STIHL TS 500i Instruction Manual
STIHL TS 480i, 500i
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.
{
Instruction Manual
Manual de instrucciones
Instruction Manual
1 - 48
Manual de instrucciones
49 - 101
Contents
English
Guide to Using this Manual 2
Safety Precautions and Working
Techniques 3
Sample applications 16
Cutting wheels 20
Composite resin cutting wheels 20
Diamond cutting wheels 21
Electronic water control 24
Original Instruction ManualPrinted on chlorine-free paper
Assembling the cast arm and guard 25
Tensioning the ribbed V-belt 29
Fitting / replacing an abrasive
wheel 29
Fuel 31
Fueling 31
Starting / Stopping the Engine 32
Air Filter System 34
Engine Management 35
STIHL Injection 35
Spark Arresting Screen in Muffler 35
Spark Plug 36
Rewind Starter 37
Replacing the V-belt 37
Printing inks contain vegetable oils, paper can be recycled.
Cut-off machine cart 38
Storing the Machine 39
Maintenance and Care 40
Main Parts 42
Specifications 44
Maintenance and Repairs 45
Disposal 45
STIHL Incorporated Federal
Emission Control Warranty
Statement 46
Trademarks 48
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 your cut-off
machine. 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 highspeed cutting tool, some special safety
precautions must be observed to reduce
the risk of personal injury. Careless or
improper use may cause serious or even
fatal injury.
{
© ANDREAS STIHL AG & Co. KG, 2014
0458-753-8621-B. VA7.L14.
0000006169_009_GB
TS 480i, TS 500i
This instruction manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process
with electronic systems.
1
English
Guide to Using this Manual
Pictograms
The meanings of the pictograms
attached to or embossed on the
machine are explained in this manual.
Depending on the model concerned, the
following pictograms may be on your
machine.
Fuel tank for gasoline
and engine oil mixture
Press to operate decompression valve
Press to operate manual
fuel pump
Water attachment, flow
control
Tensioning nut for engaging drive belt
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. 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 an imminent risk of severe or
fatal injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in severe or
fatal injury.
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.
Pull starter grip
2
Indicates a risk of property damage,
including damage to the machine or its
individual components.
TS 480i, TS 500i
NOTICE
English
Safety Precautions and
Working Techniques
The use of any cut-off
machine may be hazardous. Because a cut-off
machine is a high-speed,
fast-cutting power tool,
special safety precautions must be observed to
reduce the risk of personal injury and fire.
It is important that you
read, fully understand
and observe the following
safety precautions and
warnings. Read the
instruction manual and
the safety precautions
periodically.
WARNING
Careless or improper use of any cut-off
machine may cause serious or fatal
injury.
Have your STIHL dealer show you how
to operate your cut-off machine.
Observe all applicable national, state
and local safety regulations, standards
and ordinances.
WARNING
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.
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. These
safety precautions and warnings apply
to the use of all current STIHL Cutquiks.
WARNING
Use your cut-off machine only for
authorized uses. For instance, it is not
suitable for cutting wood or wooden
objects. Misuse may result in 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.
Different models may have different
parts and controls. See the appropriate
section of your instruction manual for a
description of the controls and function
of the parts of your model cut-off
machine.
Safe use of a cut-off machine involves
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;
tiredness may result in loss of control.
Working with any cut-off machine can be
strenuous. If you have any condition that
might be aggravated by strenuous work,
check with your doctor before operating
a cut-off machine.
WARNING
Prolonged use of cut-off machines (or
other machines) exposing the operator
to vibrations may produce whitefinger
disease (Raynaud's phenomenon) or
carpal tunnel syndrome. These
conditions reduce the hand's ability to
feel and regulate temperature, produce
numbness and burning sensations and
cause nerve and circulation damage and
tissue necrosis. All factors which
contribute to whitefinger disease are not
known, but cold weather, smoking and
diseases or physical conditions that
affect blood vessels and blood transport,
as well as high vibration levels and long
periods of exposure to vibration are
mentioned as factors in the development
of whitefinger disease. In order to
reduce the risk of whitefinger disease
and carpal tunnel syndrome, please
note the following:
TS 480i, TS 500i
3
English
– STIHL cut-off machines are
equipped with an anti-vibration
("AV") system designed to reduce
the transmission of vibrations
created by the machine to the
operator's hands. An AV system is
recommended for those persons
using cut-off machines on a regular
or sustained basis.
– Wear gloves and keep your hands
warm.
– Keep the AV system well
maintained. A cut-off machine with
loose components or with damaged
or worn AV elements will tend to
have higher vibration levels.
– Maintain a firm grip at all times, but
do not squeeze the handles with
constant, excessive pressure. Take
frequent breaks.
All the above-mentioned precautions do
not guarantee that you will not sustain
whitefinger disease or carpal tunnel
syndrome. Therefore, continual and
regular users should monitor closely the
condition of their hands and fingers. If
any of the above symptoms appear,
seek medical advice immediately.
WARNING
The ignition system of your unit
produces an electromagnetic field of a
very low intensity. This field may
interfere with some pacemakers. To
reduce the risk of serious or fatal injury,
persons with a pacemaker should
consult their physician and the
pacemaker manufacturer before
operating this tool.
Proper Clothing
WARNING
To reduce the risk of injury, the operator
should wear proper protective apparel.
Clothing must be sturdy
and snug-fitting, but allow
complete freedom of
movement. Avoid 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 unit. Wear overalls
or long pants to protect
your legs. Do not wear
shorts.
WARNING
When cutting metal, a cut-off machine
generates sparks that can ignite
clothing. Most fabrics used in clothing
are flammable – even flame-retardant
fabrics will ignite at higher temperatures.
To reduce the risk of burn injury STIHL
recommends wearing clothing made of
leather, wool, flame-retardant-treated
cotton or a tightly woven, heavier cotton
such as denim. Some flame-retardant
synthetic fabrics are also suitable, but
others such as polyester, nylon, rayon
and acetate can melt during a fire into a
tar-like matter that burns into the skin.
Check the clothing manufacturer's
instructions. Keep clothing free of oil,
fuel, grease and other flammable
substances.
Always wear heavy duty
work gloves (e.g. made of
leather or other wear
resistant material) when
handling the cut-off
machine. Heavy-duty,
nonslip gloves improve
your grip and help to protect your hands.
Good footing is important
in cut-off machine work.
Wear sturdy boots with
nonslip soles. Steel-toed
safety boots are
recommended.
WARNING
Loose objects may be thrown toward the
operator by the cutting tool.
To reduce the risk of
injury to your eyes never
operate a cut-off machine
unless wearing goggles
or properly fitted safety
glasses with adequate
top and side protection
complying with
ANSI 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
mufflers) to help protect your hearing.
