Stihl TS 440 Instruction Manual

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STIHL TS 440

Instruction Manual

Contents

English

Guide to Using this Manual 2 Safety Precautions and Working

Techniques 2 Sample Applications 11 Cutting Wheels 14 Composite Abrasive Wheels 15 Diamond Abrasive Wheels 15 Abrasive wheel brake 18

Original Instruction ManualPrinted on chlorine-free paper

Electronic Water Control 20 Mounting an Abrasive Wheel 21 Fuel 22 Fueling 23 Starting / Stopping the Engine 24 Air Filter System 28 Adjusting the Carburetor 29 Spark Arresting Screen in Muffler 30 Spark Plug 30 Storing the Machine 31 Maintenance and Care 32 Main Parts 34 Specifications 35 Maintenance and Repairs 36

Printing inks contain vegetable oils, paper can be recycled.

Disposal 36 EC Declaration of Conformity 37

Dear Customer,

Thank you for choosing a quality engineered STIHL product.

It has been built using modern production techniques and comprehensive quality assurance. Every effort has been made to ensure your satisfaction and trouble-free use of the product.

Please contact your dealer or our sales company if you have any queries concerning this product.

Your

Dr. Nikolas Stihl

0458-520-8321-A. VA6.G20.

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Guide to Using this Manual

Pictograms

Pictograms that appear on the machine are explained in this Instruction Manual.

Depending on the machine and equipment version, the following pictograms may appear on the machine.

Fuel tank; fuel mixture of gasoline and engine oil

Actuate decompression valve

Actuate manual fuel pump

Pull starter grip

Actuate brake lever and release abrasive wheel brake

Symbols in text

WARNING

Warning where there is a risk of an accident or personal injury or serious damage to property.

NOTICE

Caution where there is a risk of damaging the machine or its individual components.

Engineering improvements

STIHL's philosophy is to continually improve all of its products. For this reason we may modify the design, engineering and appearance of our products periodically.

Therefore, some changes, modifications and improvements may not be covered in this manual.

Safety Precautions and Working Techniques

Special safety precautions must be taken when working with the cut-off machine, due to the very high rotational speed of the abrasive wheel.

It is important you read and understand the User Manual before commissioning and keep it in a safe place for future reference. Non-observance of the safety precautions may result in serious or even fatal injury.

Observe all applicable local safety regulations, e.g. by trade organizations, social insurance institutions, labor safety authorities etc.

As for employers within the European Community, the provision 2009/104/EC is binding – Safety and health protection with the use of machines and devices by employees at work.

If you have never used a power tool before: have your STIHL dealer or other specialist show you how to operate the machine – or attend one of the special training courses.

Minors should never be allowed to use the machine – except for apprentices over the age of 16 when working under supervision.

Children, animals and bystanders must not be allowed near the machine.

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When not using the machine, it must be laid down in such a way that it does not endanger anyone. Ensure that the machine cannot be used without authorization.

The user is responsible for accidents or risks involving third parties or their property.

Do not lend or rent your power tool without the User Manual. Be sure that anyone using it understands the information contained in this manual.

The use of machines that emit noise may be limited to certain hours of the day as specified by national and/or regional or local regulations.

Anyone operating the machine must be well rested, in good physical health and in good mental condition.

If you have any condition that might be aggravated by strenuous work, check with your doctor before operating a machine.

If you have a pacemaker: The ignition system of your machine produces an electromagnetic field of very low intensity. This field may interfere with some pacemakers. STIHL recommends that persons with pacemakers consult their physician and the pacemaker manufacturer to reduce any health risk.

Anyone who has consumed alcohol or drugs or medicines affecting their ability to react must not operate a power tool.

Postpone the work if the weather is bad (snow, ice, wind) – higher risk of accidents!

The machine may only be used for cutting. It is not suitable for cutting wood or wooden objects.

Asbestos dust is extremely toxic - the machine must therefore never be used to cut asbestos!

Other uses are not permitted and may lead to accidents or damage to the machine.

Never attempt to modify your power tool in any way since this may increase the risk of personal injury. STIHL excludes all liability for personal injury and damage to property caused while using unauthorized attachments.

Only use abrasive wheels or accessories which have been approved by STIHL for this machine or which are technically equivalent. If you have any questions in this respect, consult your dealer. Only use high-quality abrasive wheels and attachments. in order to avoid the risk of accidents and damage to the machine.

STIHL recommends the use of genuine STIHL abrasive wheels and accessories. They are specifically designed to match the product and meet your performance requirements.

Do not use a high-pressure washer to clean the power tool. The solid jet of water may damage parts of the unit.

Do not spray the power tool with water.

Never use circular saw blades, carbide, rescue or wood cutting attachments or saws of any kind – these may cause fatal injuries!Instead of uniformly removing particles as when cutting with an abrasive wheel, the teeth of a circular saw blade may snag in the material. This causes the machine to react in a highly aggressive manner with uncontrolled and extremely dangerous kickback.

Clothing and equipment

Wear proper protective clothing and equipment.

Clothing must be sturdy but allow complete freedom of movement. Wear close-fitting clothes such as a boiler suit, not a work coat.

When cutting steel, always wear clothing made of barely flammable material (e.g., leather or cotton with flame-retardant finish) – no man made fibers – risk of fire due to flying sparks!

Clothing must be free from flammable deposits (chips, fuel, oil, etc.).

Do not wear clothes that may be caught by moving parts – no scarf, no tie, no jewelry. Tie up and confine long hair above your shoulders.

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Wear steel-toed safety boots with non-slip soles.

WARNING

To reduce the risk of eye injuries, wear close-fitting safety glasses in accordance with European Standard EN 166. Make sure the safety glasses are a snug fit.

Wear face protection and make sure it is a good fit. Face protection alone is not sufficient to protect the eyes.

Wear a safety hard hat where there is a danger of head injuries from falling objects.

Dust (e. g., crystalline material from the object being cut), fumes and smoke may be produced while cutting - health hazard!

Always wear a dust mask if dust is generated.

If fumes or smoke are anticipated (e. g., when cutting composite materials), wear respiratory protection.

Wear "personal" hearing protection – for example, ear defenders.

Wear sturdy protective gloves made of a resistant material (e. g. leather).

STIHL can supply a comprehensive range of personal protective equipment.

Transporting the machine

Always stop the engine.

Carry the device by the handlebar only – abrasive wheel pointing to the rear – hot muffler away from the body.

To avoid serious burn injuries, avoid touching hot parts of the machine, especially the surface of the muffler.

Never transport the engine-driven device with attached abrasive wheel – risk of breakage!

By vehicle: When transporting in a vehicle, properly secure your machine to prevent turnover, damage and fuel spillage.

Refueling

Gasoline is highly flammable – keep away from fire or flame – do not spill any fuel – no smoking.

Always shut off the engine before refueling.

Do not fuel a hot engine – fuel may spill and cause a fire.

Open the fuel cap carefully to allow any pressure build-up in the tank to release slowly and avoid fuel spillage.

Only refuel the machine in a well ventilated place. If fuel has been spilled, immediately clean the machine – do not allow your clothes to be splashed with fuel. If that happens, change your clothes at once.

Dust may collect on the engine unit, particularly around the carburetor. If dust gets mixed with fuel – risk of fire. For this reason, ensure that the dust is always removed.

Check for fuel leakage! Never start the engine if fuel has been spilled or is leaking – Fatal burns may result!

