Stihl TS 440 User Manual

STIHL TS 440

WARNING

Read Instruction Manual thoroughly before use and follow all safety precautions – improper use can cause serious or fatal injury.

ADVERTENCIA

Antes de usar la máquina lea y siga todas las precauciones de seguridad dadas en el manual de instrucciones – el uso incorrecto puede causar lesiones graves o mortales.

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Instruction Manual Manual de instrucciones

Instruction Manual 1 - 56

Manual de instrucciones 57 - 116

Contents

English

Guide to Using this Manual 2 Safety Precautions and Working

Techniques 2 Sample Applications 20 Abrasive Cutting Wheels 26 Composite Cutting Wheels 27 Diamond Cutting Wheels 27 Wheel Brake System 31

Original Instruction ManualPrinted on chlorine-free paper

Electronic Water Control 33 Mounting an Abrasive Cutting

Wheel 34 Fuel 36 Fueling 37 Starting / Stopping the Engine 38 Air Filter System 41 Engine Management 42 Adjusting the Carburetor 43 Spark Arresting Screen in Muffler 44 Spark Plug 44 Storing the Machine 46 Maintenance and Care 47 Main Parts 49

Printing inks contain vegetable oils, paper can be recycled.

Specifications 51 Maintenance and Repairs 52 Disposal 52 Limited Warranty 53 STIHL Incorporated Federal

Emission Control Warranty Statement for Emission-Related Parts 53

Trademarks 55

Allow only persons who fully understand this manual to operate your cut-off machine.

To receive maximum performance and satisfaction from your STIHL Cutquik cut-off machine, it is important that you read, understand and follow the safety precautions and the operating and maintenance instructions in the chapter "Safety Precautions and Working Techniques" before using it. For further information you can go to www.stihlusa.com

Contact your STIHL dealer or the STIHL distributor for your area if you do not understand any of the instructions in this manual.

WARNING

Because a cut-off machine is a powerful 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.

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TS 440

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Guide to Using this Manual

Pictograms

The meanings of the pictograms attached to or embossed on the machine are explained in this manual.

The following pictograms are on your machine.

Fuel tank for gasoline and engine oil mixture

Press to operate manual fuel pump

Pull brake lever toward the front handle to release the wheel brake

Symbols in Text

Many operating and safety instructions are supported by illustrations.

The individual steps or procedures described in the manual may be marked in different ways:

N A bullet marks a step or procedure. A description of a step or procedure that

refers directly to an illustration may contain item numbers that appear in the illustration. For example:

N Loosen the screw (1). N 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 and signal words described below:

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

NOTICE

Indicates a risk of property damage, including damage to the machine or its individual components.

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. Therefore, some changes, modifications and improvements may not be covered in this manual. If the operating characteristics or the appearance of your machine differs from those described in this manual, please contact your STIHL dealer or the STIHL distributor for your area for assistance.

Safety Precautions and Working Techniques

The use of any cut-off machine may be hazardous. Because a cut-off machine is a powerful cutting tool that often creates sparks during the cutting process, 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.

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 laws, safety regulations, standards and ordinances.

WARNING

Your cut-off machine is for professional use only. Do not lend or rent your cut-off machine without the instruction manual. Be sure that anyone using it understands the information contained in this manual.

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A first-time operator should obtain practical instruction before using the machine. Employers should establish a training program for operators of gasoline-powered, hand-held, portable cut-off machines to assure safe operation of these machines and proper choice of cutting attachments.

WARNING

Use your cut-off machine only for authorized uses. For instance, it is not suitable for cutting wood or plastic or wooden or plastic objects. Unauthorized uses may result in death, serious personal injury or property damage, including damage to the machine.

WARNING

Minors should never be allowed to use a cut-off machine. Bystanders, especially children, and animals should not be allowed in the area where a cut-off machine is in use. Never let the cut-off machine run unattended.

See the appropriate section of your instruction manual for a description of the controls and function of the parts of your cut-off machine.

Safe use of a cut-off machine involves

1. the operator

2. the power tool

3. the use of the power tool.

THE OPERATOR

Physical Condition You must be in good physical condition

and mental health and not under the influence of any substance (drugs, alcohol, etc.) which might impair vision, dexterity or judgment. Do not operate a cut-off machine when you are fatigued. Be alert – if you get tired while operating your cut-off machine, take a break; fatigue 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.

WARNING

Prolonged use of cut-off machines (or other machines) exposing the operator to vibration 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 can 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 frequently cited as factors in the development of whitefinger disease. In order to reduce the risk of whitefinger disease and carpal tunnel syndrome, please observe the following precautions:

– The TS 440 is equipped with an

anti-vibration ("AV") system designed to reduce the transmission of vibration created by the machine to the operator's hands.

– Keep the AV system well

maintained and in good condition. A cut-off machine with loose components or with damaged or worn AV elements will tend to have higher vibration levels. Replace immediately any part of the system that is damaged or worn.

– Wear gloves and keep your hands

warm.

– Maintain a firm grip at all times, but

do not squeeze the handles with constant, excessive pressure. Take frequent breaks.

These 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 cut-off machine produces a low intensity magnetic field. 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.

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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 loosefitting 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 machine. Wear overalls or long pants to protect your legs. Do not wear shorts.

WARNING

When cutting metal, including rebar and other metals embedded in concrete or other materials, a cut-off machine generates sparks that can ignite clothing and other flammable materials. 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 may also be suitable, but others, such as polyester, nylon, rayon and acetate, can melt during a fire into a tarlike 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 heavy-duty work gloves (e.g. made of leather or other wear resistant material) when handling the cut-off machine. Heavy-duty, non-slip gloves improve your grip and help to protect your hands.

Good footing is important in cut-off machine work. Wear sturdy boots with non-slip soles. Steel-toed safety boots are recommended.

WARNING

Loose objects may be thrown toward the operator by the cutting wheel.

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 and that comply with ANSI Z87 "+". 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 muffs) to help protect your hearing. Regular users should have their hearing checked regularly.

WARNING

Consult your employer for information relating to the respirator needed for your worksite-specific conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the type and level of respiratory protection needed for your worksite conditions. Information also is available from OSHA at www.OSHA.gov. Even if wet cutting at the recommended flow rate, an operator who is working with the machine for more than two hours in one day should wear a NIOSH-approved respirator that is rated for the material being cut. For additional details and warnings on this subject, see information under "Working Conditions" in this instruction manual.

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WARNING

Use only diamond cutting wheels for wet cutting with the TS 440. Wet cutting with a composite cutting wheel may increase the risk of wheel breakage, resulting in severe or fatal injury.

THE POWER TOOL

For illustrations and definitions of the parts of the cut-off machine, see the chapter "Main Parts."

WARNING

Never modify a cut-off machine in any way. Only STIHL branded parts and cutting attachments expressly approved by STIHL for use with the specific STIHL cut-off machine models are recommended. Although certain other parts or attachments may be useable, their use may be extremely dangerous.

Abrasive Cutting 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.

WARNING

Never use a reducer bushing inserted into the wheel to reduce the diameter of the arbor hole. It may slip out of place,

causing out-of-roundness, vibration, wheel breakage or loss of control, resulting in the possibility of severe or fatal injury.

WARNING

Wheels that are not STIHL branded may be more likely to shatter, break or create other hazards, such as increased reactive forces. Use only wheels with approved RPM ratings. Read and follow any addional safety precautions that accompany the wheel.

WARNING

Never use circular saw blades, carbide tipped blades, rescue blades, wood-cutting blades or toothed blades of any nature on your cut-off machine. They can cause severe personal injury from blade contact, thrown objects and/or reactive forces, including kickback. See the section "Reactive Forces" in this instruction manual. Your STIHL dealer stocks STIHL branded abrasive cutting wheels suitable for the many authorized applications of this cut-off machine.

WARNING

Using the wrong abrasive cutting wheel or cutting material for which the wheel was not designed may cause the wheel to wobble, shatter, break or increase

reactive forces, causing serious or fatal injury. See below and the section "Reactive Forces" in this instruction manual.

Cutting unauthorized materials, such as wood or plastic, or using wheels that are not rated for the material being cut, can result in severe personal injury or death from wheel breakage, reactive forces or loss of control.

