STIHL TS 400 Instruction Manual
STIH)
STIHL TS 400 Cutquik
®
Instruction Manual
Manual de instrucciones
Warning!
Read and follow all safety precautions in
Instruction Manual - improper use can cause
serious or fatal injury.
Advertencia!
Lea y siga todas las precauciones de
seguridad dadas en el manual de
instrucciones - el uso incorrecto puede
causar lesiones graves o mortales.
Contents
English / USA
Guide to Using this Manual .............. 2
Safety Precautions and
Working Techniques ......................... 3
Application Examples ..................... 18
STIHL composite resin
cutting wheels ................................. 21
STIHL diamond cutting wheels ....... 21
BA_SE_062_003_01_08.fmPrinted on chlorine-free paper.
Assembling the
bearing and guard .......................... 25
Tensioning the V-belt ...................... 26
Abrasive wheels ............................. 27
Fitting / replacing an
abrasive wheel ............................... 28
Fuel ................................................ 30
Fueling ............................................ 31
Starting / stopping the engine ......... 31
Cleaning the air filter ...................... 34
Motor Management ........................ 36
Adjusting Carburetor ...................... 36
Spark arresting screen
in the muffler ................................... 37
Checking the Spark Plug ................ 37
Replacing the starter
rope / rewind spring ........................ 38
Replacing the V-belt ....................... 41
STIHL cut-off machine cart ............. 42
Printing inks contain vegetable oils; paper can be recycled.
Storing the machine ........................ 42
Maintenance chart .......................... 43
Parts and Control ............................ 44
Specifications ................................. 46
Special Accessories ....................... 47
Maintenance and Repairs ............... 47
STIHL Incorporated
Federal Emission Control
2007Warranty Statement ................ 48
Trademarks .................................... 50
Allow only persons who understand this
manual to operate your cut-off machine.
To receive maximum performance and
satisfaction from your STIHL cut-off
machine, it is important that you read
and understand
maintenance precautions,
page 3, before using your cut-off
machine.
Contact your STIHL dealer or the STIHL
distributor for your area if you do not
understand some instruction in this
manual.
the safety and
starting on
!Warning!
Because a cut-off machine is a highspeed cutting tool, some special safety
precautions must be observed to reduce
the risk of personal injury.
Careless or improper use may cause
serious or even fatal injury.
STIHl
© ANDREAS STIHL AG & Co. KG, 2007
0458 338 8621. M3. D7. FST. Printed in Germany
1TS 400
English / USA
Guide to Using this Manual
Pictograms
All the pictograms attached to the
machine are shown and explained in
this manual.
The operating and handling instructions
are supported by illustrations.
Symbols in text
The individual steps or procedures
described in the manual may be marked
in different ways:
: A bullet marks a step or procedure
without direct reference to an
illustration.
A description of a step or procedure that
refers directly to an illustration may
contain item numbers that appear in the
illustration.
Example:
Loosen the screw (1)
Lever (2) ...
In addition to the operating instructions,
this manual may contain paragraphs
that require your special attention. Such
paragraphs are marked with the
symbols described below:
Warning where there is a risk of an
accident or personal injury or
serious damage to property.
Caution where there is a risk of
damaging the machine or its
individual components.
Note or hint which is not essential
for using the machine, but may
improve the operator’s understanding of the situation and result
in better use of the machine.
Note or hint on correct procedure in
order to avoid damage to the
environment.
Equipment and features
This instruction manual may refer to
several models with different
features. Components that are not
installed on all models and related
applications are marked with an
asterisk (*). Such components may
be available as special accessories
from your STIHL dealer.
Engineering improvements
STIHL’s philosophy is to continually
improve all of its products. As a result,
engineering changes and improvements
are made from time to time. If the
operating characteristics or the
appearance of your machine differ from
those described in this manual, please
contact your STIHL dealer for
assistance.
Therefore some changes, modifications
and improvements may not be covered
in this manual.
2
TS 400
Safety Precautions and
Working Techniques
English / USA
!Warning!
The use of any cut-off
machine may be
hazardous. Because a
cut-off machine is a highspeed, fast-cutting power tool, special
safety precautions must be observed to
reduce the risk of personal injury and
fire.
It is important that you read, fully
understand and observe the following
safety precautions and warnings.
Read the instruction
manual and the safety
precautions periodically.
Do not lend or rent your cut-off machine
without the instruction manual. Be sure
that anyone using your cut-off machine
understands the information contained
in this manual. A first-time operator
should obtain practical instruction before
using the machine. Employers should
establish a training program for
operators of gasoline-powered, handheld portable, cut-off machines to
assure safe operation of these
machines. These safety precautions
and warnings apply to the use of all
STIHL Cutquiks.
!Warning!
Careless or improper use of any cut-off
machine may cause serious or fatal
injury.
Have your STIHL dealer show you how
to operate your cut-off machine.
Observe all applicable national, state
and local safety regulations, standards
and ordinances.
!Warning!
Minors should never be allowed to use a
cut-off machine. Bystanders, especially
children, and animals should not be
allowed in the area where a cut-off
machine is in use. Never let the cut-off
machine run unattended.
Different models may have different
parts and controls. See the appropriate
section of your instruction manual for a
description of the controls and function
of the parts of your model cut-off
machine.
Safe use of a cut-off machine involves
– the operator
– the cut-off machine
– the use of the cut-off machine.
THE OPERATOR
Physical Condition
You must be in good physical condition
and mental health and not under the
influence of any substance (drugs,
alcohol, etc.) which might impair vision,
dexterity or judgment. Do not operate a
cut-off machine when you are fatigued.
Be alert - if you get tired while operating
your cut-off machine, take a break;
tiredness may result in loss of control.
Working with any cut-off machine can be
strenuous. If you have any condition that
might be aggravated by strenuous work,
check with your doctor before operating
a cut-off machine.
3TS 400
English / USA
!Warning!