Bayonet-type fuel cap

Never use a tool to open or close the bayonet-type fuel cap. This could damage the cap and cause fuel to leak out.

Close the bayonet-type fuel cap carefully after refueling.

Cut-off machine, spindle bearing

Correct spindle bearings ensure the concentricity and axial running of the diamond abrasive wheel – if necessary, get it checked by an approved dealer.

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Abrasive cutting wheels

Selecting the abrasive cutting wheels

Abrasive cutting wheels must be approved for freehand cutting. Do not use other cutting wheels and attachments – risk of accident!

Abrasive cutting wheels are suitable for different materials: Observe the identification of the abrasive cutting wheels.

STIHL generally recommends wet cutting.

Observe the outer diameter of the abrasive wheel.

Spindle hole diameter of the abrasive wheel and shaft of cut-off machine must match.

Check the spindle hole for damage. Do not use abrasive cutting wheels with a damaged spindle hole – risk of accident!

The permissible speed of the abrasive cutting wheel must be equal to or greater than the maximum spindle speed of the cut-off machine. – Refer to the chapter "Specifications".

Before fitting a used abrasive cutting wheel, check that it is not cracked, chipped, undercut or uneven, and does

not display any signs of core fatigue or overheating (discoloration); check also the spindle hole is not damaged.

Never use cracked, chipped or bent abrasive cutting wheels.

Substandard and/or unapproved diamond abrasive wheels can shimmy during cutting. This shimmying can cause such diamond abrasive wheels to be abruptly braked or become stuck in the cut – Danger of kickback! Kickback can result in fatal injuries! Diamond abrasive wheels that shimmy constantly or even only intermittently must be replaced immediately.

Never straighten diamond abrasive wheels.

Do not use an abrasive cutting wheel which has fallen to the ground – damaged abrasive cutting wheels may break – risk of accident!

Observe the expiration date where composite resin abrasive cutting wheels are concerned.

Fitting abrasive cutting wheels

Inspect the spindle of the cut-off machine. Do not use a cut-off machine if the spindle is damaged – risk of accident!

Note the arrows indicating the direction of rotation on diamond abrasive wheels.

Position the front pressure plate – tighten up the tensioning screw – rotate the abrasive cutting wheel by hand and take a sight check for concentricity and axial running.

Storing abrasive cutting wheels

Store abrasive wheels in a dry and frostfree place, on an even surface, at constant temperature – risk of breakage and splintering!

Always protect abrasive cutting wheels against sudden impact with the floor or objects.

Before starting

Inspect the cut-off machine for safe-tooperate state – observe the respective chapters in the User Manual:

– Check the fuel system for leaks,

especially the visible parts, e. g., fuel cap, hose connections, manual fuel pump (only in machines with a manual fuel pump). In case of leakage and damage, do not start the engine – risk of fire! Have the machine serviced by a dealer before using it

– The abrasive wheel must be

suitable for the material to be cut. It must be in good condition and fitted correctly (direction of rotation, secure).

– Inspect the abrasive wheel guard

for tight seat – if loose, contact your specialist dealer.

– Smooth action of throttle trigger and

throttle trigger lockout – throttle trigger must return automatically to idle position

– Slide control / master control lever /

stop switch must move easily to STOP or 0

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– Check that the spark plug boot is

secure – a loose boot may cause sparking that could ignite combustible fumes and cause a fire!

– Check the correct operation of the

abrasive cutting wheel brake. When the brake lever is activated, the abrasive cutting wheel can be turned by hand – when the brake lever is released, the abrasive cutting wheel can no longer be turned. It should not be possible to turn the abrasive cutting wheel when the brake lever is not activated.

– Never attempt to modify the controls

or safety devices

– Keep the handles clean, dry and

free of oil as well as dirt – important for safe guiding of the cut-off machine.

– For wet applications, provide

sufficient water

To reduce the risk of personal injury, do not operate your power tool if it is damaged or not properly assembled!

at machine start-up, do not work with the cut-off machine and contact a dealer. Arrange for the abrasive cutting wheel brake to be repaired.

The machine is operated by a single person only – do not allow any person to stay within the working area – nor with starting.

Do not drop start your machine – the correct starting procedure is described in the User Manual.

After releasing the throttle trigger, the abrasive wheel keeps on running for a while – danger of injury due to coasting effect!

Holding and guiding the machine

Use the cut-off machine only for handheld cutting.

Hand-held cutting

When a cut-off machine with an abrasive cutting wheel rotating is moved in the direction of the arrow, a force is produced which causes the machine to tip sideways.

The object to be cut off has to be firmly supported. Always guide the machine towards the workpiece – never the other way round.

Deflector

Starting the engine

Start the engine at least 3 meters from the fueling spot, outdoors only.

On even ground, ensure a firm and secure footing and hold the enginedriven device firmly – the abrasive cutting wheel must not touch any objects or the ground and must not be in cutting action.

When starting, the abrasive cutting wheel brake is engaged. If the abrasive cutting wheel does not immediately turn

Always hold the machine firmly with both hands: Right hand on the rear handle – even if you are left-handed. To ensure safe control, wrap your fingers tightly around both handles.

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Set the abrasive cutting wheel guard correctly: Guide particles of material away from the user and machine.

Note the direction of flight of the removed particles of material.

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While working

If there is imminent danger or in an emergency, immediately stop the engine – set the slide control / master control lever /stop switch to STOP or 0.

Check for correct idling, so that the abrasive cutting wheel is no longer driven when the throttle trigger is released and comes to a complete halt.

Check and correct the idle speed setting at regular intervals. Have the machine repaired by a STIHL dealer if the abrasive cutting wheel continues to turn after the abrasive cutting wheel brake has been released.

Keep clear the working area – bear in mind obstacles, holes and pitches.

Take special care in slippery conditions – damp, snow, ice, on slopes or uneven ground.

Don not work while standing on a ladder – not on an insecure support – not over your shoulder height – not with one hand only – risk of accident!

Make sure you always have good balance and secure footing.

Do not work alone – keep within calling distance of others in case help is needed.

Keep out further persons from the working area – maintain sufficiently large distance to additional persons to protect them from noise and flying objects.

Be particularly alert and cautious when wearing hearing protection because your ability to hear warnings (shouts, alarms, etc.) is restricted.

Take a break in good time before you get tired.

Work calmly and carefully – in daylight conditions and only when visibility is good. Proceed with caution, do not put others in danger.

As soon as the engine is running, the power machine generates toxic exhaust gas. These gases may be odorless and invisible and may contain unburned hydrocarbons and benzene. Never run the engine indoors or in poorly ventilated locations, even if your model is equipped with a catalytic converter.

Ensure proper ventilation when working in trenches, hollows or similar locations – risk of fatal injury from breathing toxic fumes!

Stop work immediately if you start suffering from nausea, headaches, impaired vision (e.g. your field of vision gets smaller), impaired hearing, dizziness, or impaired concentration – these symptoms may possibly be the result of too-high exhaust gas concentration – Risk of accidents!

To reduce the risk of fire, do not smoke while operating or standing near your power tool.

If your power tool is subjected to unusually high loads for which it was not designed (e.g. heavy impact or a fall), always check that it is in good condition before continuing work – see also "Before Starting". Check in particular that the fuel system has no leaks and the

safety equipment is fully operative. Never use a power tool that is no longer safe to operate. In case of doubt, contact a dealer.

Do not operate your power tool in the starting throttle position – engine speed cannot be controlled in this position.