WARNING

Use only diamond cutting wheels for wet cutting with the TS 440. Wet cutting with a composite cutting wheel may increase the risk of wheel breakage, resulting in severe or fatal injury.

Composite Cutting Wheels Free-hand cutting with composite

cutting wheels can subject the wheels to particularly high bending and compression stress, which can increase the possibility of wheel breakage. Avoid side loading the cutting wheel and always use proper working technique. See the chapter "Sample Applications" in this instruction manual.

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WARNING

Inspect the composite cutting wheel frequently and replace immediately if it is cracked or warped. Cracked or warped wheels may shatter or break and cause serious or fatal personal injury. Out-of-round or unbalanced wheels increase vibration, reduce the service life of the cut-off machine and may result in loss of control.

Composite cutting wheels are heat sensitive. Always store your cut-off machine in a place where a composite cutting wheel is not exposed to direct sunlight or other sources of heat. Store spare composite cutting wheels flat on a level surface 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.

STIHL has only developed one composite cutting wheel suitable for use on the TS 440. It is rated for dry cutting metal only. Composite cutting wheels designed for use on traditional, highspeed cut-off machines should not be used on the TS 440. They are not designed for the slower cutting speeds and higher torque of the TS 440 and will wear prematurely and perform poorly. Never use a composite wheel not rated for the material to be cut.

Diamond Cutting Wheels

WARNING

Some diamond cutting wheels that are not STIHL branded utilize poor quality steel cores, are not properly hardened or tensioned, or have other design or manufacturing defects that can result in wheel breakage, thrown segments and other safety issues, including wheel wobble. Wheels that wobble during use can result in reactive forces and present other safety issues that could result in loss of control and severe personal injury or death. Wobbling, for example, can lead to a severe binding of the wheel in the cut, that, under certain circumstances, can then result in serious or fatal injury from kickback or other reactive forces. See the section "Reactive Forces including Kickback" in this instruction manual. Never use a wheel that wobbles or that has ever wobbled. Even though such a wheel may temporarily cease to wobble, e.g., if run without load, it will always be prone to wobble again under certain conditions. Replace it immediately before further use of the cut-off machine.

Diamond cutting wheels generally have a better cutting performance than composite cutting wheels. Diamond cutting wheels have steel cores and cutting segments embedded with diamonds attached to their outer edges.

Properly rated diamond cutting wheels can be used for cutting concrete, asphalt, natural stone, clay pipe, brick and the like. STIHL also offers diamond cutting wheels for cutting ductile iron and some structural steel. They are not, however, suitable for cutting all metals

or other materials, including wood or plastic. See the chapter "Diamond Cutting Wheels" in this instruction manual for more details regarding the type of materials that can be cut with properly rated STIHL diamond cutting wheels.

WARNING

Wet or dry cutting is possible with the appropriate diamond cutting wheel. A water attachment kit is mounted on your STIHL cut-off machine. Wet cutting reduces dust and reactive forces and is recommended whenever possible. See the chapter "Sample Applications" in this instruction manual.

WARNING

Do not remount a used diamond cutting wheel without first inspecting it for under-cutting, flatness, core fatigue or damage, segment damage or loss, signs of overheating (discoloration) and possible arbor hole damage. See the chapter "Diamond Cutting Wheels." Check the wheel for cracks and make sure that no pieces have broken off the wheel before use. Never use any wheel, diamond or composite, that has been damaged.

Always mount the diamond cutting wheel so that the arrow on the wheel points in the direction of the rotation of the spindle.

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THE USE OF THE POWER TOOL

Transporting the STIHL Cutquik

WARNING

To reduce the risk of injury from unintended activation and/or contact with a moving wheel, always shut off the engine before putting the machine down or carrying it. The abrasive cutting wheel continues to rotate (coast down) for a few seconds after the throttle trigger is released and before the brake engages. If faster stoppage time is required, bring the wheel to a stop by lightly contacting the bottom of the wheel with a hard surface. Carrying a cut-off machine with the wheel turning or the engine running is extremely dangerous. Contact with a moving wheel, even if the engine is turned off, can result in severe personal injury or death, and accidental acceleration of the engine can cause the wheel to rotate if the engine is still running. Avoid touching the hot muffler or allowing it to touch you.

WARNING

Always protect the cutting wheel from accidentally hitting the ground or any other objects, which can increase the risk of serious personal injury or death from a shattered composite cutting wheel, from loss of diamond cutting wheel segments or from loss of control.

Transporting by hand: When carrying your cut-off machine by hand, the engine must be shut off and the rotating wheel stopped, and the cut-off machine must be correctly positioned. Grip the

front handle and place the muffler at the side away from the body with the cutting attachment to the rear.

Transporting by vehicle: Properly secure your cut-off machine to prevent turnover, fuel spillage and damage to the cut-off machine. Never transport your cut-off machine with a cutting wheel mounted. A wheel damaged during transportation can cause serious personal injury or death.

Fuel Your STIHL cut-off machine uses an oil-

gasoline mixture for fuel. See the chapter "Fuel" in this 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 a oilgasoline fuel mix. Do not smoke or bring any fire or flame near the fuel or the power tool. Do not refuel near any ignition source. Note that combustible fuel vapor may escape from the fuel system or gas can during fueling operations.

WARNING

Dust or other debris may collect on the powerhead, especially around the carburetor, and may absorb gasoline, resulting in a risk of fire. Clean dust and debris from the powerhead regularly.

Fueling Instructions

WARNING

To reduce the risk of personal injury and property damage, fuel your cut-off machine in well-ventilated areas, outdoors. Always shut off the engine and allow the machine to cool before refueling. Never remove the fuel cap near any ignition source.

Under certain conditions, gasoline vapor pressure may build up inside the fuel tank depending on the fuel used, weather conditions and the condition of the tank venting system. In order to reduce the risk of burns and other personal injury from escaping gas vapor and fumes, allow the machine to cool adequately before opening the cap. Do not smoke. Remove the fuel filler cap slowly and as described in this instruction manual to allow any residual pressure in the tank to release gradually. Never remove the fuel filler cap while the engine is still running.

Select bare ground for fueling and move at least 10 feet (3 m) from the fueling spot before starting the engine. Wipe off any spilled fuel before starting your machine. If gasoline has spilled or contaminated your clothing, change clothes before starting the power tool, resuming work or approaching an ignition source.

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Always use fuels blended for the season and conditions in which you are cutting. Avoid the use of winter blend fuels in summer weather conditions. Use fresh fuel of good quality and at least 89 octane. STIHL MotoMix, available from your authorized STIHL servicing dealer, is recommended for best performance.

WARNING

Check for fuel leakage while refueling and during operation. If fuel leakage is found, do not start or run the machine until the leak is fixed and any leaked fuel has been wiped away. Take care not to get fuel on your clothing. If this happens, change your clothing immediately. Always move at least 10 feet (3 m) from the fueling spot before starting the engine.

WARNING

If fuel is 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 or other materials capable of creating sparks with a cut-off machine when clothes are contaminated with fuel or gasoline is extremely dangerous, as the operator's clothes might catch fire and

cause serious or fatal injury. Do not approach any ignition source with clothes contaminated by fuel.

WARNING

An improperly installed fuel cap can come off and spill quantities of fuel.

Fuel Filler Cap

Never use a tool to open or close the fuel filler cap, as this could damage the cap and cause fuel leakage or spillage.

The fuel filler cap must be securely closed after refuelling.

WARNING

Never attempt to force the fuel cap open by using a tool. It may damage the cap and allow fuel to leak.

WARNING

Before use, make sure that the fuel cap has been securely and properly installed 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 machine until the leak is fixed and all leaked fuel has been wiped away.

Before Starting For wheel installation, follow the

procedure described in the chapter "Mounting an Abrasive Wheel" in this instruction manual.

WARNING

Check the fuel system for leaks, especially the visible parts, e.g., fuel tank, filler cap, hose connections and manual fuel pump. To reduce the risk of personal injury or property damage from fire, do not start the engine if there are fuel leaks or damage to the fuel system. Have the machine repaired by an authorized STIHL servicing dealer before using it.