Prolonged use of cut-off machines (or
other machines) exposing the operator
to vibrations may produce whitefinger
disease (Raynaud's phenomenon) or
carpal tunnel syndrome. These
conditions reduce the hand's ability to
feel and regulate temperature, produce
numbness and burning sensations and
cause nerve and circulation damage and
tissue necrosis. All factors which
contribute to whitefinger disease are not
known, but cold weather, smoking and
diseases or physical conditions that
affect blood vessels and blood transport,
as well as high vibration levels and long
periods of exposure to vibration are
mentioned as factors in the development
of whitefinger disease. In order to
reduce the risk of whitefinger disease
and carpal tunnel syndrome, please
note the following:
– Most STIHL cut-off machine models
are available with an anti-vibration
("AV") system designed to reduce
the transmission of vibrations
created by the engine to the
operator's hands. An AV system is
recommended for those persons
using cut-off machines on a regular
or sustained basis.
– Wear gloves and keep your hands
warm.
– Keep the AV system well
maintained. A cut-off machine with
loose components or with damaged
or worn AV buffers will tend to have
higher vibration levels.
– Maintain a firm grip at all times, but
do not squeeze the handles with
constant, excessive pressure. Take
frequent breaks.
All the above-mentioned precautions do
not guarantee that you will not sustain
whitefinger disease or carpal tunnel
syndrome. Therefore, continual and
regular users should monitor closely the
condition of their hands and fingers. If
any of the above symptoms appear,
seek medical advice immediately.
!Warning!
The ignition system of your unit
produces an electromagnetic field of a
very low intensity. This field may
interfere with some pacemakers. To
reduce the risk of serious or fatal injury,
persons with a pacemaker should
consult their physician and the
pacemaker manufacturer before
operating this tool.
Proper Clothing
!Warning!
To reduce the risk of
injury, the operator should
wear proper protective
apparel.
Clothing must be sturdy and snug-fitting,
but allow complete freedom of
movement. Avoid loose-fitting jackets,
scarfs, neckties, jewelry, flared or cuffed
pants, unconfined long hair or anything
that could become caught on any
obstacles or moving parts of the unit.
Wear overalls or long pants to protect
your legs. Do not wear shorts.
4
TS 400
English / USA
!Warning!
When cutting metal, a cut-off machine
generates sparks that can ignite
clothing. Most fabrics used in clothing
are flammable - even flame-retardant
fabrics will ignite at higher temperatures.
To reduce the risk of burn injury STIHL
recommends wearing clothing made of
leather, wool, flame-retardant-treated
cotton or a tightly woven, heavier cotton
such as denim. Some flame-retardant
synthetic fabrics are also suitable but
others such as polyester, nylon, rayon
and acetate can melt during a fire into a
tar-like matter that burns into the skin.
Check the clothing manufacturer's
instructions. Keep clothing free of oil,
fuel, grease and other flammable
substances.
Always wear gloves when
handling the cut-off
machine. Heavy-duty,
nonslip gloves improve
your grip and help to
protect your hands.
Good footing is most
important in cut-off
machine work.
Wear sturdy boots with
nonslip soles. Steel-toed
safety boots are recommended.
!Warning!
Loose objects may be thrown toward the
operator by the cutting tool.
To reduce the risk of injury
to your eyes never
operate a cut-off machine
unless wearing goggles or
properly fitted safety
glasses with adequate top
and side protection complying with
ANSI Z 87.1. Proper eye protection is a
must.
Wear an approved safety hard hat to
protect your head. Cut-off machine
noise may damage your hearing. Always
wear sound barriers (ear plugs or ear
mufflers) to help protect your hearing.
Regular users should have their hearing
checked regularly.
!Warning!
When wet cutting is not
utilized, the operator
should always wear a
respirator approved by
NIOSH/MSHA for the
material being cut to
reduce the risk of serious or fatal
respiratory illness. For additional details
and warnings on this subject, see
information under "Working Conditions"
in this instruction manual.
THE CUT-OFF MACHINE
For illustrations and definitions of the
parts of the cut-off machine, see "Main
parts of the machine."
!Warning!
Never modify a cut-off machine in any
way. Only attachments supplied by
STIHL or expressly approved by STIHL
for use with the specific STIHL cut-off
machine models are authorized.
Although certain unauthorized
attachments are useable with the STIHL
powerhead, their use may, in fact, be
extremely dangerous.
5TS 400
English / USA
!Warning!
Dust may collect on the powerhead,
especially around the carburetor, and
may absorb gasoline resulting in danger
of fire. Clean dust from the powerhead
regularly.
Abrasive Wheels
!Warning!
Before mounting the cutting wheel,
make sure that the maximum operating
wheel speed is above or equal to the
spindle speed of your cut-off machine as
provided in the Specifications of this
manual. A wheel that is not so rated may
shatter or break and poses a threat of
serious or fatal injury to the operator and
other nearby persons.
Abrasive wheels for free-hand cutting
are subjected to particularly high
bending and compression stresses.
!Warning!
Unauthorized wheels may be more likely
to shatter or break. Use only STIHL
wheels or other authorized wheels with
approved RPM ratings. Read and follow
any addional safety precautions that
accompany the wheel.
!Warning!
Inspect the abrasive
wheel frequently and
replace immediately if the
abrasive wheel is cracked
or warped. Cracked or
warped wheels may
shatter or break and cause serious or
fatal personal injury. Out-of-round or
unbalanced abrasive wheels increase
vibration and reduce the service life of
the cut-off machine.
Abrasive wheels are heat sensitive.
Always store your cut-off machine in a
place where the cutting wheel is not
exposed to direct sunlight or other
sources of heat. Store spare cutting
wheels in a dry place where there is no
risk of frost damage. Failure to follow
these directions may cause the wheel to
shatter or crack in use causing serious
or fatal injury.
!Warning!
Never use circular saw
blades, carbide tipped
blades, rescue blades,
wood-cutting blades or
toothed blades of any
nature. They can cause
severe personal injury from blade
contact, thrown objects and/or reactive
forces, including kickback. See section
on “Reactive Forces.“ Your STIHL
dealer stocks a range of special
abrasive wheels for the many
applications of the cut-off machine.
!Warning!
Use of the wrong abrasive wheel or the
cutting of material for which the wheel
was not designed may cause the wheel
to shatter causing serious or fatal injury.
Only use the abrasive wheel approved
for the type of material to be cut. There
are different abrasive wheels, each
specially marked. For example:
6
TS 400
English / USA
1. Stone
Also can be used for concrete,
masonry, reinforced concrete and
brick cutting.
