machine repaired by
a STIHL servicing dealer if the diamond
abrasive chain continues to run
nevertheless.
Reactive forces
The most frequently occurring reactive
forces are pull-in and pushback.
Pull-in (A)
When the diamond abrasive chain on
the bottom of the guide bar –
overbucking – is jammed or encounters
a solid object, the concrete cutter may
suddenly be drawn forward to the
workpiece.
Pushback (B)
When the diamond abrasive chain on
the top of the guide bar – underbucking
– is jammed or encounters a solid object,
the concrete cutter may suddenly be
driven straight back toward the operator.
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002BA146 KN
2411BA003 KN
– Do not allow the guide bar to
become jammed
– Always be aware that the object to
be cut may move and other factors
may cause the cut to close and jam
the diamond abrasive chain
– The object to be cut must be
secured and supported so that the
cut remains open during and after
cutting
– Do not twist the guide bar in the cut
Working – abrasive cutting
Ensure sufficient water supply to
diamond abrasive chain – do not allow
diamond abrasive chain to run dry.
Always wet cut – regardless of the
material to be cut.
The diamond abrasive chain must be
guided straight in the cut, without
wedging. Never exert lateral pressure on
the diamond abrasive chain.
Do not use the diamond abrasive chain
for lateral grinding or scrubbing.
Do not use the starting throttle position
for cutting. Engine speed cannot be
controlled with the throttle trigger in this
position.
Examine the workplace. Avoid all
danger due to damaged piping or
electrical wiring.
The machine must not be used near
inflammable substances or gases.
Never use the machine to cut inside
pipes, metal troughs or other containers
unless you are absolutely sure that they
do not contain any volatile or
inflammable substances.
Never leave the machine unattended
with the engine running. Switch off the
engine before leaving the machine
(e. g., for a break).
Work calmly and methodically – only
with good lighting and visibility. Do not
endanger others – stay alert at all times.
Make certain that all parts of your body
are well clear of the extended range of
travel of the diamond abrasive chain.
Only pull concrete cutter out of the
object being cut with the diamond
abrasive chain running.
Only use concrete cutter for cutting – no t
for prying or shoveling away objects.
Always decide the cutting direction
before positioning the concrete cutter.
After that, do not change the cutting
direction. Avoid knocks and bumps with
the machine while in the cut – do not
drop the machine into the cut – danger of
breakage!
If cutting performance begins to
deteriorate, check the sharpness of the
diamond abrasive chain, resharpen as
needed. To do this, briefly cut through
abrasive material, e. g., sandstone,
aerated concrete or asphalt.
When working above ground level:
– Always use a lift bucket
– Never use the machine while
standing on a ladder
– Never use the machine in unsteady
locations
– Never cut above shoulder height
– Never use the machine with one
hand
Begin cutting with the concrete cutter at
full throttle.
At the end of the cut, the concrete cutter
is no longer supported by the cutting
attachment in the cut. The machine's
weight must be borne by the user – risk
of loss of control!
Keep water and sludge away from
electric cables - risk of electric shocks!
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.
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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 circulation (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.
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 spare parts.
Otherwise, there may be a risk of
accidents or damage to the machine.
Contact a servicing 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 – risk
of injury! – Exception: adjustment of
carburetor and idle speed.
To reduce the risk of fire due to ignition
outside the cylinder, move the slide
control to STOP or 0 before turning the
engine over on 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 "Specifications".
Inspect ignition lead (insulation in good
condition, secure connection).
Check that the muffler is in perfect
working condition.
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!
The condition of the antivibration
elements influences vibration behavior –
inspect antivibration elements
periodically.
Switch off the engine
– to check the chain tension
– to retension the chain
– to change chains
– for remedying malfunctions
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3.
2411BA004 KN
1.
2.
A
2411BA005 KN
2411BA006 KN
Sample applications
Use diamond abrasive
chain only with water.
Connect concrete cutter
to water supply network
(min. 1.5 bar).
The water introduced is used to cool the
diamond abrasive chain and rinse the
cutting attachment, and for binding dust.
After finishing work, run the concrete
cutter for a few seconds with water and
at operating speed to rinse the cutting
attachment.
If the water pressure or water volume is
too low, this leads to significantly
increased wear and irreparable damage
to the cutting attachment – danger of
breakage!
Objects to be cut
– Must be fully supported
– Must be secured so it cannot roll or
slip off
– Must be prevented from vibrating
Severed parts
With openings, recesses, etc., the
sequence of the cuts is important.
Always make the last cut so that the
diamond abrasive chain does not
become jammed and so that the
operator is not endangered by the
severed or separated part.
If necessary, use wedges and 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.
Plunge-cutting
Begin cutting with the concrete cutter at
full throttle.
1. Apply the lower portion of the guide
bar nose
2. Swing slowly into the plunge-cutting
position
3. Make the plunge cut very carefully
When making the plunge cut into
existing, narrower joints, proceed with
extreme care.
Cut in several passes
N Mark cutting line (A)
N Work along the cutting line. When
making corrections, do not tilt the
diamond abrasive chain, always
reposition it afresh
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2411BA007 KN
2411BA008 KN
Cutting round and hollow bodies
N Secure pipes, round bodies, etc.
against rolling away
N Mark a cutting line - when
determining the cutting line, avoid
reinforcement, especially in the
direction of the severing cut
N Make the plunge cut very carefully
N Feed with full cutting depth along
the cutting line – for small
corrections of direction, do not tilt
the diamond abrasive chain, but
always position it anew instead – if
necessary, use wedges and if
necessary, leave small ridges that
hold the part that is to be separated
in position. Break these ridges later
Shaping pipe
N Secure pipes, round bodies, etc.
against rolling away
N Mark a cutting line - when
determining the cutting line, avoid
reinforcement, especially in the
direction of the severing cut
DANGER
Manual cutting along this line requires
particular caution and precision.
always position it anew instead – if
necessary, use wedges and if
necessary, leave small ridges that
hold the part that is to be separated
in position. Break these ridges later
10
N Cut into pipes, round bodies, etc. in
the area at the ends of the cutting
line, so that the material does not
break away
N Make the plunge cut very carefully
at the apex and cut outward on both
sides - feed with full cutting depth
along the cutting line – for small
corrections of direction, do not tilt
the diamond abrasive chain, but
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