WARNING

Never operate a cut-off machine if it is damaged, improperly adjusted or maintained, or not completely or properly assembled. Check that the machine is ready for safe operation.

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, throttle trigger lockout, stop switch), brake and the other safety devices are working properly, the carburetor idle and maximum speed settings are correctly adjusted, the wheel is properly mounted, and the wheel guard is properly positioned and securely fastened to your unit. All wheels should be carefully inspected for

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002BA058 KN

damage before mounting. Never mount or use an abrasive cutting wheel that is cracked or otherwise damaged.

Adjust the wheel guard so that sparks, dust and cut material are deflected away from the operator, and cannot reach flammable surroundings or materials. See the section "Operating Instructions" in this instruction manual. Never direct sparks or cutting debris toward flammable materials or toward the operator.

When it is necessary to open the guard to access the underside of an in-ground pipe or other structure (see "Sample Applications"), always be aware of your surroundings. Make sure sparks and other debris are not directed toward flammable materials or the operator. Always wear appropriate eye protection and protective apparel. Return the guard to cover the top of the cutting wheel as soon as it is possible to continue the work with the guard in that position. STIHL recommends always guarding as much of the top of the wheel as possible and not opening the guard any further than necessary to make or complete a cut.

WARNING

Check that the spark plug boot is securely mounted on the spark plug – a loose boot may cause arcing that could ignite combustible fumes or spilled fuel and cause a fire.

Starting

WARNING

Your cut-off machine is a one-person tool. Do not allow other persons to be near a running cut-off machine. Start and operate your cut-off machine without assistance. Check the wheel brake system before starting and follow the specific starting instructions, found in the chapter "Starting/Stopping the Engine" in this instruction manual.

Do not drop start the cut-off machine. Drop starting means pushing the machine away from the operator, or allowing it to drop toward the ground, while pulling on the starter grip. This method is very dangerous because you may lose control of the cut-off machine.

Instead, to start the cut-off machine place it on firm ground or other solid surface in an open area and hold it securely to the ground or surface.

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 or surface on which the machine is being started. Never attempt to start the cut-off machine when the abrasive cutting wheel is in a cut.

Once the engine has started, immediately blip the throttle trigger, which should release the slide control to the run position and allow the engine to slow down to idle. After the choke lever is set to e, pull the brake lever toward the front handle and release the wheel brake. The abrasive cutting wheel should not rotate when the engine is idling and the wheel brake is released. If the wheel does turn, adjust the carburetor to set the proper idle speed. See the chapter "Adjusting the Carburetor" in this instruction manual. If you cannot adjust the carburetor to the proper idle speed, shut the machine off and take it to an authorized STIHL servicing dealer for repair before using the TS 440. For complete starting information, see the chapter "Starting/Stopping the Engine" in this instruction manual.

WARNING

When you pull the starter grip, do not wrap the starter rope around your hand. Do not allow the grip to snap back, but guide the starter rope slowly back to permit the rope to rewind properly. Failure to follow this procedure may result in injuries to hand or fingers and may damage the starter mechanism.

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Important Adjustments At correct idle speed, the wheel should

not turn, even when the wheel brake is released. For directions on adjusting idle speed, see the chapter "Adjusting the Carburetor" in this manual.

WARNING

Do not use a cut-off machine with the idle speed incorrectly adjusted. The rotating wheel may cause injury. If you cannot obtain the correct setting, have your STIHL dealer check your cut-off machine and make proper adjustments or repairs.

Working Conditions Operate the cut-off machine under good

visibility and daylight conditions only. Wearing hearing protection reduces

sound perception. Be alert not to miss voice or other audible signals from coworkers or supervisors. Keep within calling distance to other persons who may assist in case of emergency.

WARNING

As soon as the engine is running, this machine generates toxic exhaust fumes containing chemicals, such as unburned hydrocarbons (including benzene) and carbon monoxide, that are known to cause respiratory problems, cancer, birth defects, or other reproductive harm, and other injuries. Some of the gases (e.g. carbon monoxide) may be colorless and odorless and can cause asphyxiation and death very quickly. To reduce the risk of serious or fatal injury/illness from inhaling toxic fumes, never run the machine indoors or in poorly ventilated locations. Ensure proper ventilation when working in trenches or other confined areas.

WARNING

Use of this product to cut masonry, 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, and other injuries. If you are unfamiliar with the risks associated with the material being cut, review the applicable 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, and other injuries. Control dust and fumes at the source where possible.

In this regard, use engineering controls, good work practices and follow the recommendations of the material manufacturer/supplier, OSHA/NIOSH, and occupational and trade associations.

A water attachment kit is provided with your cut-off machine and should be used to reduce dust whenever wet cutting is feasible. For dust suppression purposes, the flow rate should be at least 20 fl. oz. (0.6 liters) of water per minute. If wet cutting at the recommended flow rate is not utilized or cannot be confirmed, to reduce the risk of serious or fatal respiratory illness or cancer the operator and any bystanders should always wear a respirator approved by NIOSH for the material being cut and with an Assigned Protection Factor sufficient to provide the necessary level of respiratory protection for worksite- specific conditions.

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Consult your employer for information regarding worksite conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the required type and level of respiratory protection needed for your worksite. Alternatively, information is available from OSHA at www.osha.gov. See the section on “Respiratory Protection” in the chapter “Sample Applications” in this instruction manual.

Even if wet cutting at the recommended flow rate, to reduce the risk of serious or fatal respiratory illness or cancer an operator who is working with the machine for more than two hours in one day should wear a NIOSH-approved respirator rated for the material being cut and with an Assigned Protection Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions. Consult your employer for information relating to the respirator needed for your worksitespecific conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the type and level of respiratory protection needed for your worksite conditions. Information also is available from OSHA at www.OSHA.gov. Consult and follow any federal, state or local laws or regulations with respect to dry and wet cutting, including any requirements for engineering controls, work practices and respiratory protection to reduce exposure to respirable crystalline silica or other potentially harmful substances.

WARNING

Cutting masonry, concrete and other materials with silica in their composition may produce dust containing crystalline silica. Silica is a basic component of sand, quartz, brick clay, granite and numerous other minerals and rocks. Inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis. California and some other authorities have listed respirable crystalline silica as a substance known to cause cancer. OSHA has established a maximum permissible exposure limit for crystalline silica. When cutting materials that may contain crystalline silica, always follow the respiratory precautions described in this instruction manual.

WARNING

Breathing asbestos dust is dangerous and can cause severe or fatal injury, respiratory illness or cancer, including mesothelioma. The use and disposal of asbestos-containing products are strictly regulated by OSHA and the Environmental Protection Agency. Do not use your cut-off machine to cut or disturb asbestos, asbestos-containing products, or products such as pipes which are wrapped or covered with asbestos-containing insulation or material. If you have any reason to believe that you might be cutting asbestos containing-material, or if you cannot be sure, stop work and immediately contact your employer or a local OSHA or EPA representative.

002BA549 AM

WARNING

The STIHL TS 440 is designed for handheld use only. It should not be used on a cart, as the added torque delivered by the TS 440 will cause the drive belt system to wear prematurely.

WARNING

Cutting with your cut-off machine resting on the ground or other surface can cause excessive wear to the bracket designed to protect the bottom of the tank housing. Loss of fuel and property damage or severe personal injury or death from fire may result. Replace damaged or badly worn brackets immediately.

WARNING

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 the front handle and your right hand on the rear handle and throttle trigger. Left-handed users also must follow this instruction in order to reduce the risk of severe or fatal personal injury from kickback and/or loss of control. Using the machine "left-handed" positions your body in the plane of the abrasive cutting

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wheel and increases the risk that you will be struck by the moving wheel if kickback occurs.

Wrap your fingers tightly around the handles, keeping the handles cradled between your thumbs and forefingers. Make sure the cut-off machine’s handles and grip are in good condition and free of moisture, pitch, oil, fuel mix or grease.

Never touch a rotating wheel with your hand or any part of your body or allow it to touch you.

WARNING

Clear the area where you are working. Avoid stumbling on obstacles and be alert for ditches or other irregularities and impediments. Be extremely cautious when working on slopes or rocky 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.