2. Steel
Can be used for all ferrous metal
cutting.
3. Asphalt
Also can be used for aggregate
concrete cutting.
4. Ductile iron
Also can be used for certain grades
of cast iron (SG 17-24), bronze and
copper cutting.
For cutting composite materials please
ask your STIHL dealer.
Diamond Abrasive Wheels
Diamond abrasive wheels have a much
better cutting performance than
composite abrasive wheels. The
diamond wheels are steel centered, and
diamond particles are imbedded in their
cutting edges.
They can be used for concrete, asphalt,
natural stone, clay pipe, brick and the
like.
They are not normally suitable for
cutting metal or other materials.
Wet or dry cutting is possible. With wet
cutting your diamond wheel will have a
longer life. Water attachments are
included with your STIHL cut-off
machine. See the appropriate section of
your instruction manual.
!Warning!
Do not remount a used diamond
abrasive wheel without first inspecting
for under-cutting, flatness, core fatigue,
segment damage or loss, signs of
overheating (discoloration) and possible
arbor hole damage.
Check the wheel for cracks and make
sure that no pieces have broken off the
wheel before use.
Always fit the wheel so that the arrow on
the wheel points in the direction of the
rotation of the spindle.
THE USE OF THE CUT-OFF
MACHINE
Transporting the STIHL Cutquik
!Warning!
Always stop the engine before putting a
cut-off machine down or carrying it. The
abrasive wheel continues to rotate for a
short while after the throttle trigger is
released (flywheel effect). Carrying a
cut-off machine with the engine running
is extremely dangerous. Accidental
acceleration of the engine can cause the
wheel to rotate. Avoid touching the hot
muffler.
By hand: When carrying your cut-off
machine by hand, the engine must be
stopped and the cut-off machine must
be in the proper position. Grip the front
handle and place the muffler at the side
away from the body.
!Warning!
Always protect the cutting wheel from
hitting the ground or any other objects.
Damaged wheels may shatter and
cause serious or fatal injury.
7TS 400
English / USA
By vehicle: Properly secure your cut-off
machine to prevent turnover, fuel
spillage and damage to the cut-off
machine. Never transport with cutting
wheel mounted. A wheel damaged
during transportation may shatter during
operation and cause serious personal
injury.
Preparation for the Use of the Cut-Off
Machine
For assembly, follow the procedure
described in the appropriate section of
your instruction manual.
Keep the handles dry, clean and free of
oil and fuel.
!Warning!
Before operation of your cut-off
machine, be sure the controls (e.g.
throttle trigger, stop switch) and the
safety devices are working properly, the
carburetor idle and maximum speed are
correctly adjusted, the wheel is properly
mounted, and the wheel guard is in
place and securely fastened to your unit.
All wheels should be carefully inspected
for good condition before mounting.
Adjust the wheel guard so
that sparks, dust and cut
material are deflected
away from the operator,
and cannot reach
flammable surroundings.
See section “Operating Instructions“ of
your instruction manual.
Never operate a cut-off machine that is
damaged, improperly adjusted or not
completely and securely assembled.
Inspect for safety in operation.
Proper tension of the V-belt is important.
In order to avoid an incorrect setting, the
tensioning procedure must be followed
as described in your manual. Always
make sure the hexagonal collar nuts for
the cast arm are tightened securely.
Check V-belt tension after one hour of
operation and correct if necessary.
Fuel
Your STIHL power tool uses an oilgasoline mixture for fuel (see the chapter on “Fuel” of your instruction manual).
!Warning!
Gasoline is an extremely
flammable fuel. If spilled
and ignited by a spark or
other ignition source, it
can cause fire and serious
burn injury or property
damage. Use extreme caution when
handling gasoline or fuel mix.
Do not smoke or bring any fire or flame
near the fuel or the power tool. Note that
combustible fuel vapor may escape from
the fuel system.
Fueling Instructions
!Warning!
Fuel your power tool in well-ventilated
areas, outdoors. Always shut off the
engine and allow it to cool before
refueling. Gasoline vapor pressure may
build up inside the fuel tank depending
on the fuel used, the weather conditions
and the tank venting system.
In order to reduce the risk of burns and
other personal injury from escaping gas
vapor and fumes, remove the fuel filler
cap on your power tool carefully so as to
allow any pressure build-up in the tank
to release slowly. Never remove the fuel
filler cap while the engine is running.
8
TS 400
English / USA
Select bare ground for fueling and move
at least 10 feet (3 m) from the fueling
spot before starting the engine. Wipe off
any spilled fuel before starting your
machine.
!Warning!
Check for fuel leakage while refueling
and during operation. If fuel leakage is
found, do not start or run the engine until
the leak is fixed and any spilled fuel has
been wiped away. Take care not to get
fuel on your clothing. If this happens,
change your clothing immediately.
!Warning!
If fuel gets spilled on clothes, especially
trousers, it is very important to change
clothes immediately. Do not rely upon
evaporation. Flammable quantities of
fuel may remain on clothes after a spill
for longer than expected. Cutting metal
with a cut-off machine when clothes are
wet or damp from gasoline is extremely
dangerous, as the operator's clothes
might catch fire and cause serious or
fatal injury.
Different cut-off machines may be
equipped with different fuel filler caps:
Bayonet filler cap
Never use a tool to open or close the
bayonet filler cap, as this could damage
the cap and cause fuel to leak out.
The bayonet filler cap must be closed
with care after refuelling.
Fuel filler cap with screw thread
Secure the fuel filler cap
as tightly as possible after
refuelling.
This reduces the risk of the cap working
loose due to engine vibrations and fuel
leaking out.
!Warning!
Never attempt to force the cap open by
using a tool. It may damage the cap and
allow fuel to leak.
Before use, make sure that the fuel cap
has been properly tightened and any
spilled fuel wiped away. Check for fuel
leakage while refueling and during
operation. If a fuel leak is suspected, do
not start or run the engine until the leak
is fixed and spilled fuel has been wiped
away.
!Warning!
An improperly tightened fuel cap can
loosen or come off and spill quantities of
fuel.
9TS 400
English / USA
Starting
!Warning!
Your cut-off machine is a one-person
tool. Do not allow other persons to be
near the cut-off machine. Start and
operate your cut-off machine without
assistance. For specific starting
instructions, see the appropriate section
of your instruction manual.