Regular users should have their hearing
checked regularly.
4
TS 480i, TS 500i
English
WARNING
When wet cutting at the
recommended flow rate
is not utilized, the operator should always wear a
respirator approved by
NIOSH/MSHA for the
material being cut to
reduce the risk of serious
or fatal respiratory illness.
For additional details and
warnings on this subject,
see information under
"Working Conditions" in
this instruction manual.
THE 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
with the STIHL powerhead, their use
may, in fact, be extremely dangerous.
Abrasive Wheels
WARNING
Before mounting the cutting wheel,
make sure that the maximum operating
wheel speed is above or equal to the
spindle speed of your cut-off machine as
provided in the specifications of this
manual. A wheel that is not so rated may
shatter or break and poses a threat of
serious or fatal injury to the operator and
other nearby persons.
Abrasive wheels for free-hand cutting
are subjected to particularly high
bending and compression stresses.
WARNING
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 and
wheel breakage.
WARNING
Wheels that are not STIHL branded may
be more likely to shatter or 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
Inspect the abrasive
wheel frequently and
replace immediately if the
abrasive wheel is
cracked or warped.
Cracked or warped
wheels may shatter or
break and cause serious
or fatal personal injury.
Out-of-round or unbalanced abrasive wheels
increase vibration and
reduce the service life of
the cut-off machine.
Some diamond abrasive wheels that are
not STIHL branded utilize poor quality
steel cores, are not properly tensioned,
or have other design or manufacturing
defects. As a result, they may begin to
wobble during use, which can cause
wheel breakage. Such wobbling can
also lead to a severe binding of the
wheel in the kerf, that, under certain
circumstances, can then result in
serious or fatal injury from reactive
forces. See the section entitled
"Reactive Forces including Kickback."
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.
Composite abrasive wheels are heat
sensitive. Always store your cut-off
machine in a place where a composite
wheel is not exposed to direct sunlight or
other sources of heat. Store spare
composite 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.
TS 480i, TS 500i
5
English
WARNING
Never use circular saw
blades, carbide tipped
blades, rescue blades,
wood-cutting blades or
toothed blades of any
nature. They can cause
severe personal injury
from blade contact,
thrown objects and/or
reactive forces, including
kickback. See section on
"Reactive Forces." Your
STIHL dealer stocks a
range of special abrasive
wheels for the many
applications of the cut-off
machine.
WARNING
Use of the wrong abrasive wheel or the
cutting of material for which the wheel
was not designed may cause the wheel
to wobble, shatter or increase reactive
forces, causing serious or fatal injury.
See below and section on "Reactive
Forces."
Only use the abrasive wheel approved
for the type of material to be cut. There
are different types of abrasive wheels,
each specially marked. With respect to
STIHL composite wheels, for example:
1. Stone
Also can be used for concrete,
masonry, reinforced concrete and
brick cutting.
2. Steel
Can be used for all ferrous metal
cutting.
3. Asphalt
Also can be used for aggregate
concrete cutting.
4. Ductile iron
Also can be used for certain grades
of cast iron (SG 17-24), bronze and
copper cutting.
For cutting composite materials please
ask your STIHL dealer.
Diamond Abrasive Wheels
Diamond abrasive wheels have a much
better cutting performance than
composite abrasive wheels. The
diamond wheels are steel centered, and
diamond particles are imbedded in their
cutting edges.
They can be used for concrete, asphalt,
natural stone, clay pipe, brick and the
like. STIHL also offers diamond wheels
for cutting ductile iron and some
structural steel.
They are not, however, suitable for
cutting all metals and other materials.
Wet or dry cutting is possible. Water
attachments are included with your
STIHL cut-off machine. See the
appropriate section of your instruction
manual.
WARNING
Do not remount a used diamond
abrasive wheel without first inspecting
for under-cutting, flatness, core fatigue,
segment damage or loss, signs of
overheating (discoloration) and possible
arbor hole damage. See the chapter
"Diamond Cutting Wheels." Check the
wheel for cracks and make sure that no
pieces have broken off the wheel before
use.
Always fit the wheel so that the arrow on
the wheel points in the direction of the
rotation of the spindle.
THE USE OF THE POWER TOOL
Transporting the STIHL Cutquik
WARNING
To reduce the risk of injury from
unintended activation and/or contact
with a moving wheel, always stop the
engine before putting a cut-off machine
down or carrying it. The abrasive wheel
continues to rotate (coast down) for a
short while after the throttle trigger is
released (flywheel effect). Bring the
wheel to a stop by lightly contacting the
bottom of the wheel with a hard surface
or wait until the wheel comes to a
complete stop on its own. Carrying a cutoff machine with the engine running is
extremely dangerous. Accidental
acceleration of the engine can cause the
wheel to rotate. Avoid touching the hot
muffler.
By hand: When carrying your cut-off
machine by hand, the engine must be
stopped and the cut-off machine must
be in the proper position. Grip the front
handle and place the muffler at the side
away from the body with the cutting
attachment to the rear.
WARNING
Always protect the cutting wheel from
hitting the ground or any other objects.
Damaged wheels may shatter and
cause serious or fatal injury.
6
TS 480i, TS 500i
English
By vehicle: Properly secure your cut-off
machine to prevent turnover, fuel
spillage and damage to the cut-off
machine. Never transport with cutting
wheel mounted. A wheel damaged
during transportation may shatter during
operation and cause serious personal
injury.
Fuel
Your STIHL power tool uses an oil-
gasoline mixture for fuel (see the
chapter on "Fuel" of your instruction
manual.)
WARNING
Gasoline is an extremely
flammable fuel. If spilled
and ignited by a spark or
other ignition source, it
can cause fire and serious burn injury or
property damage. Use
extreme caution when
handling gasoline or fuel
mix. Do not smoke or
bring any fire or flame
near the fuel or the power
tool. Note that combustible fuel vapor may
escape from the fuel
system.
WARNING
Dust may collect on the powerhead and
may absorb gasoline resulting in a risk of
fire. Clean dust from the powerhead
regularly.
Fueling Instructions
WARNING
Fuel your power tool in well-ventilated
areas, outdoors. Always shut off the
engine and allow it to cool before
refueling. Gasoline vapor pressure may
build up inside the fuel tank depending
on the fuel used, the weather conditions
and the tank venting system.
In order to reduce the risk of burns and
other personal injury from escaping gas
vapor and fumes, remove the fuel filler
cap on your power tool carefully so as to
allow any pressure build-up in the tank
to release slowly. Never remove the fuel
filler cap while the engine is running.