WARNING

Sparks from cutting metal can burn the operator or cause clothing or other objects or materials to catch fire. Direct sparks away from the operator and 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, work with a fire watch and have appropriate fire extinguishing equipment readily available. Do not use the cut-off machine if you cannot direct sparks away from flammable substances or the operator.

WARNING

To reduce the risk of severe personal injury or death from fire, exlosion or other event, do not cut into any pipe, drum or other container without first ensuring that it does not contain a volatile or flammable substance and is not pressurized.

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 or pressurized materials, substances and structures. Make sure that power, water and gas have been shut off and pipes drained before starting to cut.

Operating Instructions

0000-GXX-5154-A0

WARNING

The wheel guard on the TS 440 is adjustable. It is extremely important that the wheel guard is in place and adjusted properly for the type of work you are doing, your stance and your work position. 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.

Particular care must be taken when the guard is adjusted to expose the top of the wheel. The guard should only be adjusted to this position when necessary to access the underside of a pipe or other structure or to finish cuts requiring use of the top portion of the wheel. When cutting the underside of a pipe or other structure, the pipe or other structure itself should provide protection against debris, but if the operator is endangered by debris, the guard must be adjusted to protect the operator. That may mean, in some circumstances, the TS 440 cannot be used to complete a cut. The guard always should be adjusted forward to cover the top of the wheel immediately upon completion of

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any cut requiring the top of the wheel to be exposed. STIHL recommends always guarding as much of the top of the wheel as possible and not opening the guard any further than necessary to make or complete a cut.

The recommended guard position for use of the TS 440, whenever possible, is fully forward to the forward stop position, which will then cover the top of the abrasive cutting wheel down to the point roughly midway between 9:00 and 12:00 (when viewing the wheel from the fan wheel housing side of the machine).

WARNING

To reduce the risk of severe injury or death, always shut off the machine and allow the wheel to stop before attempting to adjust the guard. After shutting off the machine, the wheel will continue to rotate for a few seconds before the brake engages. Never attempt to adjust the guard while the engine is running or the wheel is still rotating.

WARNING

Always check the wheel before use and after unintentionally striking any object; check it frequently during use when the engine is turned off. Look for cracks and other damage, such as cracked, missing or broken segments on a diamond cutting wheel. Make sure that the wheel is undamaged and in good condition, that it is not cracked, that no pieces have broken off and that no segments are loose, missing or damaged. See the sections "Abrasive Cutting Wheels" and "Reactive Forces" in this manual. Check the wheel guard for cracks or other

damage. If you discover any breaks, cracks or other damage, mount a new guard before further use.

WARNING

It is essential to determine the exact direction of the cut before applying the abrasive cutting wheel to the workpiece. Wheels are constructed for radial pressure only. To reduce the risk of wheel breakage and severe personal injury or death, avoid putting lateral pressure (side loading) on the wheel. Hold the cut-off machine steady. Work along a straight cutting line. Do not attempt to correct the position or direction of a cut by tilting or twisting the machine or cutting wheel. If corrections are necessary, always lift the machine and reposition the cutting wheel, taking care to ensure that it is not wedged, tilted, twisted or side loaded. Attempting to change the position or direction of a cut while the wheel is in the cut can bind the wheel. This can lead to kickback, other reactive forces or a shattered composite cutting wheel, which could result in severe or fatal personal injury. See the section "Reactive Forces" in this manual.

WARNING

Use your cut-off machine for cutting only. It is not designed for prying, shoveling or moving any objects.

Do not use abrasive cutting wheels for rough grinding using the sides of the wheel. Large bending stresses occur during such work, which may result in reactive forces, including kickback, or cause the wheel to shatter or break, resulting in serious or fatal injury.

WARNING

To reduce the risk of injury from damaged abrasive cutting wheels:

1. Do not use a wheel on your machine that has a rated operating speed lower than the maximum operating speed of you machine's spindle, as specified in this instruction manual.

2. Do not use a wheel that has been dropped or damaged.

3. Run each new wheel immediately after installation for approximately one minute at maximum speed without cutting, making sure to keep bystanders away. If the wheel wobbles or otherwise shows operational problems, do not use it.

4. Do not cut any material for which the wheel is not authorized.

5. Do not grind using the sides of the wheel.

6. Do not twist, thrust, knock or drop the machine. This can cause damage to the wheel.

7. Do not transport the cut-off machine with the cutting wheel mounted.

To achieve a clean and efficient cut, maintain a firm grip and apply the cutting wheel to workpiece, allowing the cutting wheel to engage the material naturally. Don't force or jam the cutting wheel into the workpiece. The machine will have a natural tendency to move away from the operator. Slowly pulling the machine back through the cut or kerf toward the operator and then allowing it to move forward again will improve cutting performance.

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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, concrete and similar materials – leave a thin layer of material uncut. This layer can be easily broken afterwards using a hammer or other appropriate tool. Always wear properly rated eye protection when breaking any uncut piece or layer. Do not cock, jam or wedge the wheel in the cut, as this may result in reactive forces or a damaged or broken wheel and the possibility of severe or fatal personal injury.

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 cutting wheel completes the cut. The abrasive cutting wheel may contact the operator or strike some foreign object and break or shatter.

Always shut off the engine and be sure the wheel has stopped rotating before setting the cut-off machine down.

WARNING

When the engine is shut off, the wheel brake will engage within a few seconds. If the cut-off machine is on the ground, it may tip forward when the wheel brake engages. The abrasive cutting wheel can touch the ground and may shatter, break or sustain damage. It also may cause damage to the surface it contacts.

STIHL Quickstop Wheel Brake System The STIHL Quickstop wheel brake

system is designed to stop the rotation of the cutting wheel during kickback if the kickback energy is sufficiently high.

WARNING

The Quickstop does not prevent kickback. It is designed to reduce the risk of kickback injury, if activated, when the guard on the TS 440 has been "opened," exposing the top of the cutting wheel. In order for the Quickstop to reduce the risk of kickback injury, it must be properly maintained and in good working order. An improperly maintained wheel brake may increase the time needed to stop the abrasive cutting wheel after activation, or it may not activate at all. See the chapter entitled "Wheel Brake System" in this instruction manual.

WARNING

The brake is intended to substitute for the wheel guard when the guard has been "opened," i.e., pulled back toward the operator, exposing the top of the wheel, by stopping the rotation of the wheel if kickback occurs and kickback energies are sufficiently high. Like all safety devices, the brake cannot protect the operator in all circumstances. There must be enough distance between the top of the wheel and the operator to ensure that the Quickstop has sufficient time to activate and stop the abrasive cutting wheel before potential contact with the operator. Always stand outside of the plane of the cutting wheel when

using a cut-off machine, including the TS 440, and do not crouch over the wheel.

Always maintain at least a 45° angle between the top of the wheel and the operator’s head, neck and body to reduce the risk of severe personal injury or death in the event of a kickback, particulary when the guard has been opened to expose the top of the wheel.

WARNING

The primary device intended to reduce the risk of injury from kickback on the TS 440 is the wheel guard. The wheel guard also reduces the risk of injury from shattered wheels, thrown segments, sparks and cutting debris. The brake is intended to substitute for the wheel guard in kickback situations when the guard has been "opened," exposing the top of the wheel. The TS 440 should be used with the guard in this position only when necessary to make a cut as, for example, when accessing the underside of a pipe in a trench. The guard should be returned to the forward stop position (covering the top of the wheel down to the point on the cutting wheel roughly midway between 9:00 and 12:00 when viewing the wheel from the fan wheel housing side of the machine) as soon as the cut requiring a more open guard position has been completed. Make this adjustment sooner if it is necessary to protect the operator from thrown debris generated during cutting.

The guard should not be opened to expose the top portion of the wheel if doing so means that cutting debris or

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sparks will be directed toward the operator, or if sparks or debris would be directed into flammable surroundings.

WARNING

If you experience kickback of sufficient magnitude to activate the Quickstop, please review the operating instructions and safety precautions in this chapter before resuming work. Kickback situations can and always should be avoided. Pinching or binding of the wheel can be prevented by proper support of the workpiece (see below), proper working technique (e.g., not side loading the wheel and standing outside the plane of the wheel), and by the use of properly designed, manufactured and maintained abrasive cutting wheels that do not wobble and that do not have friction-generating abrasive material on their sides.