Do not drop start. This method is very
dangerous because you may lose
control of the cut-off machine.
Place the cut-off machine on firm ground
or other solid surface in an open area.
Maintain good balance and secure
footing. Be absolutely sure that the
cutting wheel is clear of you and all other
obstructions and objects, including the
ground. When the engine starts at
starting-throttle, engine speed will be
fast enough for the clutch to engage the
V-belt pulley and turn the wheel. Never
attempt to start the cut-off machine
when the abrasive wheel is in a cut.
Once the engine has started,
immediately blip the throttle trigger,
which should release the starting throttle
and allow the engine to slow down to
002BA058 KN
idle.
!Warning!
When you pull the starter grip, don't
wrap the starter rope around your hand.
Do not allow the grip to snap back, but
guide the starter rope slowly back to
permit the rope to rewind properly.
Failure to follow this procedure may
result in injuries to hand or fingers and
may damage the starter mechanism.
Working Conditions
Operate the cut-off machine under good
visibility and daylight conditions only.
Wearing of hearing protection reduces
sound perception. Be alert not to miss
voice signals from co-workers. Keep
within calling distance to other persons
who may assist in case of emergency.
!Warning!
Your cut-off machine
produces toxic exhaust
fumes as soon as the
combustion engine is
running. These gases
(e.g. carbon monoxide)
may be colorless and odorless. To
reduce the risk of serious or fatal injury
from breathing toxic fumes, never run
the cut-off machine indoors or in poorly
ventilated locations. Ensure proper
ventilation when working in trenches or
other confined areas.
10
TS 400
English / USA
!Warning!
Use of this product to cut masonry,
concrete, metal and other materials can
generate dust and fumes containing
chemicals known to cause serious or
fatal injury or illness, such as respiratory
disease, cancer, birth defects or other
reproductive harm. If you are unfamiliar
with the risks associated with the
particular material being cut, review the
material safety data sheet and/or consult
your employer, the material
manufacturer/supplier, governmental
agencies such as OSHA and NIOSH
and other sources on hazardous
materials. California and some other
authorities, for instance, have published
lists of substances known to cause
cancer, reproductive toxicity, etc. Control
dust and fumes at the source where
possible. In this regard use good work
practices and follow the
recommendations of the manufacturer/
supplier, OSHA/NIOSH, and
occupational and trade associations. A
water attachment kit is provided with
your cut-off machine and should be used
for dust suppression when wet cutting is
feasible. If wet cutting is not utilized, the
operator and any bystanders should
always wear a respirator approved by
NIOSH/MSHA for the material being cut.
Consult and follow any federal, state or
local laws or regulations with respect to
dry and wet cutting.
!Warning!
Cutting masonry, concrete and other
materials with silica in their composition
may give off dust containing crystalline
silica. Silica is a basic component of
sand, quartz, brick clay, granite and
numerous other minerals and rocks.
Repeated and/or substantial inhalation
of airborne crystalline silica can cause
serious or fatal respiratory diseases,
including silicosis. In addition, California
and some other authorities have listed
respirable crystalline silica as a substance known to cause cancer. When
cutting such materials, always follow the
respiratory precautions mentioned
above.
!Warning!
Breathing asbestos dust is dangerous
and can cause severe or fatal injury,
respiratory illness or cancer. The use
and disposal of asbestos-containing
products have been strictly regulated by
OSHA and the Environmental Protection
Agency. Do not use your cut-off machine
to cut or disturb asbestos, asbestoscontaining products, or products such as
pipes which are wrapped or covered
with asbestos insulation. If you have any
reason to believe that you might be
cutting asbestos, immediately contact
your employer or a local OSHA
representative.
002BA060 KN
!Warning!
Your STIHL cut-off machine is designed
for hand-held use or operation on a cutoff machine cart. Cutting with your cutoff machine resting on the ground or
other surface can cause excessive wear
to the bracket designed to protect the
bottom of the tank housing. Loss of fuel
and personal injury from fire may result.
Replace damaged or badly worn
brackets immediately.
Grip: Never use the cut-off machine with
one hand. Always hold the cut-off
machine firmly with both hands when the
engine is running. Place your left hand
on front handle bar and your right hand
on rear handle and throttle trigger. Lefthanded users should follow this
instruction too.
11TS 400
English / USA
Wrap your fingers tightly around the
handles, keeping the handles cradled
between your thumbs and forefingers.
Make sure your cut-off machine handles
and grip are in good condition and free
of moisture, pitch, oil or grease.
!Warning!
Clear the area where you are working.
Avoid stumbling on obstacles and watch
out for holes or ditches. Be extremely
cautious when working on slopes or
uneven ground. Take extreme care in
wet and freezing weather (rain, snow,
ice).
!Warning!
Never operate the cut-off machine with
the starting-throttle lock engaged as this
does not permit proper control of the
speed of the unit and may lead to
serious injury.
002BA061 KN
!Warning!
Sparks from cutting metal
can burn or cause
clothing to catch fire.
Always direct sparks
away from the operator or
any flammable
surroundings. Never cut metal while
standing on a flammable surface, such
as wood or tar paper. Where there is a
risk of fire, have appropriate fire
extinguishing equipment readily
available.
!Warning!
To reduce the risk of injury from fire, do
not cut into any pipe, drum or other
container without first ensuring that it
does not contain a volatile or flammable
substance.
Operating Instructions
!Warning!
The wheel guard is adjustable. It is
extremely important that the wheel
guard is in place and set to suit the type
of work and your stance. The guard
should always be adjusted so that the
user is not endangered by particles of
the material being cut, sparks or pieces
of damaged wheels either directly or by
ricochet. Failure to follow this instruction
could result in serious or fatal injury.
!Warning!
Always check the wheel before use and
after unintentionally striking any object;
frequently check it during use when it is
stopped. Look for cracks, and make sure
that it is undamaged and in good
condition and that no pieces have
broken off. See sections on "Abrasive
Wheels" and "Reactive Forces" in this
manual. Check the wheel guard for
cracks. If you discover any breaks or
cracks, fit a new guard before further
use.
12
!Warning!