Never touch a rotating abrasive cutting wheel with your hand or any other part of your body.

Examine the workplace. Avoid all danger due to damaged piping or electrical wiring.

The machine must not be used near inflammable substances or gases.

Do not cut into pipes, metal tanks or other containers if you are not sure that they do not contain any volatile or inflammable substances.

Never leave the machine unattended with the engine running. Stop the engine before leaving the machine unattended (e. g. for breaks).

Stopping the engine engages the abrasive cutting wheel brake. If the cutoff machine, with the abrasive cutting wheel running, stands on the ground and the engine is switched off there, the engagement of the abrasive cutting wheel brake may cause the cut-off machine to tilt forward, resulting in the abrasive cutting wheel touching the ground – damage to the abrasive cutting wheel!

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Before putting the cut-off machine down on the ground:

– Shut off the engine

– Wait until the abrasive cutting wheel

has come to a standstill or brake the abrasive cutting wheel until it comes to a standstill by carefully touching a hard surface (e.g., concrete slab)

Frequently inspect the abrasive cutting wheel – replace it right away if there are visible cracks, buckling or other damage (for example, overheating) – risk of accident due to breakage!

In the event of changes in cutting behavior (e. g., increased vibration, reduced cutting performance), stop work and eliminate the causes of the changes.

Reactive forces

The most frequently occurring reactive forces are kickback and pull-in.

Danger of kickback – Kickback can result in fatal injuries.

Kickback occurs when the cut-off machine is suddenly thrown up and back in an uncontrolled arc towards the operator.

Kickback occurs if, for example, the abrasive cutting wheel

– gets jammed – primarily in its upper

quarter, or

– is abruptly braked through friction

contact with a solid object

QuickStop abrasive cutting wheel brake

When the abrasive cutting wheel brake is engaged, the abrasive cutting wheel will come to a standstill in a split second – see chapter "abrasive cutting wheel Brake" in this User Manual.

To reduce the risk of kickback

– Work cautiously and avoid

situations which could cause kickback.

– Hold the cut-off machine firmly with

both hands and maintain a secure grip

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– If possible, avoid using the upper

quarter of the abrasive cutting wheel for cutting. Use extreme caution when guiding the abrasive cutting wheel into a cut, do not twist or push into the cut

– Avoid any wedge effect - the

severed part must not brake the abrasive cutting wheel

– Always be aware that the object to

be cut may move and other factors may cause the cut to close and jam the abrasive cutting wheel.

– The object to be cut must be

secured and supported so that the kerf remains open during and after cutting

– Objects to be cut must therefore be

fully supported and must be secured against rolling away, slipping off or vibrations

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– Support an uncovered pipe stable

and solid, if necessary, use wedges – always bear in mind a proper support and ground – material may crumble away,

– Always work with water and wet

cutting when using diamond abrasive wheels

Pull away from

The cut-off machine pulls forward, away from the user, when the abrasive wheel touches the object to be cut from above.

Working – cutting off

The abrasive cutting wheel must be guided straight in the cut, without wedging. Never exert lateral pressure on the abrasive cutting wheel.

Do not use for lateral grinding or scrubbing.

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Do not stand in line with the abrasive wheel. Ensure sufficient freedom of movement, especially in construction trenches there must be sufficient space for the user and for the part being cut to fall.

Do not lean too far forwards and never bend over the abrasive wheel when the guard has been pulled back.

Do not work above shoulder height.

The cut-off machine may only be used for cutting. It must not be used as a lever

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or shovel.

Do not press down on the cut-off machine

Always decide the cutting direction before positioning the cut-off machine. After that, do not change the cutting direction. Never push or hit with the device into the cutting gap – do not let the concrete cutter fall into the cutting depth – risk of breakage!

Diamond abrasive cutting wheels: If cutting performance begins to deteriorate, check the sharpness of the diamond abrasive wheel, resharpen as

needed. To do this, briefly cut through abrasive material, e. g., sandstone, aerated concrete or asphalt.

At the end of the cut, the cut-off machine is no longer supported by the abrasive wheel in the cut. The user has to absorb the weight force – risk of loss of control!

When cutting steel: glowing metal particles may cause fires!

Keep water and sludge away from alive

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electrical cables – risk of electric shock!

Drag the abrasive wheel into the workpiece – do not push it into the material. Do not correct severing cuts with the cut-off machine. Do not re-cut – remove left webs or breaking edges (for example, with a hammer).

When applying diamond abrasive wheels, take a wet cut – for example, use the STIHL water connector.

Du to the reduced maximum spindle speed, STIHL developed a special composite resin abrasive cutting wheel for cutting steel with this machine. This abrasive cutting wheel is suitable for dry cutting only. If a composite resin abrasive cutting wheel of this type becomes wet, its cutting performance is reduced and it becomes dull. If a composite resin abrasive cutting wheel of this type becomes wet while working (e.g., due to puddles or water in pipes), do not increase the cutting pressure, but continue working with the same pressure – risk of breakage! Use up such composite resin abrasive cutting wheels immediately.

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Traditional composite resin abrasive cutting wheels developed for cut-off machines with high circumferential speed have an inferior cutting performance and are unsuitable.

Vibrations

Prolonged use of the power tool may result in vibration-induced circulation problems in the hands (whitefinger disease).

No general recommendation can be given for the length of usage because it depends on several factors.

The period of usage is prolonged by:

– Hand protection (wearing warm

gloves)

– Work breaks

The period of usage is shortened by:

– Any personal tendency to suffer

from poor circulation (symptoms: frequently cold fingers, tingling sensations).

– Low outside temperatures.

– The force with which the handles

are held (a tight grip restricts circulation).

Continual and regular users should monitor closely the condition of their hands and fingers. If any of the above symptoms appear (e.g. tingling sensation in fingers), seek medical advice.

Maintenance and repairs

The machine must be serviced regularly. Do not attempt any maintenance or repair work not described in the Instruction Manual. All other work should be carried out by a servicing dealer.

STIHL recommends that maintenance and repair work be carried out only by authorized STIHL dealers. STIHL dealers receive regular training and are supplied with technical information.

Use only high-quality spare parts. Otherwise, there may be a risk of accidents and damage to the machine. If you have any questions in this respect, consult a servicing dealer.

STIHL recommends the use of genuine STIHL spare parts. Such parts have been optimized for the machine and the user's requirements.

Before starting any maintenance or repair work and before cleaning the machine, always stop the engine and disconnect the spark plug boot – risk of injury if the engine starts up inadvertently! – Exception: adjustment of carburetor and idle speed.

To reduce the risk of fire due to ignition outside the cylinder, move the slide control / stop switch to STOP or 0 before turning the engine over on the starter with the spark plug boot removed or the spark plug unscrewed.

Do not service or store the machine near a naked flame – risk of fire due to the fuel.

Check fuel cap regularly for tightness.

Use only spark plugs that are in perfect condition and have been approved by STIHL – see "Specifications".

Check ignition lead (insulation in good condition, secure connection).

Check that the muffler is in perfect working condition.

Do not use the machine if the muffler is damaged or missing – risk of fire! – Hearing damage!

Never touch a hot muffler – risk of burns!

Check the rubber buffers underneath the machine – the housing must not rub against the ground – risk of damage!

The condition of the anti-vibration elements influences vibration behavior – inspect anti-vibration elements periodically.

Before starting work, check the operation of the abrasive wheel brake.