Select bare ground for fueling and move
at least 10 feet (3 m) from the fueling
spot before starting the engine. Wipe off
any spilled fuel before starting your
machine.
WARNING
Check for fuel leakage
while refueling and during
operation. If fuel leakage
is found, do not start or
run the engine until the
leak is fixed and any
spilled fuel has been
wiped away. Take care
not to get fuel on your
clothing. If this happens,
change your clothing
immediately.
WARNING
If fuel gets spilled on clothes, especially
trousers, it is very important to change
clothes immediately. Do not rely upon
evaporation. Flammable quantities of
fuel may remain on clothes after a spill
for longer than expected. Cutting metal
with a cut-off machine when clothes are
wet or damp from gasoline is extremely
dangerous, as the operator's clothes
might catch fire and cause serious or
fatal injury.
WARNING
An improperly tightened fuel cap can
loosen or come off and spill quantities of
fuel.
Bayonet Fuel Filler Cap
Never use a tool to open or close the
bayonet fuel filler cap, as this could
damage the cap and cause fuel to leak
out.
The bayonet fuel filler cap must be
securely closed after refuelling.
WARNING
Never attempt to force the cap open by
using a tool. It may damage the cap and
allow fuel to leak.
TS 480i, TS 500i
7
English
002BA058 KN
WARNING
Before use, make sure that the fuel cap
has been completely and properly
tightened and any spilled fuel wiped
away. Check for fuel leakage while
refueling and during operation. If a fuel
leak is suspected, do not start or run the
engine until the leak is fixed and spilled
fuel has been wiped away.
Before Starting
For wheel installation, follow the
procedure described in the appropriate
sections of your instruction manual.
Check the fuel system for leaks by
turning the machine in all operating
positions and inspecting all relevant
parts of that system that are visible, e.g.,
filler cap, hose connection, fuel pump
and tank. Do not start the unit if there are
leaks or damage to the fuel system – risk
of fire! Have the machine repaired by a
servicing dealer before using it.
Never operate a cut-off machine that is
damaged, improperly adjusted or not
completely and securely assembled.
Check machine that it is ready for proper
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) and the safety devices are
working properly, the wheel is properly
mounted, and the wheel guard is in
place and securely fastened to your unit.
All wheels should be carefully inspected
for good condition before mounting.
Adjust the wheel guard
so that sparks, dust and
cut material are deflected
away from the operator,
and cannot reach flammable surroundings. See
section "Operating
Instructions" of your
instruction manual.
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 and cause a
fire.
Proper tensioning of the ribbed V-belt is
important. In order to avoid an incorrect
setting, the tensioning procedure must
be followed as described in your
manual. Always make sure the
hexagonal collar nuts for the cast arm
are tightened securely.
Check ribbed belt tension after one hour
of operation and correct if necessary.
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. For specific starting
instructions, see the appropriate section
of your instruction manual.
Do not drop start. This method is very
dangerous because you may lose
control of the cut-off machine. Place the
cut-off machine on firm ground or other
solid surface in an open area. Maintain
good balance and secure footing. Be
absolutely sure that the cutting wheel is
clear of you and all other obstructions
and objects, including the ground. When
the engine starts at starting position,
engine speed will be fast enough for the
clutch to engage the belt pulley and turn
8
TS 480i, TS 500i
English
the wheel. Never attempt to start the cutoff machine when the abrasive wheel is
in a cut.
Once the engine has started,
immediately blip the throttle trigger,
which should release the starting
position and allow the engine to slow
down to idle.
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.
WARNING
At correct idle speed, the wheel should
not turn. Do not use a cut-off machine
with incorrect idle speed adjustment.
The rotating wheel may cause injury. If
the wheel rotates, 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 of hearing protection reduces
sound perception. Be alert not to miss
voice signals from co-workers. Keep
within calling distance to other persons
who may assist in case of emergency.
WARNING
As soon as the engine is
running, this product 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. Some
of the gases (e.g. carbon
monoxide) may be colorless and odorless. 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. If you are unfamiliar
with the risks associated with the
particular material being cut, review the
material safety data sheet and/or consult
your employer, the material
manufacturer/supplier, governmental
agencies such as OSHA and NIOSH
and other sources on hazardous
materials. California and some other
authorities, for instance, have published
lists of substances known to cause
cancer, reproductive toxicity, etc.
Control dust and fumes at the source
where possible.
In this regard use good work practices
and follow the recommendations of the
manufacturer/supplier, OSHA/NIOSH,
and occupational and trade
associations. A water attachment kit is
provided with your cut-off machine and
should be used to reduce dust whenever
wet cutting is feasible. For dust
suppression purposes, the flow rate
should be at least 0.6 liters (20 fl.oz) of
water per minute. If wet cutting at the
recommended flow rate is not utilized,
the operator and any bystanders should
always wear a respirator approved by
NIOSH/MSHA for the material being cut.
See the section on "Respiratory
Protection" in the chapter "Sample
Applications" in the instruction manual.
Even if wet cutting at the recommended
flow rate, an operator who is actively
cutting for more than two hours in one
day should wear at least a NIOSHapproved disposable respirator. Consult
and follow any federal, state or local
laws or regulations with respect to dry
and wet cutting.
WARNING
Cutting masonry, concrete and other
materials with silica in their composition
may give off dust containing crystalline
silica. Silica is a basic component of
sand, quartz, brick clay, granite and
numerous other minerals and rocks.
Repeated and / or substantial inhalation
of airborne crystalline silica can cause
serious or fatal respiratory diseases,
including silicosis. In addition, California
TS 480i, TS 500i
9
English
002BA549 AM
and some other authorities have listed
respirable crystalline silica as a
substance known to cause cancer.
When cutting such materials, always
follow the respiratory precautions
mentioned above.
WARNING
Breathing asbestos dust is dangerous
and can cause severe or fatal injury,
respiratory illness or cancer. The use
and disposal of asbestos-containing
products have been strictly regulated by
OSHA and the Environmental Protection
Agency. Do not use your cut-off machine
to cut or disturb asbestos, asbestoscontaining products, or products such as
pipes which are wrapped or covered
with asbestos insulation. If you have any
reason to believe that you might be
cutting asbestos, immediately contact
your employer or a local OSHA
representative.
WARNING
Your STIHL cut-off machine is designed
for hand-held use or operation on a cutoff machine cart. Cutting with your cutoff machine resting on the ground or
other surface can cause excessive wear
to the bracket designed to protect the
bottom of the tank housing. Loss of fuel
and personal injury from fire may result.
Replace damaged or badly worn
brackets immediately.