WARNING

To reduce the risk of injury from reactive forces, shattered wheels, thrown segments, sparks and cutting debris, the guard should be pushed fully forward to the forward stop position (covering the top of the wheel, down to the point on the cutting wheel roughly midway between 9:00 and 12:00 when viewing the wheel from the fan wheel housing side of the machine) whenever a more "open" guard position is not needed to make a cut. Make this adjustment sooner if it is necessary to protect the operator and surroundings from thrown debris generated during cutting.

The guard always should be positioned to cover as much of the top of the wheel as possible consistent with the type of

cut being made and the proper direction and containment of sparks and other debris. The recommended guard position is fully forward to the front stop position whenever possible.

WARNING

Check the wheel brake system before starting work as described in the chapter "Starting/Stopping the Engine" in this instruction manual. Do not work with the TS 440 if the wheel brake system is not functioning properly. Have the wheel brake system repaired by an authorized servicing dealer before using the machine.

WARNING

The wheel brake should be engaged when starting your machine. If the abrasive cutting wheel turns at startup without the brake first being disengaged, do not use the cut-off machine and have the wheel brake system repaired by an authorized servicing dealer before using it.

Reactive Forces Including Kickback

WARNING

Reactive forces may occur at any time the cutting wheel on a cut-off machine is rotating.

The powerful forces used to cut through a workpiece can be reversed and work against the operator. If the wheel is slowed or stopped sufficiently by frictional contact with any solid object or by a pinch or binding, reactive forces

can occur instantly and may result in the operator losing control of the cut-off machine, which, in turn, may result in serious or fatal injury. An understanding of the causes of these reactive forces will help you avoid them and loss of control.

Reactive forces are exerted in a direction opposite to the direction in which the wheel is moving at the point of contact or of the pinching/binding. If the wheel is slowed by frictional contact with a solid object, the resulting reactive forces are normally moderate and readily controllable by an operator who is holding the machine properly. If, however, the wheel is abruptly slowed or stopped by a severe pinch or bind, the reactive forces may be substantially greater. The greater the force generated, the more difficult it will be for the operator to control the cut-off machine. Loss of control can result in severe personal injury or death.

Pull-away, Climbing, Pinching and Rotational Kickback Forces

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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

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002BA146 KN

(climbing). When the guard is opened on the TS 440 to expose the top portion of the wheel, contact in this top portion of the wheel can cause the machine to move linearly toward the operator (push back). Any of these reactions can result in loss of control and severe personal injury or death.

Pinching occurs when the piece being cut closes on the wheel. A severe binding may also occur if the wheel is substantially sideloaded in the cut or if an improper or damaged diamond cutting wheel begins or ceases to wobble in the kerf. The location of the pinch or bind on the wheel will determine the direction the machine will move in response to any reactive force that is generated – push back from the top of the wheel, pull away from areas below the upper quadrant of the wheel. However, if the wheel is severely pinched or bound in the upper quadrant at the front of the wheel, the wheel may be instantly thrown up and back towards the operator with significant force in a rotational kickback motion. Such kickback situations can and always should be avoided.

Pinching or binding of the wheel can be prevented by proper support of the workpiece (see below), proper working technique (e.g., not side loading the wheel and standing outside the plane of the wheel) and by the use of properly designed, manufactured and maintained wheels that do not wobble or have friction-generating abrasive material on their sides.

Reducing the Risk of Kickback Injury

WARNING

To reduce the risk of kickback injury, avoid cutting with the upper quadrant of the wheel (illustrated above) whenever possible. Be especially cautious for a pinching or binding of the wheel in this area, which can cause severe reactive forces in a rotational kickback motion.

Avoid wedging action. The severed part of a workpiece must fall free and not wedge, bind or clamp the abrasive cutting wheel.

Be alert to potential movement of the workpiece or anything else that could cause the cut to close and pinch, bind or clamp the wheel. In order to reduce the risk of pinching, binding or clamping, support the workpiece in such a way that the cut remains open during the cutting process and when the cut is finished (see illustration). Never make a cut that results in a binding of the wheel. If you cannot properly support the workpiece, do not use a cutting-off machine to make the cut; select another tool or method.

Where there is a possibility of a pinch, you should leave an uncut portion of the workpiece that prevents the cut from closing and pinching the wheel, which can later be broken manually using a hammer or other appropriate tool. If you

002BA582 ST

are making a complete cut, make sure that the final, separating cut is made at the top of the workpiece using the bottom of the wheel, with the guard of the machine pushed fully forward to the forward stop position. In this way, if there is any residual pinching, it will be at the bottom of the wheel, where it may result in pull-away, but not in kickback. Be alert for pull-away.

Objects to be cut always must be properly supported and must be secured against pinching, rolling away, slipping or vibration.

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Support an exposed pipe in a trench so that it is stable and will not "sag" or "drop". If the ends of the pipe are firmly in the ground, the ground may act as a support where the pipe emerges into the open. Additional support will be needed closer to the cut, however, to prevent sagging (see illustration). Be alert for pipe that is under stress that may cause it to shift when cut; pipe in the ground may be under stress because of uneven pipe bed surfaces. The release of stress or tension in the pipe can propel the cutoff machine, causing loss of control and resulting in severe personal injury or death. It also can cause a binding or pinching of the abrasive cutting wheel, which could result in reactive forces, including kickback

Make sure any section of pipe to be removed is also properly supported and will not shift. After the first cut, you may need to move the supports or add additional support for the second cut so that both sides of that cut are fully supported, including the section to be removed.

Always pay attention in subgrade/subsurface work areas – supporting material can crumble or slide away, causing the pipe to sag and pinch the wheel.

WARNING

Be particularly alert when cutting a workpiece such as a pipe with a bell end or when cutting out a section of pipe in a trench that, if not properly supported, can sag or drop upon completion of the cut, creating a pinch or bind. Without

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proper support, a pipe with a bell end laying on the ground will tend to create a ramp effect that will cause the pipe to sag or drop as the pipe is cut. If the pinch or bind occurs in the upper quadrant of the abrasive cutting wheel, kickback can result.

WARNING

Use wet-cutting whenever feasible. Water can act as a lubricant in a pinch situation and can reduce both the likelihood of reactive forces occurring and the energy of any such forces if they do occur, making it easier to maintain control of the machine. Please note, however, that wet cutting should not be used with composite wheels on the TS 440.

WARNING

Only STIHL branded cutting attachments are recommended. Use of certain non-STIHL branded wheels may be extremely dangerous. Many substandard diamond cutting wheels are available in the market. If they are not manufactured with the proper quality materials in their core, if they are not properly hardened or tensioned, or if other design or manufacturing problems exist, they may begin to wobble during use, lose segments or exhibit other operational problems that can

substantially increase the risk of personal injury or death from reactive forces, thrown segments or loss of control. If a diamond cutting wheel begins or ceases to wobble within the cut, the change in the behavior of the wheel may cause a severe binding that can lead to loss of control and/or kickback. If the wheel you are using begins to wobble or has ever wobbled, discard it immediately. Although such a wheel may temporarily cease to wobble, e.g., if run without load, it will always be prone to wobble again. A wheel that wobbles is extremely dangerous.

WARNING

Some non-STIHL branded diamond cutting wheels are manufactured with abrasive material on their sides. Do not use such wheels, since the abrasive material increases frictional forces and will lead to substantially increased reactive forces in a pinch or side loading situation.

WARNING

Never use chipped abrasive cutting wheels, wheels with missing or damaged segments, or circular saw blades, carbide-tipped blades, rescue blades or wood-cutting or toothed blades of any nature on a cut-off machine. The use of such wheels or blades will greatly increase the risk of loss of control and severe personal injury or death from reactive forces, since the chipped or damaged section of an abrasive cutting wheel or the teeth of a saw blade may catch in the material

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being cut and generate substantially greater reactive forces, including rotational kickback.

Cut-off machines are designed for use with abrasive cutting wheels in good condition only. Machines designed for use with wood-cutting or other toothed blades use different types of guarding systems that provide the protection necessary for those types of blades. Machines, such as a cut-off machine, that are designed for use with abrasive cutting 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.