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Sample Applications

Water must always be used for wet cutting when working with diamond abrasive wheels

Extend service life and increase cutting speed

Always ensure a supply of water to the abrasive wheel.

Binding dust

The abrasive wheel must be supplied with at least 0.6 liters of water per minute.

Water attachment

– Water attachment on the machine

for all types of water supplies

– Pressurized water tank 10 l for

binding dust

STIHL composite resin cutting wheels may only be used for dry cutting

During dry cutting, wear a suitable dust mask.

If fumes or smoke are anticipated (e.g., when cutting composite materials), wear respiratory protection.

Observe with diamond and composite resin abrasive wheels

Objects to be cut

– Must be fully supported

– Must be secured so they cannot roll

or slip off

– Must be prevented from vibrating

Severed parts

With openings, recesses, etc., the sequence of the cuts is important. Always make the last cut so that the abrasive wheel does not become jammed and so that the operator is not endangered by the severed or separated part.

If necessary, leave small ridges that hold the part that is to be separated in position. Break these ridges later.

Before finally separating the part, determine:

– how heavy the part is

– how it can move after separation

– whether it is under tension

When breaking out the part, do not endanger assistants.

Cut in several passes

N Mark cutting line (A)

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N Work along the cutting line. When

making corrections, do not tilt the abrasive wheel, but always set the abrasive wheel against the workpiece anew – the cutting depth for each operation should not exceed 5 to 6 cm. Cut thicker material in multiple operations

Cutting plates

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

surface, sandbed)

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N Grind a guide groove (A) along the

line marked

N Make the cut (B) deeper N Leave a "hinge" (C) N First sever the plate at the cut ends

so that no material breaks away

N Break plate

Cutting pipes, round and hollow bodies

N Secure pipes, round and hollow

bodies against vibrations, slipping and rolling away

N Note direction of fall and weight of

the severed part

N Determine and mark the cutting

line, avoid reinforcements, especially in the direction of the severing cut

N Determine sequence of severing

cuts

N Grind a guide groove along the line

marked

N Make cut deeper along the guide

groove – observe the recommended

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cutting depth for each operation – for small corrections of direction, do not tilt the abrasive wheel, but always position it anew instead – if necessary, leave small ridges that hold the part that is to be separated in position. Break these ridges after the last planned cut

Cutting concrete pipe

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The procedure is dependent on the outer diameter of the pipe and the maximum possible cutting depth of the abrasive wheel (A).

N Secure pipe against vibrations,

slipping and rolling away

N Note weight, tension and direction

of fall of the part to be severed

N Make curves in multiple operations

– make certain that the abrasive wheel does not tilt

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N Determine and mark direction of cut N Determine sequence of cuts

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Outer diameter is smaller than the

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English

N Make one cut from the top to the

bottom

Outer diameter is greater than the maximum cutting depth

Plan first, then cut. Several cuts are needed – correct sequence is important.

N Close guard, Illustration A

N Always start cut from underneath,

Illustration A

N Open guard, Illustration B

N Insert abrasive wheel at full throttle

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into the cut you have made, Illustration B

N Continue cutting downward more

than half-way round the pipe, Illustration B

N Close guard, Illustration C

N Cut opposite underside,

Illustration C

N Open guard, Illustration D

N Insert abrasive wheel at full throttle

into the cut you have made, Illustration D

N Continue cutting downward more

than half-way round the pipe, Illustration D

N Close guard, Illustration E

N First lateral cut on the top half of the

pipe, Illustration E

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N Second lateral cut in the marked

area – never cut into the area of the last cut (X), to ensure a firm hold on the part of pipe to be cut, Illustration F

English

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Only make the last top cut once all bottom and lateral cuts have been made.

N Last cut always from the top

(approx. 15 % of the pipe circumference), Illustration G

Concrete pipe – cut recess

Sequence of cuts (1 to 4) is important:

N First, cut hard-to-reach areas

N Use wedges and/or leave ridges

that are broken after cutting

N If the severed part remains in the

recess after cutting (due to wedges, ridges used), do not make any further cuts – break the severed part

Cutting Wheels

Abrasive wheels are exposed to extremely high loads especially during freehand cutting.

Therefore only for use of approved and correspondingly labeled abrasive

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wheels with hand-held machines as per EN 13236 (diamond) or EN 12413 (composite resin). Note maximum permissible speed of the abrasive wheel – risk of accident!

The abrasive wheels, which have been developed by STIHL in cooperation with renowned manufacturers of abrasive wheels, are of high quality and tailored precisely to the respective intended use as well as the engine performance of the cut-off machine.

They are of consistently outstanding quality.

Transport and storage

N Always make severing cuts so that

the abrasive wheel is not pinched

– Do not expose abrasive wheels to

direct sunshine or other thermal stresses during transport and storage

– Avoid jolting and impacts

– Stack abrasive wheels flat on a level

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

– Do not store abrasive wheels in the

vicinity of aggressive fluids

– Store abrasive wheels in a frost-free

place

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D-B10

Composite Abrasive Wheels

Types:

– for dry applications

Because of the reduced maximum spindle speed, STIHL has developed a special composite resin abrasive wheel for cutting steel. This abrasive wheel is only suitable for dry cutting.

Do not cut any other materials – Risk of accident!

Conventional composite resin abrasive wheels developed for cut-off machines with a high circumferential speed give a poor cutting performance and are therefore unsuitable.

Diamond Abrasive Wheels

For wet applications.

The proper selection and use of diamond abrasive wheels ensures economical use and avoids accelerated wear. The product code which appears

– on the label and

– on the packaging (table with

recommendations for use) is an aid to selection

STIHL diamond abrasive wheels are suitable, depending on the version, for cutting the following materials:

– Asphalt

– Concrete

– Stone (hard stone)

– Abrasive concrete

– Fresh concrete

– Clay brick

– Clay pipe

– Ductile cast iron pipe

Do not cut any other materials – Risk of accident!

Never use diamond abrasive wheels with side plating as they jam in the cut and can result in extreme kickback – Risk of accident!

Product Codes

The product code is a combination of letters and numbers, consisting of up to four characters:

– the letters denote the main field of

application of the abrasive wheel

– the numbers denote the

performance class of the STIHL diamond abrasive wheel

Axial and radial run-out

A faultless spindle bearing of the cut-off machine is necessary for a long service life and efficient functioning of the diamond abrasive wheel.

Using the abrasive wheel on a cut-off machine with a faulty spindle bearing can lead to deviations in radial and axial run-out.

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Built-up edges, sharpen

An excessively high radial run-out deviation (A) overloads individual diamond segments, which overheat in the process. This can lead to stress cracks in the parent wheel or to annealing of individual segments.

Deviations in axial run-out (B) result in higher thermal loading and wider cuts.

Undercut

Do not cut into the base course (frequently chipped stones and gravel) when cutting roadway pavement – cutting in chipped stones and gravel is revealed by light-colored dust – excessive undercut may occur as a result – Danger of shattering!

Built-up edges take the form of a light gray deposit on the tops of the diamond segments. This deposit on the segments clogs the diamonds and blunts the segments.

Built-up edges can form:

– when cutting extremely hard

materials, e. g., granite

– with incorrect handling, e. g.,

excessive feed effort

Built-up edges increase vibration, reduce cutting performance, and cause formation of sparks.

At the first signs of built-up edges, immediately "sharpen" the diamond abrasive wheel – to do this, briefly cut through abrasive material such as sandstone, aerated concrete or asphalt.