Grip: Never use the cut-off machine with
one hand. Always hold the cut-off
machine firmly with both hands when the
engine is running. Place your left hand
on front handle bar and your right hand
on rear handle and throttle trigger. Lefthanded users should follow this
instruction too.
Wrap your fingers tightly around the
handles, keeping the handles cradled
between your thumbs and forefingers.
Make sure your cut-off machine handles
and grip are in good condition and free
of moisture, pitch, oil, fuel mix or grease.
Never touch a rotating wheel with your
hand or any part of your body.
WARNING
Clear the area where you are working.
Avoid stumbling on obstacles and watch
out for holes or ditches. Be extremely
cautious when working on slopes or
uneven ground. Take extreme care in
wet and freezing weather (rain, snow,
ice.)
WARNING
Sparks from cutting metal
can burn or cause clothing to catch fire. Always
direct sparks away from
the operator or any flammable surroundings.
Never cut metal while
standing on a flammable
surface, such as wood or
tar paper. Where there is
a risk of fire, have appropriate fire extinguishing
equipment readily
available.
WARNING
To reduce the risk of injury from fire, do
not cut into any pipe, drum or other
container without first ensuring that it
does not contain a volatile or flammable
substance.
WARNING
When cutting into existing walls, floors or
similar structures, be alert for hidden
hazards such as electrical cables, water
and gas pipes and flammable
substances. Make sure that power,
water and gas have been shut off and
pipes drained before starting to cut.
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TS 480i, TS 500i
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Operating Instructions
WARNING
The wheel guard is adjustable. It is
extremely important that the wheel
guard is in place and set to suit the type
of work and your stance. The guard
should always be adjusted so that the
user is not endangered by particles of
the material being cut, sparks or pieces
of damaged wheels either directly or by
ricochet. Failure to follow this instruction
could result in serious or fatal injury.
WARNING
Your cut-off machine is equipped with a
wheel guard limit stop that restricts the
positioning of the wheel guard. To
reduce the risk of injury from wheel
contact and/or reactive forces and to
avoid damaging the guarding system,
never attempt to pull the adjusting lever
past the limit stop.
WARNING
Always check the wheel before use and
after unintentionally striking any object;
frequently check it during use when it is
stopped. Look for cracks and make sure
that it is undamaged and in good
condition and that no pieces have
broken off. See sections on "Abrasive
Wheels" and "Reactive Forces" in this
manual. Check the wheel guard for
cracks. If you discover any breaks or
cracks, fit a new guard before further
use.
WARNING
It is essential to determine the exact
direction of the cut before applying the
002BA550 AM
abrasive wheel to the work. Wheels are
constructed for radial pressure only.
Lateral pressure must be avoided. Hold
the cut-off machine steady. To reduce
the risk of serious or fatal injury, do not
change the direction of the cut during the
cut as this may produce a high torsional
load on the abrasive wheel and may
cause it to bind, break or shatter. A
binding of the wheel can also result in
reactive forces. See section on
"Reactive Forces."
WARNING
Do not use abrasive wheels for rough
grinding. Large bending stresses occur
during such work, which may cause
abrasive wheels to shatter or break and
result in serious or fatal injury.
WARNING
To reduce the risk of injury from
shattered abrasive wheels:
1. Do not exceed the maximum
operating speed marked on the
wheel.
2. Do not use a wheel that has been
dropped.
3. Test each new wheel immediately
after installation for approximately
one minute at maximum speed
without cutting, making sure to keep
bystanders away.
4. Do not cut any material for which the
abrasive wheel is not authorized.
5. Do not grind on the side of the
abrasive wheel.
6. Do not twist, thrust, knock or drop
the machine. This can cause
damage to the wheel.
To achieve a clean and efficient cut, pull
the abrasive wheel across the work or
move it "to and fro" in the cutting
direction. Do not use force to push the
abrasive wheel into the work.
Insert the wheel into the material only as
deep as necessary to make the cut. To
reduce the amount of dust created, do
not cut all the way through stone and
concrete materials – leave a thin piece
uncut. For most such materials, this
piece can be easily broken afterwards.
Do not cock, jam or wedge the wheel in
the cut.
Always stop the engine and be sure the
wheel has stopped rotating before
setting down the cut-off machine.
If a cut-off machine cart is used, sweep
debris from the path of the wheels, as
debris under one of the cart’s wheels
may cause flexing of the abrasive wheel.
This could result in high frictional forces
and thus greatly reduce the engine
power available for the actual cutting
work. It could also damage the abrasive
wheel.
STIHL recommends the use of the cart
for longer cuts in a straight line.
TS 480i, TS 500i
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English
002BA553 AM
Wet Cutting with Abrasive Wheels
Before wet cutting, make sure water will
not damage the floor or building.
WARNING
To reduce the risk of electrocution to you
or bystanders, do not allow water or
sludge to contact live electric wires.
WARNING
To reduce the risk of injury from wheel
breakage when wet cutting with any
composite wheel:
1. Make certain water does not flow on
a wheel that is not running, since the
wheel will absorb water, which will
affect wheel balance.
2. Be certain water is applied to both
sides of wheel, since uneven
distribution can cause "one sided"
wear.
3. After finishing work, run the cutting
wheel at normal operating speed for
about 3 to 6 seconds without water
so that the remaining water is flung
off.
WARNING
To reduce the risk of injury from wheel
breakage when wet cutting with a
composite wheel that is not specifically
designed for wet cutting, never store and
reuse such a wheel that has been used
with water. Use these wheels up the
same day.
Reactive Forces including Kickback
WARNING
Reactive forces may
occur at any time the cutting wheel on a cut-off
machine is rotating.
The powerful force used to cut through a
workpiece can be reversed and work
against the operator. If the wheel is
slowed or stopped 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 may help you avoid loss
of control. Reactive forces are exerted in
a direction opposite to the direction in
which the wheel is moving at the point of
contact or of pinching/binding. If the
wheel is slowed solely by frictional
contact with a solid object, such as the
workpiece, 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 pinch or severe 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
The most common reactive forces are
pull-away and climbing. If the contact is
at the bottom of the wheel, a cut-off
machine will try to pull away from the
operator (pull-away.) If the contact is at
the front of the wheel, the wheel may
attempt to climb the object being cut
(climbing.)
Pinching occurs when the piece being
cut closes on the wheel. A severe
binding may also occur if the wheel is
substantially sideloaded in the kerf or if
an improper or damaged diamond wheel
begins or ceases to wobble in the kerf. If
the wheel is severely pinched or bound
in the upper quadrant, the wheel may be
instantly thrown up and back towards
the operator with great force in a
rotational kickback motion. Such
kickback situations can and should
always be avoided. Pinching of the
wheel can be prevented by proper
support of the workpiece. (See below.)