When cutting into existing walls, floors or
similar structures, be alert for hidden
hazards such as electrical cables, water
and gas pipes and flammable
substances. Make sure that power,
water and gas have been shut off and
pipes drained before starting to cut.
TS 400
English / USA
!Warning!
It is essential to determine the exact
direction of the cut before applying the
abrasive wheel to the work. Wheels are
constructed for radial pressure only.
Lateral pressure must be avoided. Hold
the cut-off machine steady. To reduce
the risk of serious or fatal injury, do not
change the direction of the cut during the
cut as this may produce a high torsional
load on the abrasive wheel and may
cause it to break or shatter.
!Warning!
Do not use abrasive wheels for rough
grinding. Large bending stresses occur
during such work and abrasive wheels
may shatter or break and could cause
serious or fatal injury.
!Warning!
To reduce the risk of injury from
shattered abrasive wheels:
1. Do not exceed the maximum
operating speed marked on the
wheel.
2. Do not use a wheel that has been
dropped.
3. Test each new wheel immediately
after installation for approximately
one minute at maximum speed
without cutting, making sure to keep
bystanders away.
4. Do not cut any material for which the
abrasive wheel is not authorized.
5. Do not grind on the side of the
abrasive wheel.
6. Do not twist, thrust, knock or drop
the machine. This can cause
damage to the wheel.
To achieve a clean and efficient cut, pull
the abrasive wheel across the work or
move it "to and fro" in the cutting
direction. Do not use force to push the
abrasive wheel into the work.
Insert the wheel into the material only as
deep as necessary to make the cut. To
reduce the amount of dust created, do
not cut all the way through stone and
concrete materials - leave a thin piece
uncut. For most such materials, this
piece can be easily broken afterwards.
Do not cock, jam or wedge the wheel in
the cut.
Always stop the engine and be sure the
wheel has stopped rotating before
setting down the cut-off machine.
If a cut-off machine cart is used, sweep
debris from the path of the wheels, as
debris under one of the cart’s wheels
may cause flexing of the abrasive wheel.
This could result in high frictional forces
and thus greatly reduce the engine
power available for the actual cutting
work. It could also damage the abrasive
wheel.
STIHL recommends the use of the cart
for longer cuts in a straight line.
Wet Cutting with Abrasive Wheels
Before wet cutting, make sure water will
not damage the floor or building.
!Warning!
To reduce the risk of electrocution to you
or bystanders, do not allow water or
sludge to contact live electric wires.
!Warning!
To reduce the risk of injury from wheel
breakage when wet cutting with a
composite non-diamond wheel:
1. Never store and re-use a wheel that
has been used with water. Use
these wheels up the same day.
13TS 400
English / USA
2. Make certain water does not flow on
a wheel that is not running, since the
wheel will absorb water, which will
affect wheel balance.
3. Shut water off before the wheel
stops so that excess water will be
dissipated.
4. Be certain water is applied to both
sides of wheel, since uneven
distribution can cause "one sided"
wear.
Important Adjustments
At correct idle speed, the wheel should
not turn. For directions to adjust idle
speed, see the appropriate section of
your instruction manual.
!Warning!
Do not use a cut-off machine with
incorrect idle speed adjustment. The
rotating wheel may cause injury. Have
your STIHL dealer check your cut-off
machine and make proper adjustments
or repairs.
Never touch a rotating wheel with your
hand or any part of your body.
Reactive Forces including Kickback
!Warning!
Reactive forces may occur at any time
the cutting wheel on a cut-off machine is
rotating. If the wheel is slowed or
stopped by frictional contact with any
solid object or by a pinch, reactive forces
may occur instantly and with great force.
These reactive forces may result in the
operator losing control of the cut-off
machine, which may, in turn, result in
serious or fatal injury.
An understanding of the causes of these
reactive forces may help you avoid loss
of control. Reactive forces are exerted in
a direction opposite to the direction in
which the wheel is moving at the point of
contact or pinch.
Pull-away, climbing, pinching and
rotational kickback forces
The most common reactive forces are
pull-away and climbing. If the contact is
at the bottom of the wheel, a cut-off
machine will try to pull away from the
operator (pull-away). If the contact is at
the front of the wheel, the wheel may
attempt to climb the object being cut
(climbing). Pinching occurs when the
piece being cut closes on the wheel. If
the wheel is severely pinched at the
front, especially in the upper quadrant,
the wheel may be instantly thrown up
and back towards the operator with
great force in a rotational kickback
motion.
The greater the force generated, the
more difficult it will be for the operator to
control the cut-off machine. Any of the
reactive forces can, in some
circumstances, cause the operator to
lose control of a cut-off machine,
allowing the rotating wheel to come into
contact with the operator. Severe
personal injury or death can result.
14
TS 400
English / USA
Reducing the Risk of Kickback Injury
!Warning!
To reduce the risk of kickback injury,
avoid cutting with the upper quadrant of
the wheel where possible. Be especially
cautious for a pinching of the wheel in
this area, which can cause severe
reactive forces in a rotational kickback
motion.
Be alert to potential movement of the
work piece or anything else that could
cause the cut to close and pinch the
wheel. In order to reduce the risk of
pinching, support the work piece in such
a way that the cut remains open during
the cutting process and when the cut is
finished (see illustration). Never make a
cut that results in a binding of the wheel.
002BA242 KN
!Warning!
Be particularly alert when cutting a work
piece that, if not properly supported, can
sag upon completion of the cut, creating
a pinch not where you are actually
cutting but, rather, at or near the top of
the work piece (see illustration). If that
pinch is in the upper quadrant of the
abrasive wheel, kickback can result.
!Warning!
Use only cutting attachments authorized
by STIHL. Never use chipped abrasive
wheels, circular saw blades, carbidetipped blades, rescue blades or woodcutting or toothed blades of any nature
on a cut-off machine. The use of such
002BA146 KN
wheels or blades will greatly increase
the risk of loss of control and severe
personal injury or death from reactive
forces, since the chipped section of an
abrasive wheel, or the teeth of a saw
blade may catch in the material being
cut and generate substantially greater
reactive forces, including rotational
kickback.
