Stihl TS 440 Instruction Manual
STIHL TS 440
Instruction Manual
Contents
English
Guide to Using this Manual 2
Safety Precautions and Working
Techniques 2
Sample Applications 11
Cutting Wheels 14
Composite Abrasive Wheels 15
Diamond Abrasive Wheels 15
Abrasive wheel brake 18
Original Instruction ManualPrinted on chlorine-free paper
Electronic Water Control 20
Mounting an Abrasive Wheel 21
Fuel 22
Fueling 23
Starting / Stopping the Engine 24
Air Filter System 28
Adjusting the Carburetor 29
Spark Arresting Screen in Muffler 30
Spark Plug 30
Storing the Machine 31
Maintenance and Care 32
Main Parts 34
Specifications 35
Maintenance and Repairs 36
Printing inks contain vegetable oils, paper can be recycled.
Disposal 36
EC Declaration of Conformity 37
Dear Customer,
Thank you for choosing a quality
engineered STIHL product.
It has been built using modern
production techniques and
comprehensive quality assurance.
Every effort has been made to ensure
your satisfaction and trouble-free use of
the product.
Please contact your dealer or our sales
company if you have any queries
concerning this product.
Your
Dr. Nikolas Stihl
© ANDREAS STIHL AG & Co. KG, 2020
0458-520-8321-A. VA6.G20.
0000008170_004_GB
TS 440
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
Actuate decompression
valve
Actuate manual fuel
pump
Pull starter grip
Actuate brake lever and
release abrasive wheel
brake
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
Special safety precautions must be taken when
working with the cut-off
machine, due to the very
high rotational speed of
the abrasive wheel.
It is important you read
and understand the User
Manual before commissioning 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
Community, 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.
Children, animals and bystanders must
not be allowed near the machine.
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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.
Do not lend or rent your power tool
without the User Manual. Be sure that
anyone using it understands the
information contained in this manual.
The use of machines that emit noise
may be limited to certain hours of the
day as specified by national and/or
regional or local regulations.
Anyone operating the machine must be
well rested, 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. This field may interfere with
some pacemakers. STIHL recommends
that persons 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 specifically
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, carbide, rescue
or wood cutting attachments 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 aggressive manner
with uncontrolled and
extremely dangerous
kickback.
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 cotton 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 moving parts – no scarf, no tie, no
jewelry. Tie up and confine long hair
above your shoulders.
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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 face protection and make sure it is
a good fit. Face protection alone is not
sufficient to protect the eyes.
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!
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
example, ear defenders.
Wear sturdy protective
gloves made of a resistant material (e. g.
leather).
STIHL can supply a comprehensive
range of personal protective equipment.
Transporting the machine
Always stop the engine.
Carry the device by the handlebar only –
abrasive 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, properly secure your machine to
prevent turnover, damage and fuel
spillage.
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!
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.
Cut-off machine, spindle bearing
Correct spindle bearings ensure the
concentricity and axial running of the
diamond abrasive wheel – if necessary,
get it checked by an approved dealer.
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Abrasive cutting wheels
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 abrasive cutting
wheels.
STIHL generally recommends wet
cutting.
Observe the outer diameter of the abrasive wheel.
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 abrasive 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 cutting wheels.
Substandard and/or unapproved
diamond abrasive 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.
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 rotation 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 concentricity and
axial running.
Storing abrasive cutting wheels
Store abrasive wheels in a dry and frostfree place, on an even surface, at
constant temperature – risk of breakage
and splintering!
Always protect abrasive cutting wheels
against sudden impact with the floor or
objects.
Before starting
Inspect the cut-off machine for safe-tooperate 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
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002BA549 AM
180BA022 KN
– Check that the spark plug boot is
secure – a loose boot may cause
sparking that could ignite
combustible fumes and cause a fire!
– Check the correct operation of the
abrasive cutting wheel brake. When
the brake lever is activated, the
abrasive cutting wheel can be
turned by hand – when the brake
lever is released, the abrasive
cutting wheel can no longer be
turned. It should not be possible to
turn the abrasive cutting wheel
when the brake lever is not
activated.
– 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!
at machine start-up, do not work with the
cut-off machine and contact a dealer.
Arrange for the abrasive cutting wheel
brake to be repaired.
The machine is operated by a single
person only – do not allow any person to
stay within the working area – nor with
starting.
Do not drop start your machine – the
correct starting procedure is described
in the User Manual.