WARNING

To reduce the risk of injury from loss of control from reactive forces, including kickback, when cutting:

1. Hold the cut-off machine firmly with both hands, left hand on the front handle, right hand on the rear handle.

2. Maintain good balance and footing at all times. Never cut while standing on a ladder or other unsecure platform.

3. Position the cut-off machine in such a way that your body is clear of the cutting attachment and outside the plane of the cutting attachment. That means the operator must avoid standing in direct line with the wheel (see illustration). Never bend over the cutting attachment or position your head and upper body forward of the front handle, especially when the guard is pulled back exposing the top of the wheel. Always maintain at least a 45° angle between the top of an exposed wheel and the operator’s head, neck and body. Ensure sufficient freedom of movement, especially in trenches. Make sure there is sufficient space for the user and the fall of the severed portion of the workpiece.

4. STIHL recommends using only STIHL branded abrasive cutting wheels properly rated for the material to be cut.

5. Never work with a diamond cutting wheel that wobbles or that has ever wobbled or that is manufactured with abrasive material on its sides.

6. Do not cut wood, plastic or any other material for which the abrasive cutting wheel is not authorized.

7. Begin cutting and continue cutting at full throttle. Do not overreach. Never cut above shoulder height.

8. Never sideload, jam or twist a wheel in the cut.

9. Be especially alert for reactive forces, including kickback, when

002BA554 AM

cutting with the front and upper quadrant of the wheel.

10. Be alert to shifting of the workpiece or anything that could cause the cut to close and pinch the wheel, especially in the upper quadrant. Support the workpiece in such a way that the cut remains open. Never make a cut that results in a binding, pinching or clamping of the wheel. Finish a separating cut in the top portion of the workpiece using the bottom section of the wheel and the guard adjusted fully forward covering the top of the wheel.

11. Use wet-cutting whenever feasible. In a pinch situation the water can act as a lubricant and reduce the energy of reactive forces. It also helps control dust. Do not wet cut when using a composite wheel on the TS 440.

12. Use extreme caution when reentering a cut and do not twist the wheel in the cut, turn it at an angle or jam it into the cut as this may result in a binding or 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.,

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when the operator attempts to move the machine in a sideways direction, and can result in loss of control.

Maintenance, Repair and Storing of the Cut-Off Machine

Never operate a cut-off machine that is damaged, improperly adjusted or not completely or properly assembled. Follow the maintenance and repair instructions in the appropriate sections of this instruction manual.

WARNING

STIHL recommends the use of only STIHL replacement parts for maintenance and repair. Use of parts manufactured by others may be extremely dangerous and could result in serious or fatal injury.

WARNING

Always shut off the machine and make sure that the wheel is stopped before doing any maintenance or repair work or cleaning the cut-off machine. When the machine is shut off, the wheel continues to rotate for a few seconds before the brake engages. Do not attempt any maintenance or repair work not described in this manual as appropriate for users. STIHL recommends that you have all other work performed at your authorized STIHL servicing dealer.

Clean off dust and other cutting debris after finishing work. Check and, if necessary, tighten all nuts, bolts and screws except the carburetor adjustment screws after each use.

Do not clean your machine with a pressure washer. The solid jet of water may damage the machine or its components.

WARNING

Never test the ignition system with the spark plug boot removed from the spark plug or with an unseated spark plug, since uncontained sparking may cause a fire.

WARNING

To reduce the risk of fire and burn injury or property damage, use only spark plugs authorized by STIHL. Always press the spark plug boot snugly onto the spark plug terminal of the proper size. A loose connection between the spark plug terminal and the ignition wire connector in the boot may create arcing that could ignite combustible fumes and cause a fire. Keep the spark plug clean, and make sure the ignition lead is in good condition. Do not use a spark plug with a detachable SAE adapter terminal. Arcing may occur that could ignite combustible fumes and cause a fire. This can result in serious injuries or damage to property.

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. Your muffler is equipped with a spark-arresting screen to reduce the risk

of fire. Never operate your cut-off machine if the screen is missing or damaged.

WARNING

Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrester is required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

In California, it is a violation of § 4442 or

§ 4443 of the Public Resources Code to

use or operate gasoline-powered tools on forest-covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a complying spark arrester that is maintained in effective working order. The owner/operator of this product is responsible for properly maintaining the spark arrester. Other states or governmental entities/agencies, such as the U.S. Forest Service, may have similar or additional requirements. Contact your local fire agency or forest service for the laws or regulations relating to fire protection requirements. Even if the spark arrester is in place, it may not be advisable to use gasolinepowered equipment, including cut-off machines, in hot, dry conditions or around dry vegetation or brush. Contact your local fire authorities or the U.S. Forest Service if you have any question about whether conditions are suitable for the use of a cut-off machine.

For any maintenance please refer to the maintenance chart and to the warranty statement near the end of this manual.

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Do not store a cut-off machine with a wheel mounted on the machine. Store the cut-off machine in a high or locked place, out of reach and inaccessible to children.

Empty the fuel tank before storing your cut-off machine 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. Dispose of fuel in accordance with all applicable laws and regulations.

WARNING

Check the wheel brake system as described in this manual before starting work. Do not work with the cut-off machine if the wheel brake system is not functioning properly. If the brake is not operating properly, have it repaired by an authorized STIHL servicing dealer before using the machine.

Sample Applications

Water connection

– A water attachment kit is mounted

on the machine for use with all types of water supply.

– A pressurized 2.6 gallon (10 liter)

water tank also is available from STIHL for wet cutting.

For proper dust suppression, always ensure that you have sufficient water pressure to produce the recommended flow rate of 20 fluid ounces per minute (0.6 liters/minute), regardless of the water source.

The pressure and flow rate available from the water source will affect the actual amount of water available for dust suppression when wet cutting with your cut-off machine. For example, when using a pressurized or gravity-fed water tank, water pressure will decrease as the water level in the tank decreases. STIHL recommends using the highest flow setting on your cut-off machine whenever possible. When connected to a gravity-fed or pressurized water tank, maintain pressure by re-filling gravityfed tanks and re-pressurizing pressurized tanks periodically. The highest flow setting is obtained by pressing the (+) control button on the water control panel 9 times in succession or by depressing it for at least 5 seconds.

Water pressure from a household water supply, such as an outside water faucet, often will be sufficient to achieve desired levels of dust suppression at settings 7,

8 or 9 on your water control panel. These settings can be set by pressing the (+) control button 9 times in succession and then the (-) control button either once or twice if setting 8 or 7 is desired. STIHL recommends always wet cutting at the highest flow rate when conditions permit.

If the operator cannot achieve and maintain a sufficient flow rate using the highest flow setting on the cut-off machine, connect the cut-off machine to a water source with sufficient pressure to deliver at least 20 fluid ounces (0.6 liters) of water per minute. If a source of water with adequate pressure is unavailable or if water flow cannot be confirmed, to reduce the risk of serious or fatal respiratory illness or cancer the operator and any bystanders should always wear a NIOSH-approved respirator that is rated for the material being cut and with an Assigned Protection Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions. Consult your employer for information relating to the respirator needed for your worksite-specific conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the type and level of respiratory protection needed for your worksite conditions. Information also is available from OSHA at www.OSHA.gov. If worksite conditions do not allow use of a flow rate of 20 fluid ounces per minute (0.6 liters/minute), or anytime the flow rate cannot be confirmed, the operator and any bystanders should wear a NIOSHapproved respirator that is rated for the material being cut and with an Assigned

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Protection Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions.

Wet Cutting with Diamond Cutting Wheels

STIHL diamond cutting wheels are suitable for wet cutting. The composite wheel developed by STIHL for use on the TS 440 is not approved for wet cutting and may shatter or break if used for wet cutting, resulting in severe or fatal injury. You should not wet cut with any composite wheel on the TS 440.

Wet cut whenever feasible. It increases the service life of diamond wheels, reduces reactive forces and will help control dust.