Severe binding of the wheel can be
prevented by proper cutting techniques,
e.g., not sideloading the wheel, and by
the use of properly designed,
manufactured and maintained wheels.
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002BA146 KN
002BA603 KN
Reducing the Risk of Kickback Injury
WARNING
To reduce the risk of kickback injury,
avoid cutting with the upper quadrant of
the wheel where possible. Be especially
cautious for a pinching or binding of the
wheel in this area, which can cause
severe reactive forces in a rotational
kickback motion.
Avoid wedge action. The severed part
must not bind the abrasive wheel.
Be alert to potential movement of the
workpiece or anything else that could
cause the cut to close and pinch the
wheel. In order to reduce the risk of
pinching, 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 cutting technique that is not
subject to kickback.
Where there is a possibility of a pinch,
you can leave an uncut part that
prevents the kerf from closing and
pinching the wheel, which can later be
broken manually. If you are making a
002BA582 ST
complete cut, make sure that the final,
separating cut is made at the top of the
workpiece with the bottom of the wheel.
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 pullaway.
Objects to be cut must therefore be
properly supported and must be secured
against rolling away, slipping or
vibrations.
Support an exposed pipe in a trench so
that it is stable and capable of bearing
weight. 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
surfaces.
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. That section can also be
supported by means of a strap from
above, e.g., suspended from a backhoe.
It must be evenly supported and
properly tensioned, however, so that the
section remains in its position and does
not tend to go up or down as a whole or
on one side when separated.
Always pay attention in
subgrade/subsurface work areas –
supporting material can crumble or slide
away.
TS 480i, TS 500i
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WARNING
Be particularly alert when cutting a
workpiece such as a pipe with a belled
end or 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 not where you are
actually cutting but, rather, at or near the
top of the workpiece. If the pinch is in the
upper quadrant of the abrasive wheel,
kickback can result.
WARNING
Use wet-cutting whenever feasible,
since the water can act as a lubricant in
a pinch situation and thus reduce the
likelihood of reactive forces occurring
and the energy of any such forces that
do occur, making it easier to maintain
control of the machine.
WARNING
Only STIHL branded cutting
attachments are recommended. Use of
certain non-STIHL branded wheels may
be extremely dangerous. Many
substandard diamond wheels, for
instance, are available in the market. If
they are not manufactured with the
proper quality steel in their core, if they
are not properly tensioned, or if other
design or manufacturing defects exist,
they may, e.g., begin to wobble during
use, lose segments or exhibit other
operational problems that can
substantially increase the risk of
personal injury or death. If a diamond
wheel begins or ceases to wobble within
the kerf, 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 under certain
conditions.
WARNING
Some other non-STIHL branded
diamond wheels are manufactured with
abrasive material on their sides. Do not
use such wheels, since the abrasive
material may lead to substantially
increased reactive forces in a pinch or
sideloading situation.
WARNING
Never use chipped abrasive wheels 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 section of an abrasive
wheel or the teeth of a saw blade may
catch in the material being cut and
generate substantially greater reactive
forces, including rotational kickback.
Cut-off machines are designed for use
with abrasive wheels in good condition
only. Machines designed for use with
wood-cutting or other toothed blades
use different types of guarding systems
that provide the protection necessary for
those types of blades. Machines, such
as a cut-off machine, that are designed
for use with abrasive wheels require a
different guarding system, which is not
designed to provide protection against
all dangers presented by circular saw
blades, carbide-tipped blades, rescue
blades or wood-cutting or toothed
blades of any nature.
WARNING
To reduce the risk of injury from loss of
control from reactive forces, including
kickback:
1. Hold the cut-off machine firmly with
both hands.
2. Maintain good balance and footing
at all times. Never cut while
standing on a ladder.
002BA554 AM
3. Position the cut-off machine in such
a way that your body is clear of the
cutting attachment. Avoid standing
in direct line with the wheel (See
illustration.) Never bend over the
cutting attachment, especially when
the guard is pulled back towards the
top and there is a risk of reactive
forces. Ensure sufficient freedom of
movement, especially in trenches.
Make sure there is sufficient space
for the user and the fall of the
severed part.
4. Do not cut above shoulder height.
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5. Only STIHL branded diamond and
composite abrasive wheels are
recommended. The use of nonSTIHL branded wheels can be
extremely dangerous. Never work
with a diamond wheel that wobbles
or that has ever wobbled or that is
manufactured with abrasive
material on its sides.
6. Do not cut wood or any other
material for which the abrasive
wheel is not authorized.
7. Never use circular saw blades,
carbide-tipped blades, rescue
blades, wood-cutting blades or
toothed blades of any nature. Their
use increases the risk of injury from
blade contact, thrown tips and
reactive forces, including kickback.
8. Begin cutting and continue at full
throttle.
9. Do not overreach.
10. Never sideload a wheel in the kerf.
11. Use your cut-off machine for cutting
only. It is not designed for prying or
shoveling away any objects.
12. Be especially alert for reactive
forces, including kickback, when
cutting with the front and upper
quadrant of the wheel. Never pull
the top of the wheel guard back
beyond the limit stop.
13. 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 of the wheel.
14. Use wet-cutting whenever feasible.
In a pinch situation the water can act
as a lubricant and reduce the
energy of reactive forces.
15. Release the pressure on the cut-off
machine as you reach the end of the
cut. Too much pressure may cause
the operator to lose control of the
cut-off machine when the abrasive
wheel completes the cut. The
abrasive wheel may contact the
operator or strike some foreign
object and shatter.
16. Use extreme caution when
reentering a cut and do not turn the
wheel at an angle or push the wheel
into the cut as this may result in a
binding of the wheel.
Gyroscopic Forces
Be alert for gyroscopic forces that are
caused by the rapid spinning of the cutoff wheel. These forces result in
opposition to directional change, e.g.,
when the operator attempts to move the
machine in a sideways direction.
Maintenance, Repair and Storing of the
Cut-Off Machine
Maintenance, replacement, or repair of
the emission control devices and
systems may be performed by any
nonroad engine repair establishment or
individual. However, if you make a
warranty claim for a component that has
not been serviced or maintained
properly or if nonapproved replacement
parts were used, STIHL may deny
warranty coverage.
Never operate a cut-off machine that is
damaged, improperly adjusted or not
completely or securely assembled.
Follow the maintenance and repair
instructions in the appropriate sections
of your instruction manual.
WARNING
Use only STIHL replacement parts for
maintenance and repair. Use of parts
manufactured by others may cause
serious or fatal injury.