After releasing the throttle trigger, the
abrasive wheel keeps on running for a
while – danger of injury due to coasting
effect!
Holding and guiding the machine
Use the cut-off machine only for handheld cutting.
Hand-held cutting
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
supported. Always guide the machine
towards the workpiece – never the other
way round.
Deflector
Starting the engine
Start the engine at least 3 meters from
the fueling spot, outdoors only.
On even ground, ensure a firm and
secure footing and hold the enginedriven device firmly – the abrasive
cutting wheel must not touch any objects
or the ground and must not be in cutting
action.
When starting, the abrasive cutting
wheel brake is engaged. If the abrasive
cutting wheel does not immediately turn
6
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.
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 particles of material.
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While working
If there is imminent danger or in an
emergency, immediately stop the
engine – set the slide control / master
control lever /stop switch to STOP or 0.
Check for correct idling, so that the
abrasive cutting 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 regular intervals. Have the machine
repaired by a STIHL dealer if the
abrasive cutting wheel continues to turn
after the abrasive cutting wheel brake
has been released.
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.
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. These
gases may be odorless
and invisible and may
contain unburned hydrocarbons and benzene.
Never run the engine
indoors or in poorly ventilated locations, 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 controlled 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 containers if you are not sure that
they do not contain 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).
Stopping the engine engages the
abrasive cutting wheel brake. If the cutoff machine, with the abrasive cutting
wheel running, stands on the ground
and the engine is switched off there, the
engagement of the abrasive cutting
wheel brake may cause the cut-off
machine to tilt forward, resulting in the
abrasive cutting wheel touching the
ground – damage to the abrasive cutting
wheel!
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002BA555 AM
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 cutting wheel –
replace it right away if
there are visible cracks,
buckling or other damage
(for example, overheating) – risk of accident due
to breakage!
In the event of changes in cutting
behavior (e. g., increased vibration,
reduced cutting performance), stop work
and eliminate the causes of the
changes.
Reactive forces
The most frequently occurring reactive
forces are kickback and pull-in.
Danger of kickback –
Kickback can result in
fatal injuries.
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 cutting wheel
– gets jammed – primarily in its upper
quarter, or
– is abruptly braked through friction
contact with a solid object
QuickStop abrasive cutting wheel brake
When the abrasive cutting wheel brake
is engaged, the abrasive cutting wheel
will come to a standstill in a split second
–
see chapter "abrasive cutting wheel
Brake" in this User Manual.
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
002BA551 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
– 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 supported so that the
kerf remains open during and after
cutting
– Objects to be cut must therefore be
fully supported and must be
secured against rolling away,
slipping off or vibrations
002BA552 AM
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– 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
Pull away from
The cut-off machine pulls forward, away
from the user, when the abrasive wheel
touches the object to be cut from above.
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.
0000-GXX-4256-A0
Do not stand in line with the abrasive
wheel. Ensure sufficient freedom of
movement, especially in construction
trenches there must be sufficient 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 cutting. It must not be used as a lever
002BA553 AM
or shovel.
Do not press down on the cut-off
machine
Always decide the cutting direction
before positioning 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 performance begins to
deteriorate, check the sharpness of the
diamond abrasive wheel, resharpen as
needed. To do this, briefly cut through
abrasive 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
002BA554 AM
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 connector.
Du to the reduced maximum spindle
speed, STIHL developed a special
composite resin abrasive cutting wheel
for cutting steel with this machine. This
abrasive cutting wheel is suitable for dry
cutting only. If a composite resin
abrasive cutting wheel of this type
becomes wet, its cutting performance is
reduced and it becomes dull. If a
composite resin abrasive cutting wheel
of this type becomes wet while working
(e.g., due to puddles or water in pipes),
do not increase the cutting pressure, but
continue working with the same
pressure – risk of breakage! Use up
such composite resin abrasive cutting
wheels immediately.
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Traditional composite resin abrasive
cutting wheels developed for cut-off
machines with high circumferential
speed have an inferior cutting
performance and are unsuitable.
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 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 and damage to the machine. If
you have any questions in this respect,
consult a servicing dealer.
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 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".
Check 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!
Check the rubber buffers underneath
the machine – the housing must not rub
against the ground – risk of damage!
The condition of the anti-vibration
elements influences vibration behavior –
inspect anti-vibration elements
periodically.
Before starting work, check the
operation of the abrasive wheel brake.
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