Cut-off machines are designed for use
with abrasive wheels in good condition
only. Machines designed for use with
wood-cutting or other toothed blades
use different types of guarding systems
which provide the protection necessary
for those types of blades. Machines,
such as a cut-off machine, that are
designed for use with abrasive wheels,
require a different guarding system,
which is not designed to provide
protection against all dangers presented
by circular saw blades, carbide-tipped
blades, rescue blades or wood-cutting or
toothed blades of any nature.
15TS 400
English / USA
!Warning!
To reduce the risk of injury from loss of
control from reactive forces, including
kickback:
1. Hold the cut-off machine firmly with
both hands.
2. Maintain good balance and footing
at all times. Never cut while
standing on a ladder.
3. Position the cut-off machine in such
a way that your body is clear of the
cutting attachment. Avoid standing
in direct line with the wheel. Never
bend over the cutting attachment,
especially when the guard is pulled
back towards the top and there is a
risk of reactive forces.
4. Do not cut above shoulder height.
5. Do not cut wood or any other
material for which the abrasive
wheel is not authorized.
6. Never use circular saw blades,
carbide-tipped blades, rescue
blades, wood-cutting blades or
002BA059 KN
toothed blades of any nature. Their
use increases the risk of injury from
blade contact, thrown tips and
reactive forces, including kickback.
7. Begin cutting and continue at full
throttle.
8. Do not overreach.
9. Use your cut-off machine for cutting
only. It is not designed for prying or
shoveling away any objects.
10. Be especially alert for reactive
forces, including kickback, when
cutting with the front and upper
quadrant of the wheel.
11. Be alert to shifting of the work piece
or anything that could cause the cut
to close and pinch the wheel,
especially in the upper quadrant.
Support the work piece in such a
way that the cut remains open.
Never make a cut that results in a
binding of the wheel.
12. Use wet cutting if feasible. In a pinch
situation the water can act as a
lubricant and reduce the energy of
reactive forces.
13. Release the pressure on the cut-off
machine as you reach the end of the
cut. Too much pressure may cause
the operator to lose control of the
cut-off machine when the abrasive
wheel completes the cut. The
abrasive wheel may contact the
operator or strike some foreign
object and shatter.
14. Use extreme caution when
reentering a cut and do not turn the
wheel at an angle or push the wheel
into the cut as this may result in a
pinching of the wheel.
Gyroscopic Forces
Be alert for gyroscopic forces that are
caused by the rapid spinning of the cutoff wheel. These forces result in
opposition to directional change, e.g.
when the operator attempts to move the
machine in a sideways direction.
16
TS 400
English / USA
Maintenance, Repair and Storing
of the Cut-Off Machine
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
nonroad engine repair establishment
or individual. However, if you claim
warranty for a component which has
not been serviced or maintained
properly or if nonapproved
replacement parts were used, STIHL
may deny warranty.
Never operate a cut-off machine that is
damaged, improperly adjusted or not
completely or securely assembled.
Follow the maintenance and repair
instructions in the appropriate section of
your owner's manual.
! Warning!
Use only STIHL replacement parts for
maintenance and repair. Use of parts
manufactured by others may cause
serious or fatal injury.
!Warning!
Always stop the machine, make sure
that the wheel is stopped, and remove
the spark plug boot from the spark plug
before doing any maintenance or repair
work or cleaning the cut-off machine. Do
not attempt any maintenance or repair
work not described in your instruction
manual. Have such work performed at
your STIHL service shop only.
Clean off grinding dust after finishing
work. Tighten all nuts, bolts and screws
except the carburetor adjustment
screws after each use.
!Warning!
Never test the ignition system with spark
plug boot removed from spark plug or
with unseated spark plug, since
uncontained sparking may cause a fire.
!Warning!
To reduce the risk of fire and burn injury,
use only spark plugs authorized by
STIHL. Always press spark plug boot
snugly onto spark plug terminal of the
proper size. (Note: If terminal has
detachable SAE adapter nut, it must be
attached.) A loose connection between
spark plug terminal and ignition wire
connector in the boot may create arcing
that could ignite combustible fumes and
cause a fire. Keep spark plug clean, and
make sure ignition lead is in good
condition.
!Warning!
Do not operate your cut-off machine if
the muffler is damaged, missing or
modified. An improperly maintained
muffler will increase the risk of fire and
hearing loss. Never touch a hot muffler
or spill fuel or other flammable liquid
over it. Burn injuries or fire will result. If
your muffler was equipped with a sparkarresting screen to reduce the risk of fire
(e. g. in the USA, Canada and Australia),
never operate your cut-off machine if the
screen is missing or damaged.
For any maintenance please refer to the
maintenance chart and to the warranty
statement near the end of the instruction
manual.
Store wheels on a flat surface in a dry
place, preferably at a constant
temperature, where there is not a risk of
frost. Do not store a cut-off machine with
a wheel mounted on the machine. Store
cut-off machine in a high or locked
place, away from children.
Empty the fuel tank before storing for
longer than a few days. Store fuel only in
correctly labeled and approved
containers. Avoid direct skin contact and
do not inhale the gas vapors.
17TS 400
English / USA
Application Examples
Most diamond cutting wheels are
suitable for wet cutting
Wet cut whenever feasible. It
increases the service life and cutting
speed of diamond cutting wheels
Ensure that the cutting wheel is
generously supplied with water,
up to 10 liters per minute.
Wet cutting helps to suppress dust.
The water binds the dust.
The cutting wheel must be supplied with
at least 0.6 liters water per minute.
Wet cutting can reduce the energy of
reactive forces. In a pinch situation, the
water can act as a lubricant.
Water connection
– A water attachment kit is mounted
on the machine, for use with all
types of water supply.
– A pressurized 10 liter water tank is
available from STIHL for dust
suppression.
– A water tank for mounting on the
Cutquik cart is also available for
dust suppression.
Composite resin cutting wheels
can be used for dry cutting of
metals or for wet or dry cutting of
concrete, stone or masonry.
Special procedures must be followed
when dry cutting with a composite nondiamond wheel. See in the section
entitled „Wet Cutting with Composite
Wheels“ lin the safety precautions of this
manual. Wet cutting is generally not
suitable for cutting metals.
Respiratory protection
!Warning!
When wet cutting is not utilized, the
operator and any bystanders should
always wear a respirator approved by
NIOSH/MSHA for the material being cut.