The cutting wheel must be supplied with at least 20 fl. oz (0.6 liters) of water per minute for proper dust suppression. If you cannot achieve, maintain or confirm this flow rate, to reduce the risk of serious or fatal respiratory illness or cancer the operator and any bystanders should always wear a NIOSH-approved respirator rated for the material being cut and with an Assigned Protective Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions. Consult your employer for information regarding worksite conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the type and level of respiratory protection needed for your worksite. Information also is available from OSHA at www.OSHA.gov.

Even if wet cutting, an operator who is working with the machine for more than two hours in one day should wear a properly rated, NIOSH-approved respirator with an Assigned Protection Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions.

Before wet cutting, make sure water will not damage the floor, building or other property, the material being cut or any surrounding objects. Make sure that "run-off" will not cause any type of environmental damage or come into contact with electrical sources.

WARNING

STIHL recommends the use of only STIHL-branded cutting wheels on the TS 440. Use of non-STIHL cutting wheels may be extremely dangerous. See the chapter "Reducing the Risk of Kickback Injury" in this instruction manual.

WARNING

To reduce the risk of electrocution to you or bystanders, do not allow water or sludge to contact live electric wires or other electrical power sources.

Dry Cutting with Composite Cutting Wheels

STIHL has developed a composite cutting wheel suitable for dry cutting metal with the TS 440.

STIHL has not developed a composite cutting wheel for cutting non-metal materials with the TS 440, or for wet cutting. Do not use a composite cutting

wheel on the TS 440 when wet cutting. Composite cutting wheels designed for use on higher speed machines will perform poorly on the TS 440.

WARNING

Use only diamond cutting wheels for wet cutting with the TS 440. Wet cutting with a composite cutting wheel may increase the risk of wheel breakage, resulting in severe or fatal injury.

Respiratory protection

WARNING

When wet cutting at the flow rate recommended in this instruction manual is not utilized or cannot be confirmed, to reduce the risk of serious or fatal respiratory illness or cancer the operator and any bystanders should always wear a properly rated respirator approved by NIOSH for the material being cut and with an Assigned Protection Factor sufficient to provide the level of respiratory protection needed for worksite-specific conditions. Consult your employer for information relating to the respirator needed for your worksitespecific conditions. Your employer is likely to have in place an OSHA-required respiratory protection program and can provide information regarding the type and level of respiratory protection needed for your worksite conditions. Information also is available from OSHA at www.OSHA.gov. Even if wet cutting, an operator who is working with the machine for more than two hours in one day should wear a properly rated, NIOSH-approved respirator with the

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appropriate Assigned Protection Factor. If you are unable to determine the water flow rate, to reduce the risk of serious or fatal respiratory illness or cancer the operator and any bystanders should always wear a properly rated, NIOSHapproved respirator with an Assigned Protection Factor sufficient to provide the level of respiratory protection needed for worksite- specific conditions.

Points to be noted with diamond and composite 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

and movement

The cutting sequence There are many ways to cut materials

and objects with a cut-off machine and the operator and/or his supervisor, with knowledge of the job site conditions and requirements, always must exercise good judgment and discretion in determining how to safely complete a cutting task. The methods described in the following sections, while constituting proven techniques, are illustrative only and are not meant to substitute for the judgment of the experienced workmen with direct knowledge of on-site conditions.

However, the cutting sequence is important. The last cut must always be made in such a way that the cutting wheel cannot become pinched, bound or clamped and so that the operator, co-

workers and bystanders are not at risk of being injured by a falling part that has been cut off or out, or by cutting debris or sparks.

Leave small sections of uncut material to hold the part being severed in position. These sections can later be broken through manually, using a hammer or other appropriate tool. Always continue to wear appropriate eye protection when finishing a cut by breaking it manually.

A number of points must be decided before the part is finally severed:

– How heavy is the part? – In which direction can it move or fall

after being severed?

– Is it under tension? – Is it properly supported to prevent

pinching or binding of the wheel?

The operator, co-workers and bystanders must not be put at risk of injury when the part is broken off or falls.

Cutting in several passes

N Mark cutting line (A).

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N Work along the cutting line. If

corrections are necessary, always lift the machine and reposition the cutting wheel, taking care to ensure that it is not wedged, tilted, twisted or side loaded. Attempting to change the position or direction of a cut while the wheel is in the cut can bind the wheel. This can lead to kickback, other reactive forces or a shattered composite cutting wheel, which could result in severe or fatal personal injury.The cutting depth per pass should not exceed 2“ to 2 1/2“ (5 to 6 cm). Thicker material must be cut in several passes. The maximum cutting depth for abrasive cutting wheels with a 14" diameter is

4.9 in. (125 mm).

Cutting slabs

N Secure the slab (e. g. on a non-slip

surface, sandbed) and mark the cutting line.

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N Cut a shallow guiding groove (A)

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along the marked line.

N Cut deeper into the parting cut (B). N Leave a section (C) of uncut

material.

N Cut through the slab at the ends so

the material does not chip.

N Break the slab manually using a

hammer or other appropriate tool. Always continue to wear appropriate eye protection when finishing any cut by breaking it manually.

N Curves must be cut in several

straight passes, taking care to ensure that the cutting wheel does not become wedged. Do not attempt to correct the position or direction of a cut by tilting or twisting the machine or cutting wheel. If corrections are necessary, always lift the machine and reposition the cutting wheel, taking care to ensure that it is not wedged, tilted, twisted or side loaded.

Cutting pipes or other round, hollow bodies

The procedure is dependent on the outer diameter of the object being cut, the maximum possible cutting depth of the abrasive cutting wheel (A), and whether the pipe or other body can be rolled during the cutting process. The

maximum cutting depth for abrasive cutting wheels with a 14" diameter is

4.9 in. (125 mm).

N Secure and support pipes and other

round, hollow bodies against sagging, slipping, dropping, moving, rolling or vibrating.

N Determine the sequence of the cuts. N Determine the weight, tension and

the likely direction of fall of the part to be severed.

N Determine and mark the cutting line;

avoid rebar and other metal reinforcement to the extent possible, especially in the direction of the severing cut.

N Determine and mark the direction of

the cut.

N Cut a shallow guide groove along

the line marked.

N Make cuts progressively deeper

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along the guide groove. Observe the recommended cutting depth for each pass. If corrections are necessary, always lift the machine and reposition the cutting wheel, taking care to ensure that it is not wedged, tilted, twisted or side loaded. Attempting to change the position or direction of a cut while the wheel is in the cut can bind the

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wheel. This can lead to kickback, other reactive forces or a shattered composite cutting wheel, which could result in severe or fatal personal injury.

N If necessary, leave small sections

that hold the part that is to be separated in position. Break these sections manually with a hammer or other appropriate tool after making the last cut.

If the outer diameter of the pipe or other round, hollow body is smaller than the maximum cutting depth of the wheel:

N Make one cut from the top to the

bottom of the pipe.

If the outer diameter of the pipe or other round, hollow body is greater than the maximum cutting depth of the wheel:

Plan first, then cut. The sequence shown in this manual is illustrative and not meant to substitute for the judgment of the experienced workmen with actual knowledge of on-site conditions. However, the last cut must always be made in such a way that the cutting wheel cannot become pinched, bound or clamped and so that the operator, coworkers and bystanders are not at risk of being injured by a falling part that has been cut off or out, by cutting debris or sparks. Generally, this should be in the

top portion of the pipe using the bottom section of the cutting wheel with the guard covering the top of the wheel.

If the pipe is in-ground or otherwise cannot be rolled:

N Support the pipe and chock it if

necessary to prevent it from rolling, moving or vibrating.

N Rotate the guard to the forward

position shown in illustration A.

N To reduce the risk of pinching or

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binding and kickback, start cutting in the lower section of the pipe. Illustration A.

N Rotate the guard to the rear limit

stop as shown in illustration B.

N Insert the abrasive cutting wheel at

full throttle into the existing cut, being careful not to tilt or twist the

wheel, and continue the cut down to the center of the bottom half of the pipe. Illustration B.

N Rotate the guard to the forward

position shown in illustration C.

N Cut the opposite lower side of the

pipe. Illustration C.

N Rotate the guard to the rear limit

stop as shown in illustration D.