Addition of water prevents the formation of built-up edges.

If work continues with dull segments, these may soften due to the high heat generated – the parent wheel is annealed and its strength is compromised – this can lead to stresses that are clearly recognizable by gyrations of the abrasive wheel. Do not continue to use the abrasive wheel – Risk of accident!

TS 440

Troubleshooting

Abrasive wheel

English

Defects Cause Remedy ragged edges or cut surfaces, crooked

Deviation in radial or axial run-out Contact a servicing dealer

cut heavy wear on the sides of the segments Abrasive wheel gyrates use a new abrasive wheel ragged edges, crooked cut, no cutting

performance, generation of sparks

Abrasive wheel is dull; built-up edges with abrasive wheels for stone

Sharpen abrasive wheels for stone by briefly cutting through abrasive materials; replace abrasive wheel for asphalt with a new one

poor cutting performance, high segment wear

Breakdowns or tears in the parent wheel

Abrasive wheel is turning in the wrong direction

Mount abrasive wheel so that it turns in the right direction

Overloading use a new abrasive wheel

and segment Undercut Cutting in the wrong material use new abrasive wheel; observe sepa-

rating layers of various materials

STIHL recommends STIHL servicing dealers

TS 440

English

0813BA003 KN

0813BA004 KN

Abrasive wheel brake

This cut-off machine is fitted with the STIHL QuickStop cutting wheel brake.

When starting, the cutting wheel brake is engaged. After starting, the cutting wheel brake must be released.

The cutting wheel brake will be triggered if there is a sufficiently forceful kickback. When activated, the cutting wheel brake stops the abrasive cutting wheel within a fraction of a second.

Checking function of the cutting wheel brake

Each time before starting work

N Operate brake lever (1) in the

direction of the handlebar and hold the abrasive cutting wheel can be turned by hand.

N Release the brake lever (1) - the

cutting wheel brake is engaged - the abrasive cutting wheel cannot be turned by hand.

N If the abrasive cutting wheel can be

moved without operating the brake lever (1): Do not use the cut-off machine and consult your servicing dealer. Arrange for the cutting wheel brake to be repaired.

The brake lever must be free of dirt and easily movable.

Releasing cutting wheel brake

N When the engine is running,

operate the brake lever in the direction of the handlebar and release - the cutting wheel brake is released

NOTICE

The cutting wheel brake must be released before opening the throttle and before using the cut-off machine.

Increasing engine speeds with the cutting wheel brake engaged even for a short time results in damage to engine, clutch and cutting wheel brake.

If the cutting wheel brake cannot be released with the engine running

The following causes are possible:

– Note regarding required

maintenance for the cutting wheel brake

– Note regarding required repair for

the cutting wheel brake

TS 440

English

370BA085 KN

0000-GXX-4257-A0

N Hold down button (3) on control

panel for 3 seconds with the engine running

N Pull brake handle in the direction of

the handlebar and release

If this allows the cutting wheel brake to be released, the cutting wheel brake requires maintenance.

N Carry on working and consult a

STIHL servicing dealer after finishing the work

N Arrange for the required

maintenance to be carried out on the cutting wheel brake

This procedure should be carried out afresh each time the engine is started. The number of such procedures is recorded in the control unit.

If this still does not allow the cutting wheel brake to be released, the cutting wheel brake requires repair.

N Stop work and consult a STIHL

servicing dealer

N Arrange for the cutting wheel brake

to be repaired

Retensioning the front V belts

The V belts belong to the cutting wheel brake.

If the front V belt slips or squeals when accelerating or working, the front V belt is not tensioned correctly. The abrasive cutting wheel can remain stuck during cutting.

N Undo bolt (1) N Remove guard (2)

N Slacken nut (3). The front V belt (4)

is tensioned

N Pull brake lever (5) in the direction

of the handlebar and hold it there

N Turn the belt pulley (6) 3 turns. The

tension is evenly distributed.

N Release the brake lever (5) N Tighten nut (3) with a tightening

torque of 20 Nm

WARNING

To ensure correct function of the cutting wheel brake, the nut must be tightened with the specified torque. If it is not

possible to ensure that the nut can be tightened with the correct tightening torque, have the front V belt retensioned by a STIHL servicing dealer.

N Fit cover (2) N Insert and tighten bolt (1)

If a V belt continues to slip or squeal when accelerating or working, a V belt may be worn. The abrasive cutting wheel can remain stuck during cutting, and the cutting wheel brake can no longer function correctly.

N Stop work and consult a STIHL

servicing dealer

0000-GXX-8851-A0

N Arrange for the cutting wheel brake

to be repaired

Maintain cutting wheel brake

The cutting wheel brake is subject to wear due to friction. In order for it to fulfill its function, it must be serviced and maintained periodically by trained personnel. STIHL recommends that maintenance and repair work be carried out only by authorized STIHL dealers.

N Note regarding necessary

maintenance and required repair of the cutting wheel brake will be provided to the user when starting the engine and releasing the cutting

0000-GXX-4257-A0

TS 440

English

1307BA001 KN

370BA085 KN

wheel brake, see section “Check function of the cutting wheel brake” and section “Releasing cutting wheel brake” in the chapter “Cutting wheel brake”

Electronic Water Control

STIHL cut-off machines may be equipped with an electronic water control system.

The electronic water control system makes it possible to feed the optimum amount of water to the abrasive wheel. No water is fed to the abrasive wheel during idling.

Before starting work

N Familiarize yourself with the

sequence of motions while the engine is switched off

N All of the control panel buttons can

be operated with the thumb of the right hand – the right hand always remains on the rear handle while doing so

N The left hand always remains on the

handlebar

Control panel

When the engine is running, you can activate/deactivate the electronic water control system and adjust the water flow.

1 Button (+):

activate the electronic water control or increase water flow to abrasive wheel

2 Button (–):

activate the electronic water control or decrease water flow to abrasive wheel

3 Deactivate the electronic water

control; no water is fed to the abrasive wheel

Using the electronic water control

N Start the engine, see

"Starting / Stopping the engine"

N Blip the (+) button or (–) button with

the thumb of your right hand – the right hand always remains on the rear handle while doing so, the left hand always remains on the handlebar – no water is fed to the abrasive wheel yet during idling

During use, the set amount of water is fed to the abrasive wheel.

N Adjust water flow if necessary – to

do so, blip the (+) button or (–) button with the thumb of your right hand until the correct water quantity is attained – the right hand always

TS 440

English

370BA086 KN

0813BA002 KN

370BA053 KN

remains on the rear handle while doing so, the left hand always remains on the handlebar

If the cut-off machine is idling after use, no more water will be fed to the abrasive wheel – the electronic water control, however, remains activated. On resuming use, the last quantity of water set will be fed to the abrasive wheel again automatically.

If the engine is stopped and restarted, the electronic water control is switched off.

Maintenance and Care

If too little water or no water is fed to the abrasive wheel during use although the electronic water control has been activated:

Mounting an Abrasive Wheel

The engine must be switched off for fitting or replacement – set slide control to STOP or 0.

Blocking the shaft

Removing the abrasive wheel

N Use the combination wrench to

loosen and remove the hexagon head screw (2)

N Remove the front thrust washer (3)

from the shaft together with the abrasive wheel

N Remove the coupling sleeve (1) N Unscrew "water connection with

screen" (2) and rinse under running water – the screen remains on the water connection

If too little water or no water is fed to the abrasive wheel even though the screen has been cleaned, contact your servicing dealer.