WARNING
Always stop the machine, make sure
that the wheel is stopped, and remove
the spark plug boot from the spark plug
before doing any maintenance or repair
work or cleaning the cut-off machine. Do
not attempt any maintenance or repair
work not described in your instruction
manual. Have such work performed only
at your STIHL servicing dealer.
Clean off grinding dust after finishing
work. Tighten all nuts, bolts and screws
after each use.
Do not clean your machine with a
pressure washer. The solid jet of water
may damage parts of the machine.
WARNING
Never test the ignition system with spark
plug boot removed from 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,
use only spark plugs authorized by
STIHL. Always press spark plug boot
TS 480i, TS 500i
15
English
snugly onto spark plug terminal of the
proper size. (Note: If terminal has a
detachable SAE adapter nut, it must be
attached.) A loose connection between
spark plug terminal and ignition wire
connector in the boot may create arcing
that could ignite combustible fumes and
cause a fire. Keep spark plug clean, and
make sure ignition lead is in good
condition.
WARNING
Do not operate your cut-off machine if
the muffler is damaged, missing or
modified. An improperly maintained
muffler will increase the risk of fire and
hearing loss. Never touch a hot muffler
or spill fuel or other flammable liquid
over it. Burn injuries or fire will result. If
your muffler was equipped with a sparkarresting screen to reduce the risk of fire
(e. g. in the USA, Canada and
Australia), never operate your cut-off
machine if the screen is missing or
damaged.
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 requirements. Contact your local
fire agency or forest service for the laws
or regulations relating to fire protection
requirements.
For any maintenance please refer to the
maintenance chart and to the warranty
statement near the end of the instruction
manual.
Store wheels on a flat surface in a dry
place, preferably at a constant
temperature, where there is not a risk of
frost. Do not store a cut-off machine with
a wheel mounted on the machine. Store
cut-off machine in a high or locked
place, away from children.
Empty the fuel tank before storing for
longer than a few days. Store fuel only in
correctly labeled and approved
containers. Avoid direct skin contact and
do not inhale the gas vapors.
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 gallons (10 liter)
water tank is available from STIHL
for wet cutting.
– A water tank for mounting on the
Cutquik cart is also available for wet
cutting.
Most diamond cutting wheels are
suitable for wet cutting
Wet cut whenever feasible. It increases
the service life and cutting speed of
diamond cutting wheels.
Ensure that the cutting wheel is
generously supplied with water.
Wet cutting helps to suppress dust.
The water binds the dust.
The cutting wheel must be supplied with
at least 20 fl. oz (0.6 liters) water per
minute.
Wet cutting can reduce the energy of
reactive forces. In a pinch situation, the
water can act as a lubricant.
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Composite resin wheels can be used for
dry cutting of metals or for wet or dry
cutting of concrete, stone or masonry.
Composite resin wheels designed for
dry cutting
Special procedures must be followed
when wet cutting with a composite nondiamond wheel designed for dry cutting.
See the section entitled "Wet Cutting
with Abrasive Wheels" in the safety
precautions of this manual. Wet cutting
is generally not suitable for cutting
metals.
Composite resin wheels designed for
wet cutting
Adjust water flow rate
during cutting so it is sufficient to bind all the dust
that occurs (at least
20 fl. oz (0.6 L/min)).
If the water flow rate is too high, the
cutting wheel may skim on the water
surface in the cut and greatly reduce
cutting performance. To avoid this, do
not exceed a water flow rate of about
135fl.oz (4L/min).
Use water properly:
1. Be certain water is applied to both
sides of wheel, since uneven
distribution can cause one sided
wear with possible wheel breakage.
2. Make certain water does not flow on
wheel that is not running, since the
wheel will absorb water and that will
affect wheel balance.
3. After finishing work, run the cutting
wheel at normal operating speed for
about 3 to 6 seconds without water
so that the remaining water is flung
off.
Respiratory protection
WARNING
When wet cutting at the recommended
flow rate is not utilized, the operator and
any bystanders should always wear a
respirator approved by NIOSH/MSHA
for the material being cut. Even if wet
cutting, an operator who is actively
cutting for more than two hours a day
should wear at least a NIOSH-approved
disposable respirator.
The cutting sequence
The cutting sequence is important when
cutting openings and recesses, etc. The
last cut must always be made in such a
way that the cutting wheel cannot
become bound and so that the user is
not at risk of being injured by the part
that has been cut off or out.
If applicable, leave small ridges of uncut
material to hold the severed part in
position. These ridges can subsequently
be broken through.
A number of points must be decided
before the part is finally severed:
– How heavy is the part?
– In which direction can it move after
being severed?
– Is it under tension?
Helpers must not be put at risk of injury
when the part is broken off or out.
Cutting in several passes
TS 480i, TS 500i
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
N Mark cutting line (A).
17
English
N Work along the cutting line. If
corrections are necessary, always
reposition the cutting wheel, taking
care to ensure that it is not wedged.
The cutting depth per pass should
not exceed 5 to 6 cm (2“ to 2 1/2“).
Thicker material must be cut in
several passes.
Cutting slabs
N Secure the slab (e. g. on a non-slip
surface, sandbed).
180BA027 AM
N Cut deeper into the parting cut (B).
N Leave a ridge (C) of uncut material.
N Cut through the slab at the ends so
the material does not chip.
N Then break the slab.
N Determine sequence of severing
cuts.
N Grind a guide groove along the line
marked.
N Make cuts deeper along the guide
groove – observe recommended
cutting depth on each pass. For
180BA028 AM
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
manually after the last cut.
Cutting concrete pipe
N Cut a guiding groove (A) along the
marked line.
18
N Curves must be cut in several
straight passes, taking care to
ensure that the cutting wheel does
not become wedged.
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 metal reinforcement to the
extent possible, especially in the
direction of the severing cut.
A
002BA557 AM
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.
TS 480i, TS 500i
English
002BA559 AM
N Determine and mark direction of cut.
N Determine sequence of cuts.
Outer diameter of pipe is smaller than
the maximum cutting depth
N Make one cut from the top to the
bottom
Outer diameter of pipe is greater than
the maximum cutting depth
Plan first, then cut. Several cuts are
needed – correct sequence is important.
N Turn guard to rear stop.
002BA528 AM
N Always start at the bottom, use the
front and upper part of the abrasive
wheel for cutting.
N Use the front and upper part of the
002BA558 AM
abrasive wheel for cutting the
opposite lower side. Make sure that
the cut at the bottom is complete.
N Next, make a first lateral cut on the
top half of the pipe, connecting with
the kerf from the bottom half.
002BA560 AM002BA561 AM002BA562 AM
N A second lateral cut is then made in
the marked area. To keep the pipe
from pinching during this cut, never
cut into the area of the final cut.