N Insert the abrasive cutting wheel at

full throttle into the existing cut, being careful not to tilt or twist the wheel, and continue the cut down to the center of the bottom half of the pipe. Make sure that the cut at the bottom is complete and joins the first cut made to the bottom of the pipe. Illustration D. If the cuts fail to meet, never attempt to make them meet by twisting the machine or wheel, bending the wheel or attempting to change direction in the cut. Start a new cut that will

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meet the existing cut without twisting, jamming or side loading the wheel.

N Rotate the guard to the forward

position shown in illustration E.

N Make a cut from the top half of the

pipe down, connecting with the cut from the lower half. Illustration E. Again, do not attempt to twist or bend the machine or wheel to join the two cuts.

N Make a cut in the marked area

shown above leaving uncut the section labeled "X" on the illustration. To keep the pipe from pinching, binding or clamping the wheel during this cut, do not cut into the area labeled "X", Illustration F.

Only make the final top cut (Separating Cut) after all bottom and lateral cuts have been completed and connected with one another. Illustration G.

N Always make the final Separating

Cut from the top (approx. 15 % of the pipe circumference) using the bottom of the wheel with the guard adjusted to cover the top of the wheel and to direct cutting debris and sparks away from the operator. If the workpiece is properly supported, it should not pinch, bind or clamp when the cut is completed. By using this technique, if there is any residual pinching, binding or clamping, it should occur at the bottom of the wheel where it may result in pull-away, but not rotational kickback. Be alert for pull-away. Always adjust the guard fully forward to the forward stop position (covering the top of the wheel down to a point on the cutting wheel

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roughly midway between 9:00 and 12:00 when viewing the wheel from the fan wheel housing side of the machine) when a more open guard position is not needed to make or complete a cut.

If the pipe can be rolled: N Use only the bottom of the abrasive

cutting wheel to make an initial partial cut with the guard of the

machine pushed fully forward to the limit stop, covering the top of the wheel.

N Roll the pipe, resecure and support

it. Make another partial cut using the bottom of the wheel and the guard covering the top of the wheel.

N Repeat this process until the cut is

complete.

N Be alert to bell ends or any other

feature of the pipe that could cause the cut to close on the wheel if the pipe is not properly supported and secured. Bell ended pipes, even when lying on level ground, can create a ramp effect that may cause the pipe to sag or drop when cut, pinching, binding or clamping the cutting wheel and resulting in severe kickback or other reactive force.

Cutting recesses in pipe

The sequence of cuts (in the illustrations below, 1 to 4) is recommended:

N Always make severing cuts so that

the abrasive cutting wheel is not pinched, bound or clamped.

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N Use wedges and/or leave sections

of pipe to be manually broken out after cutting. Always continue to wear appropriate eye protection when finishing a cut by breaking it manually.

N If the severed part remains in the

recess after cutting, do not make any further cuts – break the part out manually, using a hammer or other appropriate tool. Always continue to wear appropriate eye protection when finishing a cut by breaking it manually.

Abrasive Cutting Wheels

Abrasive cutting wheels are exposed to high loads, especially during hand-held cutting.

Only use abrasive cutting wheels that comply with ANSI B 7.1 for hand-held

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machines and are correspondingly labeled. Note that the maximum permissible speed of the cutting wheel must be higher than the maximum spindle speed listed on the wheel guard label.

The abrasive cutting wheels that have been developed for STIHL for use on the TS 440 are of high quality and tailored to the intended uses as well as the engine specifications and performance of this cut-off machine. Use of other wheels on the TS 440 can be extremely dangerous and may result in severe personal injury or death. Do not wet cut with a composite wheel on the TS 440, and do not use composite wheels designed for use on traditional, high-speed cut-off machines; they will wear prematurely and perform poorly when used on the TS 440.

Transport and storage

– Do not expose composite cutting

wheels to direct sunshine or other thermal stresses during transport and storage.

– Avoid jolts and impacts.

– Stack composite cutting wheels flat

on a level surface in the original packaging in a dry place where the temperature is as constant as possible.

– Do not store composite cutting

wheels in the vicinity of aggressive fluids or chemicals.

– Store composite cutting wheels in a

frost-free place.

– Do not transport a cut-off machine

with a abrasive cutting wheel mounted, whether composite or diamond.

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Composite Cutting Wheels

Types: – for dry applications STIHL has developed a composite

cutting wheel suitable for dry cutting metals with the TS 440. STIHL has not developed a composite cutting wheel for cutting other materials with the TS 440, or for wet cutting. Composite cutting wheels should not be used for wet cutting with the TS 440. Composite cutting wheels designed for use on higher speed machines will perform poorly when mounted on the TS 440 and should not be used.

WARNING

Use only diamond cutting wheels for wet cutting with the TS 440. Wet cutting with a composite cutting wheel may increase the risk of wheel breakage, resulting in severe or fatal injury.

Diamond Cutting Wheels

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STIHL diamond cutting wheels are suitable for wet cutting.

To reduce the risk of severe personal injury or death, always use a diamond cutting wheel that is properly rated for the material to be cut and the reduced speed of your TS 440.

All STIHL-branded diamond cutting wheels can be used on the TS 440. Other brands of wheels developed for high speed cut-off machines may not perform well on the TS 440 or may show premature wear. Never use wheels that wobble or that ever have wobbled, wheels with abrasive material on their sides, or wheels not rated for the material you are cutting. Never use chipped or damaged abrasive cutting wheels, circular saw blades, carbidetipped blades, rescue blades or wood cutting tooth blades of any nature. Use of such wheels can increase the risk of severe personal injury from increased reactive forces, loss of control or other causes. The designation on the wheel’s label or packaging can help to ensure the correct choice of a cutting wheel.

STIHL offers diamond cutting wheels that are suitable for cutting the following materials with the TS 440:

– Asphalt – Concrete – Stone (hard rock) – Abrasive concrete – Green concrete – Clay bricks – Clay pipes – Ductile iron – Structural steel up to 10 mm thick

Do not cut any other materials with your diamond cutting wheel. Always use a diamond cutting wheel rated for the type of material you are cutting. Cut-off machines are not suitable for cutting certain metals and other substances, including wood and plastic.

WARNING

Never use diamond cutting wheels with abrasive material on their sides, since in a pinch or bind situation, they can increase frictional forces and result in extreme kickback, increasing the risk of severe or fatal injury.

Non-STIHL branded wheels used on the TS 440 may not perform adequately or may show premature wear because of its slower cutting speeds and increased torque. They also may have design or manufacturing flaws that make their use extremely dangerous. STIHL recommends the use of only properly rated, STIHL-branded cutting wheels on the TS 440.

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D-B10

Short names

The short name on a diamond cutting wheel is a combination of letters and numerals with up to four digits:

– The letters indicate the authorized

use for the diamond cutting wheel.

– The numerals indicate the

performance class of the STIHL diamond cutting wheel.

Letter Authorized use D-A Asphalt D-B Concrete BA Concrete, Asphalt SB* Rock, Concrete D-G Ductile iron

(*)

also can be used for structural steel up to 10 mm thick and ductile iron – not suitable for continuous cutting of such materials

Radial and axial run-out

A correctly mounted spindle bearing on the cut-off machine is essential for normal service life and efficient operation of the abrasive cutting wheel.

Using an abrasive cutting wheel on a cut-off machine with an improper, worn or damaged spindle bearing can lead to axial and radial run-out.

Excessive radial run-out (A) overloads individual diamond segments and causes them to overheat. This can lead to stress cracking in the wheel core or to softening of individual segments. The result can be broken segments that increase the risk of personal injury.

Axial run-out or spindle wobble (B) also results in higher thermal stresses and wider cuts.

Undercut

Undercutting is a wearing away of the steel core of the wheel at or just below the diamond segments. When cutting road surfaces, do not cut through into the more abrasive ballast (gravel, crushed rock) below the paved surface,

as indicated by a light colored dust. Doing so can cause undercutting. If undercutting can be detected upon visual inspection, replace the wheel.

WARNING

Undercutting can result in wheel breakage and/or thrown segments, which can lead to severe personal injury or death to the operator or bystanders. Immediately replace a diamond cutting wheel if undercutting is visible.

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.

Built-up edges increase vibration, reduce cutting performance and cause sparking.

Diamond cutting wheels must be "dressed" at the first sign of built-up edges. To dress a diamond cutting

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