Points to be noted with diamond
and composite resin cutting
wheels
Object to be cut
– Must be fully supported
– Must be secured so that it cannot
roll or slip away
– Must be protected against vibration
The cutting sequence
The cutting sequence is important when
cutting openings and recesses, etc. The
last cut must always be made in such a
way that the cutting wheel cannot
become bound and so that the user is
not at risk of being injured by the part
that has been cut off or out.
If applicable, leave small ridges of uncut
material to hold the severed part in
position. These ridges can
subsequently be broken through.
A number of points must be decided
before the part is finally severed:
– How heavy is the part?
– In which direction can it move after
being severed?
– Is it under tension?
Helpers must not be put at risk of injury
when the part is broken off or out.
18
TS 400
English / USA
Cutting in several passes
A = Mark cutting line
: Work along the cutting line. If
corrections are necessary, always
reposition the cutting wheel, taking
care to ensure that it is not wedged.
The cutting depth per pass should
not exceed 5 to 6 cm (2“ to 2 1/2“.
Thicker material must be cut in
several passes.
Cutting slabs
: Place the slab securely on a non-
slip surface.
: Thick-walled workpieces should be
cut with a uniform swinging
movement, back and forth.
A = Cut a guiding groove along the
marked line.
B = Cut deeper into the parting cut with
uniform back-and-forth movements.
C = Leave a ridge of uncut material.
: Cut through the slab at the ends so
the material does not chip.
: Then break the slab.
19TS 400
English / USA
: Curves must be cut in several
straight passes, taking care to
ensure that the cutting wheel does
not become wedged.
Cutting round and hollow
workpieces
: Pipes and round objects, etc. must
be secured so that they cannot roll.
: Avoid reinforcing elements,
especially in the direction of the cut,
when deciding on the cutting line.
: Cut a guiding groove along the
marked line.
: Cut deeper into the parting cut with
uniform back-and-forth movements.
Advance the cutting wheel along the
guiding groove at full cutting depth.
Always reposition the cutting wheel,
taking care not to wedge it, if the
cutting direction has to be corrected
slightly. If necessary, leave small
ridges of uncut material to hold the
severed part in position. These
ridges can subsequently be broken
through.
Cutting shapes on pipes
: Mark the cutting line.
!Warning!
Particular care and precision are
required for free-hand cutting along such
cutting lines. Avoid side-loading the
wheel or causing it to bind.
: Cut a guiding groove along the
marked cutting line, starting at the
top and moving out towards both
sides.
: Cut into the pipe or round object,
etc. at the ends of the cutting line so
that the material does not chip.
20
TS 400
English / USA
: Cut deeper into the parting cut with
uniform back-and-forth movements,
starting at the top and moving out
towards the sides. Advance the
cutting wheel along the guiding
groove at full cutting depth. Always
reposition the cutting wheel afresh,
taking care not to wedge it if the
cutting direction has to be corrected
slightly. If necessary, leave small
ridges of uncut material to hold the
severed part in position. These
ridges can subsequently be broken
through.
STIHL composite resin
cutting wheels
Economic benefit is improved and
premature wear can be avoided by
choosing and using the correct
composite resin cutting wheel. The
short name (e.g. “asphalt“, “concrete“)
– on the label and
– on the packaging (table with
recommended uses)
can help to ensure the correct choice.
STIHL composite resin cutting wheels
cannot be used to cut railway tracks.
STIHL diamond cutting
wheels
Economic benefit is improved and
premature wear can be avoided by
choosing and using the correct diamond
cutting wheel. The short name (see
following explanation)
– on the label and
– on the packaging (table with
recommended uses)
can help to ensure the correct choice.
21TS 400
English / USA
Short names
The short name is a combination of
letters and numerals with up to four
digits:
: The letters indicate the main area of
use for the cutting wheel.
Letter Main area of use
A Asphalt
B Concrete
S Stone (rock)
: The numerals indicate the
performance class of the STIHL
diamond cutting wheel.
Radial and axial run-out
A correctly mounted spindle bearing on
the cut-off machine is essential for a
long service life and efficient operation
of the diamond cutting wheel.
Using a cutting wheel on a cut-off
machine with defective spindle bearing
can lead to axial and radial run-out.
Excessive radial run-out (A) causes
individual diamond segments to be
overloaded and to overheat. This can in
turn lead to stress cracking in the wheel
core or to softening of individual
segments.
Axial run-out or wobble (B) results in
higher thermal stress and wider cuts.
22
TS 400
Troubleshooting
Cutting wheel
Problem Cause Remedy
Frayed edges or tears, cut wanders out
of line, increased wear at the sides of the
segments
Radial or axial run-out Consult a dealer1)
Cutting wheel wobbles Use a new cutting wheel
English / USA
Frayed edges, cut wanders out of line,
little or no cutting performance, sparking
Poor cutting performance, high level of
Cutting wheel is blunt; built-up edges on
cutting wheels for stone
Cutting wheel rotates in the wrong direction Mount the cutting wheel with correct
segment wear
Chipping or cracking in the wheel core
Overload Replace immediately with a new cutting
and segments
Undercutting Cutting in a material for which the wheel is
not rated
1)
STIHL recommends that a STIHL
servicing dealer be consulted.
Dress the cutting wheel for stone by
briefly cutting in abrasive material; use a
new cutting wheel for cutting asphalt
direction of rotation
wheel
Use a new cutting wheel; note the
different cutting layers in different
materials
23TS 400
English / USA
Undercut
Undercutting is a wearing away of the
steel core at or just below the diamond
segments. When cutting road surfaces,
do not cut through into the more
abrasive ballast (gravel, crushed rock)
below, as indicated by a light colored
dust. This can cause excessive
undercutting, resulting in wheel
breakage and/or thrown segments.
!Warning!
Immediately replace a diamond wheel if
the core has been severely undercut
Built-up edges, dressing
Built-up edges are identified by a pale
grey deposit on the top of the diamond
segments that clogs and blunts the
segments.
Built-up edges can form:
– when cutting extremely hard
material, such as granite,
– as a result of incorrect handling,
such as applying excessive feed
force,
– if extremely large sections are cut
without a pendulum movement
(back and forth in the cutting plane).
Built-up edges increase vibrations,
reduce cutting performance and cause
sparking.