Only make the final top cut once all
bottom and lateral cuts have been
completed and connect with one
another.
N Always make the final separating
cut from the top (approx. 15 % of the
pipe circumference). If the
workpiece is properly supported, it
should not pinch when the cut is
completed. If there is any residual
pinching, however, 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.
Concrete pipe – cut recess
002BA563 AM
TS 480i, TS 500i
Sequence of cuts (1 to 4) is important:
N First, cut hard-to-reach areas.
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180BA025 AM
1
2
N Always make severing cuts so that
the abrasive wheel is not pinched.
N Use wedges and/or leave ridges
that are broken after cutting.
4
3
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 Composite resin cutting
wheels
Cutting wheels are exposed to
extremely high loads especially during
hand-held cutting.
Only use abrasive whhels that comply
with ANSI B 7.1 for hand-held machines
180BA024 AM
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 cutting wheels that have been
developed for STIHL by well-known
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.
Transport and storage
– Do not expose cutting wheels to
direct sunshine or other thermal
stresses during transport and
storage.
– Avoid jolting and impacts.
– Stack cutting wheels flat on a level
180BA026 AM
surface in the original packaging in
a dry place where the temperature
is as constant as possible.
– Do not store cutting wheels in the
vicinity of aggressive fluids.
– Store cutting wheels in a frost-free
place.
Types:
– for dry applications
– for wet applications
Economic benefit is improved and
premature wear can be avoided by
choosing and using the correct
composite resin cutting wheel. The short
name (e.g. “asphalt“, “concrete“)
– on the label and
– on the packaging (table with
recommended uses)
can help to ensure the correct choice.
STIHL composite resin cutting wheels
are suitable, depending on the version,
for cutting the following materials:
– Asphalt
– Concrete
– Stone
– Ductile cast pipes
– Steel; STIHL composite resin
cutting wheels cannot be used to cut
railway tracks.
Do not cut any other materials – risk of
accident!
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TS 480i, TS 500i
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Diamond cutting wheels
For wet applications.
Economic benefit is improved and
premature wear can be avoided by
choosing and using the correct diamond
cutting wheel. The short name (see
following explanation)
– on the label and
– on the packaging (table with
recommended uses)
can help to ensure the correct choice.
STIHL diamond cutting wheels are
suitable, depending on the version, for
cutting the following materials:
– 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. Cut-off
machines are not suitable for cutting
certain metals and other substances.
Never use diamond abrasive wheels
with abrasive material on their sides,
since in a pinch situation, they can result
in extreme kickback – Risk of severe or
fatal injury.
Short names
The short name is a combination of
letters and numerals with up to four
digits:
– The letters indicate the main area of
use for the cutting wheel.
– The numerals indicate the
performance class of the STIHL
diamond cutting wheel.
Letter Main area of use
A Asphalt
B Concrete
BA Concrete, Asphalt
S Stone (rock)
SB* Rock, Concrete
*)
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 a
long service life and efficient operation
of the diamond cutting wheel.
Using a cutting wheel on a cut-off
machine with defective spindle bearing
can lead to axial and radial run-out.
Excessive radial run-out (A) causes
individual diamond segments to be
overloaded and to overheat. This can in
turn lead to stress cracking in the wheel
core or to softening of individual
segments.
Axial run-out or spindle wobble (B)
results in higher thermal stress and
wider cuts.
TS 480i, TS 500i
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English
Troubleshooting
Cutting wheel
Problem Cause Remedy
Frayed edges or tears, cut wanders out
Radial or axial run-out Consult a dealer
of line, increased wear at the sides of the
segments
Cutting wheel wobbles Use a new cutting wheel
Frayed edges, cut wanders out of line, lit-
tle or no cutting performance, sparking
Cutting wheel is blunt; built-up edges on cut-
ting wheels for stone
Dress the cutting wheel for stone by
briefly cutting in abrasive material; use a
new cutting wheel for cutting asphalt
Poor cutting performance, high level of
segment wear
Chipping or cracking in the wheel core
and segments
Undercutting Cutting in a material for which the wheel is
1)
STIHL recommends that a STIHL servicing dealer be consulted.
Cutting wheel rotates in the wrong direction Mount the cutting wheel with correct
direction of rotation
Overload Replace immediately with a new cutting
wheel
Use a new cutting wheel; note the differ-
not rated
ent cutting layers in different materials
1)
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TS 480i, TS 500i
English
Undercut
Undercutting is a wearing away of the
steel core at or just below the diamond
segments. When cutting road surfaces,
do not cut through into the more
abrasive ballast (gravel, crushed rock)
below, as indicated by a light colored
dust. This can cause excessive
undercutting, resulting in wheel
breakage and/or thrown segments.
WARNING
Immediately replace a diamond wheel if
the core has been severely undercut.
Built-up edges, dressing
Built-up edges 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 vibrations,
reduce cutting performance and cause
sparking.
Diamond cutting wheels must be
"dressed" at the first sign of built-up
edges. For this purpose, briefly cut a
more abrasive material, such as
sandstone, aerated concrete or asphalt.
Wet cutting helps to prevent the
formation of built-up edges.
WARNING
Such cutting wheels may break apart or
throw off segments during use or lead to
significant reactive forces, causing
serious or fatal injury. Replace them
immediately.
Built-up edges are identified by a pale
grey deposit on the top of the diamond
segments that clogs and blunts the
segments.
TS 480i, TS 500i
If you continue to use a cutting wheel
with blunt segments, the segments may
soften as a result of excessive heat built
up. The wheel core will also overheat
and lose its mechanical strength. This
can lead to considerable stress, as
clearly indicated by stress cracks and/or
a wobbling movement of the cutting
wheel.
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English
1307BA001 KN
2
1
370BA085 KN
3
Electronic water control
STIHL cut-off machines may be
equipped with an electronic water
control system.
The electronic water control makes it
possible to feed the optimum amount of
water to the cutting wheel. No water is
fed to the cutting wheel during idling or
when the machine is turned off.
Before starting work
N Familiarize yourself with the control
panel and sequence of motions
while the engine is switched off.
N All of the control panel buttons can
be reached with the thumb of the
right hand while the right hand
remains on the rear handle.
N The left hand always remains on the
handlebar.
Control Panel
When the engine is running, it is
possible to activate/deactivate the
electronic water control and adjust the
water flow.
1 Button (+):
activates the electronic water
control or increases water flow to
cutting wheel.
2 Button (–):
activates the electronic water
control or decreases water flow to
cutting wheel.
3 Deactivates electronic water
control; no water is fed to the cutting
wheel.
Using the Electronic Water Control
N Start engine: see the chapter
"Starting/Stopping the Engine."