TS 440

N Slide the locking pin (1) through the

bore in the V-belt guard

N Actuate and hold the brake lever. N Turn the shaft with the combination

wrench until the locking pin (1) engages in the bore behind the guard

N Release brake lever

English

370BA054 KN

Fitting the abrasive wheel

N Fit the new abrasive wheel (4)

WARNING

Note the arrows indicating the direction of rotation on diamond abrasive wheels.

N Fit the front thrust washer (3). The

catches of the front thrust washer (3) must engage in the shaft grooves.

N Screw in the hexagon bolt and

tighten it with the combination wrench – if using a torque wrench, refer to the "Specifications" for the tightening torque

N Draw the locking pin out of the V-

belt guard

WARNING

Never use two abrasive wheels at the same time. The uneven wear creates a risk of breaking and an injury hazard!

Fuel

Your engine requires a mixture of gasoline and engine oil.

WARNING

For health reasons, avoid direct skin contact with gasoline and avoid inhaling gasoline vapor.

STIHL MotoMix

STIHL recommends the use of STIHL MotoMix. This ready-to-use fuel mix contains no benzol or lead, has a high octane rating and ensures that you always use the right mix ratio.

STIHL MotoMix uses STIHL HP Ultra two-stroke engine oil for an extra long engine life.

MotoMix is not available in all markets.

Mixing Fuel

NOTICE

Unsuitable fuels or lubricants or mix ratios other than those specified may result in serious damage to the engine. Poor quality gasoline or engine oil may damage the engine, sealing rings, hoses and the fuel tank.

Gasoline

Use only high-quality brand-name gasoline with a minimum octane rating of 90 – leaded or unleaded.

TS 440

English

370BA093 KN

Gasoline with an ethanol content of more than 10% can cause running problems in engines with a manually adjustable carburetor and should not be used in such engines.

Engines equipped with M-Tronic deliver full power when run on gasoline with an ethanol content of up to 25% (E25).

Engine Oil

If you mix the fuel yourself, use only STIHL two-stroke engine oil or another high-performance engine oil in accordance with JASO FB, JASO FC, JASO FD, ISO-L-EGB, ISO-L-EGC or ISO-L-EGD.

STIHL specifies STIHL HP Ultra twostroke engine oil or an equivalent highperformance engine oil in order to maintain emission limits over the machine’s service life.

Mix Ratio

STIHL 50:1 two-stroke engine oil: 50 parts gasoline to 1 part oil

Examples

Gasoline STIHL engine oil 50:1 Liters Liters (ml)

10.02(20) 5 0.10 (100) 10 0.20 (200) 15 0.30 (300) 20 0.40 (400) 25 0.50 (500)

N Use a canister approved for storing

fuel. Pour oil into canister first, then add gasoline and mix thoroughly.

Storing Fuel

Store fuel only in approved safety-type fuel canisters in a dry, cool and safe location protected from light and the sun.

Fuel mix ages – only mix sufficient fuel for a few weeks work. Do not store fuel mix for longer than 30 days. Exposure to light, the sun, low or high temperatures can quickly make the fuel mix unusable.

STIHL MotoMix may be stored for up to 2 years without any problems.

N Thoroughly shake the mixture in the

canister before fueling your machine.

WARNING

Pressure may build up in the canister – open it carefully.

N Clean the fuel tank and canister

from time to time.

Dispose of remaining fuel and cleaning fluid properly in accordance with local regulations and environmental requirements.

Fueling

Preparing the machine

N Before fueling, clean the filler cap

and the area around it so that dirt cannot fall into the tank

N Always position the machine so that

the filler cap is facing upwards

WARNING

Never use a tool to open the bayonet filler cap. The cap can be damaged and fuel may escape.

Opening the twist lock

N Press the filler cap down as far as

possible by hand, then turn it counterclockwise (approx. 1/8 turn) and remove

TS 440

English

370BA094 KN

370BA095 KN

370BA019 KN

0813BA003 KN

Refueling

Take care not to spill fuel while fueling and do not overfill the tank. STIHL recommends use of the STIHL filling system for fuel (special accessory).

Closing the filler cap

N Fit the cap and turn it until it

engages in the bayonet catch

N Press the cap down as far as

possible with your hand and turn it clockwise (approx. 1/8 of a turn) until it engages properly

Checking the lock

If the cap can be removed or the markings do not align, close the cap again – see sections "Closing the cap" and "Checking the lock".

Changing the fuel pickup body every year

N Drain the fuel tank N Pull the fuel pickup body out of the

tank with a hook and disconnect it from the hose

N Connect a new fuel pickup body to

the hose

N Return the fuel pickup body to the

tank

Starting / Stopping the Engine

Checking the correct operation of the abrasive wheel brake

Each time before starting work

N Pull up brake lever (1) toward

handlebar and hold it there – it should be possible to turn the abrasive wheel by hand

N Release brake lever (1) –the

abrasive wheel brake is engaged – the abrasive wheel cannot be turned by hand

N If the abrasive wheel can be turned

without operating the brake lever (1): Do not use the cut-off machine. Consult a STIHL servicing dealer. Have the abrasive wheel brake repaired.

The brake lever must be free of dirt and easily movable.

N Grip the cap – the cap is closed

properly if it cannot be removed and the markings (arrows) on the cap and fuel tank are aligned

TS 440

English

START

370BA020 KN

370BA055 KN

Choke

370BA101 KN

Starting the engine

N Press throttle trigger lockout (1) and

throttle trigger (2) simultaneously

N Hold both triggers down N Set the slide control (3) to START

and hold it there

N Release the throttle trigger, slide

control and throttle trigger lockout in succession – starting throttle position

Versions with decompression valve

N Set the choke lever (4) according to

the engine temperature

c if engine is cold e if engine is warm (even if the

engine is already running but is still cold or if the warm engine was shut off for less than 5 min)

f if engine is hot (if the hot engine

was switched off for longer than 5min)

N Press the button (5) of the

decompression valve before each starting procedure

TS 440

English

370BA102 KN

0000-GXX-1580-A0

370BA057 KN

Choke

370BA058 KN

START

For all versions

N Press the bulb (6) of the manual fuel

pump 7-10 times – even if the bulb is still filled with fuel

Starting

ground or any objects. There must not be anyone within the swivel range of the cut-off machine

N Make sure you have a firm footing N Press the cut-off machine firmly

against the ground, holding the handle with your left hand, thumb wrapped round the handle

N Press the cut-off machine against

the ground with your right knee on the shroud

N Pull the starter grip slowly with your

right hand until you feel it engage – then give it a brisk strong pull – do not pull out the starter rope all the way

NOTICE

Do not let the starter grip snap back – danger of breakage! Guide it back into the housing in the opposite direction so that it can rewind properly.

When the engine has turned over for the first time

N Set choke lever (4) to f position N Press the button of the

decompression valve (depending on version)

N continue cranking

Once the engine is running

N Place the cut-off machine carefully

on the ground, ensuring that the cutting wheel cannot touch the

N Blip the throttle trigger – slide

control (3) returns to the normal position F – the engine idles

N Set choke lever to e position

TS 440

Switch off the engine

0813BA004 KN

370BA085 KN

370BA059 KN

START

English

N Move brake lever toward handlebar

and release – the abrasive wheel brake is released

If the carburetor has been set correctly, the cutting wheel should not rotate when the engine is idling.