Diamond cutting wheels must be
"dressed" at the first sign of built-up
edges. For this purpose, briefly cut a
more abrasive material, such as
sandstone, aerated concrete or asphalt.
Wet cutting helps to prevent the
formation of built-up edges.
If you continue to use a cutting wheel
with blunt segments, the segments may
soften as a result of excessive heat built
up. The wheel core will also overheat
and lose its mechanical strength. This
can lead to considerable stress, as
clearly indicated by stress cracks and/or
a wobbling movement of the cutting
wheel.
!Warning!
Such cutting wheels may break apart or
throw off segments during use, causing
serious or fatal injury. Replace them
immediately.
24
TS 400
Assembling the bearing and
guard
English / USA
A
1
The bearing with guard can be mounted
on the inboard or outboard side of the
cast arm, depending on requirements.
Assembly on the inboard side is
recommended for freehand cutting on
account of the better balance; outboard
mounting is recommended when the
machine is mounted on a STIHL cut-off
machine cart.
For outboard mounting:
: Secure adjustable handle (1) in
position A.
2
338BA001
Inboard mounting
: The arrow on the tensioning nut (2)
must point to "0", otherwise:
: Turn the tensioning nut approx.
1/4 turn anticlockwise as far as the
stop = "0" with the combination
wrench.
: Fit the V-belt (3) on the V-belt
pulley (4).
5
4
3
6
7
8
338BA002
: Line up the threaded bores in the
bearing plate (5) with the slots in the
cast arm (6).
: Fit the V-belt guard (7).
: Screw in the hexagon bolts (8) as
far as the stop, but do not tighten
them yet.
Continue as described in the
chapter "Tensioning the V-belt"
25TS 400
English / USA
Tensioning the V-belt
4
3
7
Outboard mounting
: The arrow on the tensioning nut (2)
must point to "0", otherwise:
: Turn the tensioning nut approx.
1/4 turn anticlockwise as far as the
stop = "0" with the combination
wrench.
: Fit the V-belt (3) on the V-belt
pulley (4).
5
6
8
: Line up the threaded bores in the
bearing plate (5) with the slots in the
cast arm (6).
: Fit the V-belt guard (7) on the
inboard side.
: Screw in the hexagon bolts (8) as
far as the stop, but do not tighten
them yet.
Continue as described in the
chapter "Tensioning the V-belt"
2
338BA003
This machine is equipped with an
automatic spring-loaded V-belt
tensioning device.
: Before tensioning the V-belt, the
hexagon bolts (8) must be
unscrewed and the arrow on the
tensioning nut (2) must point to "0".
If not:
: Unscrew the hexagon bolts and turn
the tensioning nut approx. 1/4 turn
anticlockwise as far as the stop = "0"
with the combination wrench.
338BA004
26
TS 400
To tension the V-belt:
: Fit the combination wrench over the
tensioning nut as illustrated
The tensioning nut is spring-loaded:
the combination wrench must
therefore be held securely!
: Turn the tensioning nut clockwise.
The spring force begins to act on the
tensioning nut after approx. 1/8 turn
and turns it on as far as the stop
(approx. 1/8 turn)
Do not use force to turn the combination
wrench further!
1
The V-belt is automatically tensioned
by the force of the spring in this position.
: Remove the combination wrench
from the tensioning nut and
tighten the three hexagon bolts on
the V-belt guard
Retensioning
The V-belt is retensioned without
adjusting the tensioning nut
: Unscrew the hexagon bolts (1) on
the V-belt guard
: The V-belt is automatically
tensioned by the force of the spring
: Retighten the hexagon bolts
English / USA
Abrasive wheels
The abrasive wheels are subjected to
extremely high loads, especially when
cutting free-hand.
The abrasive wheels developed by
STIHL in cooperation with leading wheel
manufacturers are of very high quality
and precisely matched to the application
in question, as well as to the engine
power of the respective cut-off
machines.
They are of consistently outstanding
quality, with high axial and radial runout.
Transport and storage
– The abrasive wheels must not be
exposed to direct sunlight or other
sources of heat during transport and
338BA005 KN
storage
– Avoid knocks and bumps
– Spare abrasive wheels must be
stored in a dry place at constant
temperature, stacked one on top of
the other on a flat surface, in their
original packaging.
– Diamond abrasive wheels must not
be stored near corrosive liquids
– Composite abrasive wheels must
be protected against frost
27TS 400
English / USA
3
Choosing an abrasive wheel
STIHL abrasive wheels can be used to
cut the following materials:
Composite abrasive wheels
(depending on type) can be used for
– Asphalt
– Concrete
–Stone
– Ductile cast pipes
–Steel
Diamond abrasive wheels
(depending on type) can be used for
002BA139 KN
–Asphalt
– Concrete
– Stone (hard rock)
– Abrasive concrete
– Green concrete
– Clay bricks
– Clay pipes
Diamond abrasive wheels cannot be
used to cut metal.
Fitting / replacing an
abrasive wheel
002BA140 KN
1
38BA006
The engine must be switched off when
fitting or replacing an abrasive wheel –
slide control / stop switch to "0" or c
In order to block the arbor,
: slide the locking pin (1) through the
bore in the V-belt guard (turn the
arbor a short distance with the
combination wrench if necessary)
until the locking pin engages in one
of the bores behind the guard.
28
TS 400
English / USA
Two diamond wheels of the same
type can also be used together if a
wider cut is required (e.g. for laying
induction loops in carriageways).
It is essential to ensure that the
segments are positioned exactly
side by side in such a case.
However, two composite abrasive
wheels must never be used
simultaneously, for they can break
and cause injuries as they wear
down unevenly.
: Use the combination wrench to
loosen and unscrew the hexagon
bolt (2).
: Remove the front thrust washer (3)
from the arbor together with the
abrasive wheel to be replaced.
338BA007
: Fit the abrasive wheel (4).
Note the arrows indicating the
sense of rotation on diamond
abrasive wheels.
: Fit the front thrust washer (3).
The catches of the front thrust
washer must engage in the arbor
grooves.
: Fit the hex head screw and tighten
it down firmly with the combination
wrench (or to about 30 Nm if you
use a torque wrench)
: Draw the locking pin out of the
V-belt guard.
338BA008
29TS 400
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