N Briefly push the (+) button or (–)
button with the thumb of the right
hand. The right hand must always
remain on the rear handle while
doing so; the left hand must always
remain on the handlebar. No water
is fed to the cutting wheel during
idling.
During use, the set amount of water is
fed to the cutting wheel.
N Adjust water flow if necessary – to
do so, briefly push the (+) button or
(–) button with the thumb of the right
hand until the correct water quantity
is attained at one of the settings.
The right hand must always remain
on the rear handle while doing so;
the left hand must always remain on
the handlebar.
The water pressure will affect the actual
amount of water flow at any setting. It
may be necessary to use a higher
setting with a lower water pressure, e.g.,
when using a pressurized or gravity
water tank. For proper dust suppression
and cutting performance, always make
sure that the water flow is within the
proper range, as described in the
chapter "Sample Applications."
If the cut-off machine is idling after use,
no more water will be fed to the cutting
wheel – the electronic water control,
however, remains activated. With
continued use, the last setting will be
automatically re-entered.
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
cutting wheel during use although the
electronic water control has been
activated:
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TS 480i, TS 500i
English
2
370BA086 KN
1
3
2
1
1
1307BA002 KN
2
370BA069 KN
1
3
1
1
1
2
0
1307BA003 KN
N remove the coupling sleeve (1);
N unscrew the "water connection with
screen" (2) and rinse under running
water – the screen remains on the
water connection.
Assembling the cast arm and
guard
The "cast arm with guard" is mounted on
the inboard side by the manufacturer.
The "cast arm with guard" can also be
mounted on the outboard side
depending on requirements.
Assembly on the inboard side is
recommended for freehand cutting on
account of the better balance.
Outboard mounting
N Disassemble the abrasive wheel
(see “Fitting / replacing an abrasive
wheel”)
Removing the water attachment
Removing the adjusting lever
N Unscrew the banjo bolt (1) with the
combination wrench and remove it
together with the seal – in the
process, remove the square nut
from the inside of the guard from the
guide
N Unscrew the screw (2)
N Turn the adjusting lever (3) upwards
and remove
Slackening the V-belt
N Unscrew the banjo bolt (1) with the
combination wrench – in the
process, remove the square nut
from the inside of the guard from the
guide
N Remove the water hose (2) with
connector from the adjusting
lever (3)
N Pull the water hose (2) out of the
guide (arrows) in the V-belt guard
N Unscrew the nuts (1) – do not
remove them
N Turn the tensioning nut (2)
counterclockwise with the
combination wrench –
approx. 1/4 turn, as far as it will
go = 0
TS 480i, TS 500i
25
English
1
2
1307BA004 KN
3
4
1307BA005 KN
1
3
1
1
2
1307BA006 KN
1
370BA073 KN
1
370BA074 KN
4 5
3
2
A
4
5
370BA075 KN
6
Removing the V-belt guard
N Unscrew the screw (1) – screw (1) is
secured on the V-belt guard (2) to
prevent loss
N Raise the V-belt guard (2) slightly
and pull it off to the front
N Remove the V-belt (3) from the front
pulley (4)
Removing the "cast arm with guard"
N Turn the guard so that it is in the
position shown (see picture)
N Screw in and tighten the stop pin (1)
N Move the adjusting lever (2) to
position A
N Screw in the bolt (3) and tighten up
N Remove screw (4) from the limit
stop (5)
N Pull off the limit stop (5)
N Remove the nuts (1)
N Remove the "starter cover with
rewind starter" (2)
N Remove the "cast arm with
guard" (3) from the studs
Preparing the "cast arm with guard" for
outboard mounting
N Turn the "cast arm with guard" so
that the guard is on the outboard
side
N Insert limit stop (5) – align the hole
in the limit stop with the hole in the
cast arm
N Unscrew the stop pin (1)
26
N Screw in the bolt (4) and tighten up
TS 480i, TS 500i
English
2
2
3
4
1
2
1
1
1307BA007 KN
2
6
6
2
1307BA008 KN
2
5
6
7
8
1307BA009 KN
1
1
370BA078 KN
2
3
A
1307BA010 KN
N Insert the square nut into the guide
in the guard and hold it in place
N Screw in the shorter banjo bolt (6)
and washer at the adjusting lever
and tighten up with the combination
wrench
Mounting "cast arm with guard" – guard
on the outboard side
N Fit the "starter cover with rewind
starter" (5) over the studs (2)
N Tighten up the nuts (6) by hand
N Push the V-belt guard (7) into place
N Screw in the bolt (8) and tighten up
Connecting the water connection
N Fit the support with the longer banjo
bolt on the adjusting lever (3) –
screw in the banjo bolt and tighten
with the combination wrench
N Insert the water hose into the guide
in the V-belt guard (arrow) from the
water connection towards the guard
– avoid tight radiuses
Checking the adjustment range of the
guard
N Press the oblong holes (1) in the
"cast arm and guard" on to the
studs (2), guiding the ribbed V-belt
over the front pulley
NOTICE
The belt action must run smoothly.
N The belt tensioner (3) must sit close
to the lug (4)
TS 480i, TS 500i
N Insert the longer banjo bolt (1)
through the connector (2) of the
water attachment – observe the
position of the connector
N Insert the square nut into the guide
in the guard and hold it in place
N Rotate the guard forwards and
backwards as far as possible –
adjustment range (A) must be
limited by the stop pin
Continue as described in the chapter
“Tensioning the V-belt”.
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English
1
2
370BA080 KN
3
370BA081 KN
1
2
3
370BA082 KN
A
370BA083 KN
Inboard mounting
N Disassemble the abrasive wheel
(see “Fitting / replacing an abrasive
wheel”)
N Remove the water attachment
N Remove the adjusting lever
N Slacken the V-belt
N Remove the V-belt guard
N Remove the "cast arm with guard"
Preparing the "cast arm with guard" for
inboard mounting
N Remove screw (1) from the limit
stop (2)
N Pull off the limit stop (2)
N Turn the "cast arm with guard" so
that the guard is on the inboard side
N Insert limit stop (2) – align the hole
in the limit stop with the hole in the
cast arm
N Screw in the bolt (1) and tighten up
N Remove the nuts (3)
N Turn the guard so that it is in the
position shown (see picture)
N Screw in and tighten the stop pin (3)
N Install the adjusting lever
N Mount "cast arm with guard" – guard
on the inboard side
N Install the V-belt guard
N Connect water connection
Checking the adjustment range of the
guard
N Rotate the guard forwards and
backwards as far as possible –
adjustment range (A) must be
limited by the stop pin
Continue as described in the chapter
“Tensioning the V-belt”.
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TS 480i, TS 500i
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