The cut-off machine is now ready for use.

NOTICE

The abrasive wheel brake must be released before opening the throttle and before cutting.

Increasing the engine speed with the abrasive wheel brake engaged will cause damage to the engine, clutch and abrasive wheel brake, even after only a short time.

If the abrasive wheel brake cannot be released with the engine running

The following causes are possible:

– Indication that the abrasive wheel

brake needs servicing

– Indication that the abrasive wheel

brake needs repair

N Hold down button (3) on control

panel for 3 seconds with the engine running

N Pull brake handle in the direction of

the handlebar and release

If that releases the abrasive wheel brake, the abrasive wheel brake needs servicing.

N Carry on working and consult a

STIHL servicing dealer after finishing the work

N Have the necessary servicing of the

abrasive wheel brake carried out

This procedure should be carried out afresh each time the engine is started. The number of such procedures is recorded in the controller.

If the abrasive wheel brake still cannot be released, the abrasive wheel brake needs repair.

N Stop work and consult a STIHL

servicing dealer

N Have the abrasive wheel brake

repaired

N Set the slide control (3) to

STOP or 0

Additional hints on starting

If the engine does not start The choke lever was not returned to f

in time after the engine turned over for the first time.

N Set slide control to START =

starting throttle position

N Set choke lever to e = set warm

start – even if the engine is cold

N Pull the starter rope through 10-20

times to ventilate the combustion chamber

N Restart the engine

If the tank has been drained completely

N Refueling N Press the manual fuel pump bulb

7-10 times – even if it is full of fuel

N Set the choke lever in accordance

with the engine temperature

N Restart the engine

TS 440

English

370BA028 KN

Air Filter System

Basic information

The average filter life is more than 1 year. Do not dismantle the filter cover or fit a new air filter unless there is a noticeable loss of engine power.

In the long-life air filter system with the cyclone pre-separation system, dirty air is drawn in and deliberately rotated. The larger and heavier particles carried in the air are thus expelled and extracted. Only pre-cleaned air enters the air filter system and the result is extremely long filter life.

Replacing the air filter

Only if there is a noticeable loss of engine power

N Choke lever to c N Undo the screws (1). N Remove the filter cover (2) and

clean it

N Remove the main filter (3) N Remove the auxiliary filter (4) –

ensuring that dirt does not enter the intake area

N Clean the filter area N insert new auxiliary filter and new

main filter

N Refit the filter cover N Tighten down the screws

Only high-quality air filters should be used, to protect the engine against ingress of abrasive dust.

STIHL recommends the use of genuine STIHL air filters. The high quality of these parts will ensure troublefree operation, a long service life for the engine and extremely long filter life.

TS 440

English

370BA029 KN

370BA090 KN

Adjusting the Carburetor

Basic information

The ignition system of this cut-off machine is equipped with an electronic speed limiter. The maximum speed cannot be increased beyond a specified limit.

The carburetor is equipped with a factory-installed standard setting.

The carburetor has been adjusted for optimum performance and fuel efficiency in all operating states.

Preparing the machine

N Switch off engine N Check the air filter – clean or replace

it if necessary

N Check the spark arresting screen in

the muffler – clean or replace it if necessary

Standard setting

N Turn the high speed adjusting

screw (H) counterclockwise as far as possible – max. 3/4 turn

N Turn the low speed adjusting

screw (L) clockwise as far as possible – then turn it 3/4 turn counterclockwise

Setting the idle speed

N Carry out the standard setting N Start engine and let it warm up

Engine stops when idling N Turn the idle speed adjusting

screw (LA) clockwise until the abrasive cutting wheel begins to turn – then turn it back 1 turn

Abrasive cutting wheel rotates when idling

N Turn the idle speed adjusting

screw (LA) counterclockwise until the abrasive cutting wheel stops rotating – then give the screw another full turn in the same direction

WARNING

If the abrasive cutting wheel continues to rotate in idle even after adjustment, have the cut-off machine checked by a servicing dealer.

Speed erratic when idling; poor acceleration (despite adjustment to LA setting)

The idle setting is too lean. N Turn the low speed adjusting

screw (L) approx. 1/4 turn counterclockwise until the engine runs and accelerates smoothly – max. up to the stop

Idle speed cannot be increased sufficiently via the idle speed adjusting screw (LA), engine stops when changing from part-load to idle speed

The idle setting is too rich. N Turn low speed adjusting screw (L)

approx. 1/4 turn clockwise

Whenever the low speed adjusting screw (L) has been adjusted, it is usually also necessary to readjust the idle speed adjusting screw (LA).

TS 440

English

370BA031 KN

1307BA030 KN

1307BA031 KN

Correcting the carburetor setting for use at high altitudes

The setting may have to be marginally corrected if engine performance is unsatisfactory at high altitudes:

N Carry out the standard setting N Allow engine to warm up N Turn the high speed adjusting

screw (H) slightly clockwise (leaner) – max. up to the stop

NOTICE

After descending from a high altitude, restore the carburetor setting to the standard setting.

If you make the setting too lean it will increase the risk of engine damage through lack of lubrication and overheating.

Spark Arresting Screen in Muffler

N If engine performance deteriorates,

check the spark arresting screen in the muffler.

WARNING

Wait until engine has cooled completely before performing the following operations.

N Remove screw (1) N Pull the spark arresting screen (2)

upward out of the muffler

N Clean the soiled spark arresting

screen

N If the screen is damaged or heavily

carbonized, fit a new one

N Refit the spark arresting screen in

reverse order of steps

Spark Plug

N If the engine is down on power,

difficult to start or runs poorly at idle speed, first check the spark plug.

N Fit a new spark plug after about 100

operating hours – or sooner if the electrodes are badly eroded. Install only suppressed spark plugs of the type approved by STIHL – see "Specifications".

Removing the spark plug

N Switch off the engine – move stop

switch to STOP or 0

N Unscrew screw (1) and remove

cap (2) – screw (1) is secured in the cap (2) to prevent loss

N Remove the spark plug boot (3). N Unscrew the spark plug (4).

TS 440

English

000BA039 KN

000BA045 KN

Checking the Spark Plug

N Clean dirty spark plug. N Check electrode gap (A) and

readjust if necessary – see "Specifications".

N Rectify the problems which have

caused fouling of the spark plug.

Possible causes are:

– Too much oil in fuel mix.

– Dirty air filter.

– Unfavorable running conditions.

N Use resistor type spark plugs with a

properly tightened adapter nut.

Installing the spark plug

N Fit the spark plug by hand and

screw it in

N Tighten spark plug with combination

wrench

N Press the spark plug boot firmly

onto the spark plug

N Position the cap for the spark plug

boot and screw it down

Storing the Machine

If the machine is to remain out of use for approx. 3 months or more

N Drain and clean the fuel tank in a

well ventilated place

N Dispose of fuel in accordance with

the regulations and having regard for the environment

N Run the engine until the carburetor

is dry, this helps to prevent the carburetor diaphragms sticking together

N Remove the abrasive wheel N Thoroughly clean the machine N Store machine in a safe and dry

place. Protect against unauthorized use (e. g., by children)

WARNING

Arcing may occur if the adapter nut (1) is loose or missing. Working in an easily combustible or explosive atmosphere may cause a fire or an explosion. This can result result in serious injuries or damage to property.

TS 440

English

Maintenance and Care

The information applies in normal operating conditions. The specified intervals must be shortened accordingly when working for longer than normal or under difficult cutting conditions (extensive dust, etc.).

Before starting work

At the end of work and/or

daily

Whenever tank is refilled

Weekly

Monthly

Yearly

If faulty

Complete machine

Controls Check operation XX

Cutting wheel brake, multi-rib belt

Manual fuel pump (if present)

Fuel pickup body in fuel tank

Fuel tank Clean X

Air filter (all filter components) Replace Only if there is a noticeable loss of engine power

Cooling air intake slits Clean X

Cylinder fins

Spark arresting screen in muffler

Water connection

Carburetor

Spark plug

Visual inspection (condition, leaks) XX

Clean X

Check operation X

Have them repaired by a specialist

dealer

Inspect X

Have it repaired by a specialist

dealer

Inspect X

Replace XXX

Have them cleaned by a specialist

dealer

Inspect X

Clean or replace X

Inspect XX

Have it repaired by a specialist

dealer

Check idle adjustment – abrasive cutting wheel must not rotate

Readjust idle speed X

Adjust electrode gap X

Replace after 100 hours’ operation

If damaged

As required

TS 440

Before starting work

At the end of work and/or

daily

Whenever tank is refilled

Weekly

Monthly

Yearly

If faulty

All accessible screws, nuts and bolts (not adjusting screws)

Antivibration elements

Abrasive cutting wheel

Supports/rubber buffers (underneath the machine)

Safety information label Replace X

STIHL recommends the STIHL servicing dealer

Tighten XX

Inspect XXX

Have them replaced by a servicing

dealer

Inspect XX

Replace XX

Inspect X

Replace XX

If damaged

English

As required

TS 440

English

0813BA005 KN

Main Parts

1 Rear handle 2 Throttle trigger lockout 3 Throttle trigger 4 Slide control 5 Starter grip 6 Carburetor adjusting screws 7 Filler cap 8 Water connection 9 Brake lever 10 Adjusting lever 11 Abrasive cutting wheel 12 Front thrust washer 13 Guard 14 Muffler 15 Spark arresting screen 16 Handlebar 17 Decompression valve 18 Cap for spark plug boot 19 Choke shutter lever 20 Manual fuel pump 21 Filter cover # Machine no. A Safety information label B Safety information label C Safety information label

TS 440

English

Specifications

Engine

STIHL single-cylinder two-stroke engine

Displacement: 66.7 cc Cylinder bore: 50 mm Piston stroke: 34 mm Engine power accord-

ing to ISO 7293: Idle speed: 2700 rpm Max. spindle speed to

ISO 19432: 2525 rpm

Ignition system

Electronic magneto ignition

Spark plug (suppressed): Bosch WSR 6 F

Electrode gap: 0.5 mm

Fuel system

All-position diaphragm carburetor with integral fuel pump

Fuel tank capacity: 710 cc (0.71 l)

Air filter

Main filter (paper filter) and flocked wire mesh auxiliary filter

3.2 kW (4.4 HP) at 9000 rpm

Weight

Without fuel, without abrasive cutting wheel, with electronic water control:

11.1 kg

Abrasive cutting wheels

The specified maximum permitted operating speed of the abrasive cutting wheel must be greater than or equal to the maximum spindle speed of the cutoff machine used.

Outside diameter: 350 mm Max. thickness: 4.8 mm Bore diameter/spindle

diameter: 20 mm Tightening torque: 30 Nm

Composite resin abrasive cutting wheels

Minimum outside diameter of thrust washers:

Maximum cutting depth:

For Japan 118 mm

For Australia 118 mm

When using thrust washers with an

1) 2)

103 mm 125 mm

outside diameter of 118 mm, the maximum cutting depth is reduced to 116 mm

Diamond abrasive cutting wheels

Minimum outside diameter of thrust washers:

Maximum cutting depth:

For Japan 118 mm

When using thrust washers with an

103 mm 125 mm

outside diameter of 118 mm, the maximum cutting depth is reduced to 116 mm

Sound and vibration levels

For further details concerning compliance with the Employers’ Directive on Vibration 2002/44/EC, see www.stihl.com/vib

Sound pressure level L

peq

DIN EN ISO 19432

98 dB(A)

Sound power level Lw to DIN EN ISO 19432

109 dB(A)

Vibration level a

hv,eq

DIN EN ISO 19432

Left handle: 3.6 m/s Right handle: 3.9 m/s

The K-factor in accordance with Directive 2006/42/EC is 2.0 dB(A) for the sound pressure level and sound power level; the K-factor in accordance with Directive 2006/42/EC is 2.0 m/s

for the vibration level.

TS 440

English

000BA073 KN

REACH

REACH is an EC regulation and stands for the Registration, Evaluation, Authorisation and Restriction of Chemical substances.

For information on compliance with the REACH regulation (EC) No. 1907/2006 see www.stihl.com/reach.

Exhaust Emissions

The CO2value measured in the EU type approval procedure is specified at www.stihl.com/co2.

The measured CO

value was

determined on a representative engine in accordance with a standardized test procedure under laboratory conditions and does not represent either an explicit or implied guarantee of the performance of a specific engine.

The applicable exhaust emission requirements are fulfilled by the intended usage and maintenance described in this instruction manual. The type approval expires if the engine is modified in any way.

Maintenance and Repairs Disposal

Users of this machine may only carry out the maintenance and service work described in this user manual. All other repairs must be carried out by a servicing dealer.

STIHL recommends that you have servicing and repair work carried out exclusively by an authorized STIHL servicing dealer. STIHL dealers are regularly given the opportunity to attend training courses and are supplied with the necessary technical information.

When repairing the machine, only use replacement parts which have been approved by STIHL for this power tool or are technically identical. Only use highquality replacement parts in order to avoid the risk of accidents and damage to the machine.

STIHL recommends the use of original STIHL replacement parts.

Original STIHL parts can be identified by the STIHL part number, the { logo and the STIHL parts symbol K (the symbol may appear alone on small parts).

Observe all country-specific waste disposal rules and regulations.

STIHL products must not be thrown in the garbage can. Take the product, accessories and packaging to an approved disposal site for environmentfriendly recycling.

Contact your STIHL servicing dealer for the latest information on waste disposal.

TS 440

English

EC Declaration of Conformity

ANDREAS STIHL AG & Co. KG Badstr. 115 D-71336 Waiblingen

declares under our sole responsibility that

Designation: Cut-off machine Make: STIHL Series: TS 440 Serial identification

number: Displacement: 66.7 cc

conforms to the provisions for implementing the Directives 2011/65/EU, 2006/42/EC, 2014/30/EU and 2000/14/EC and has been developed and manufactured in compliance with the following standards in the versions valid on the date of production:

EN ISO 19432, EN 55012, EN 61000-6-1

The measured and the guaranteed sound power level have been determined in accordance with Directive 2000/14/EC, Annex V, and standard ISO 3744.

Measured sound power level

4238

The year of manufacture and serial number are applied to the product.

Done at Waiblingen, 03.02.2020

ANDREAS STIHL AG & Co. KG

Dr. Jürgen Hoffmann

Head of Product Data, Regulations and Licensing

113 dB(A)

Guaranteed sound power level

115 dB(A)

Technical documents deposited at:

ANDREAS STIHL AG & Co. KG Produktzulassung

TS 440

0458-520-8321-A

AUS

www.stihl.com

*04585208321A*

0458-520-8321-A

Stihl TS 440 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual