STIHL TSA 230 Instruction Manual

STIHL TSA 230

WARNING

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

ADVERTENCIA

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

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Instruction Manual Manual de instrucciones

Instruction Manual 1 - 44

Manual de instrucciones 45 - 92

Contents

English

Guide to Using this Manual 2 Safety Precautions and Working

Techniques 2 General Power Tool Safety

Warnings 16 Sample applications 20 Cutting wheels 24 Composite resin cutting wheels 24 Diamond cutting wheels 25

Original Instruction ManualPrinted on chlorine-free paper

Fitting / replacing an abrasive wheel 28

Connecting Charger to Power Supply 29

Charging the Battery 29 LEDs on Battery 30 LED on Charger 32 Connecting the water supply 32 Switching On 33 Switching Off 33 Storing the Machine 34 Maintenance and Care 35 Main Parts 36

Printing inks contain vegetable oils, paper can be recycled.

Specifications 37 Troubleshooting 40 Maintenance and Repairs 42 Battery Recycling 42 Disposal 42 Trademarks 43 Addresses 44

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.

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Guide to Using this Manual Safety Precautions and

This Instruction Manual refers to a STIHL battery-powered cut-off machine, also called the power tool or machine in this Instruction Manual.

Pictograms

All the pictograms attached to or embossed on the machine are shown and explained in this manual.

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 following symbols and signal words:

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.

NOTICE

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

Engineering Improvements

STIHL’s philosophy is to continually improve all of its products. As a result, engineering changes and improvements are made from time to time. Therefore, some changes, modifications and improvements may not be covered in this manual. If the operating characteristics or the appearance of your machine differs from those described in this manual, please contact your STIHL dealer or the STIHL distributor for your area for assistance.

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 that can create sparks, 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 before use and periodically thereafter.

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.

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A first-time operator should obtain practical instruction before using the machine. Employers should establish a training program for operators of handheld 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.

Operate this cut-off machine with STIHL type AP batteries only.

To reduce the risk of loss of control and/or balance from carrying extra weight and/or using a connecting cord, only operate the cut-off machine with STIHL battery type AP placed directly in the machine when not cutting at ground level.

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.

WARNING

To reduce the risk of injury to bystanders and damage to property, never leave your power tool unattended if it is in operating condition. When it is not in use

(e.g. during a work break), shut it off, move retaining latch to ƒ and remove the battery.

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:

– Wear gloves and keep your hands

warm.

– Maintain a firm grip at all times, but

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

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.

Proper Clothing

WARNING

To reduce the risk of injury, the operator should wear proper protective apparel.

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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 close-fitting protective glasses with adequate side protection that are impact-rated and marked as 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.

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 replacement parts are authorized, and only STIHL-branded cutting attachments expressly approved by STIH L fo r use with the spec ific STIH L 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.

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 Work." Make sure the safety devices are working properly. Do not continue operating your power tool if

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it is damaged. In case of doubt, have the machine checked by your STIHL servicing dealer.

Battery

WARNING

Risk of fire, explosion and/or burns, including chemical burns. Do not disassemble, crush, heat above 212 °F (100 °C), expose to fire or incinerate. Never expose the battery to microwaves or high pressures.

Do not place the battery on or near fires, stoves or in other high-temperature locations. Do not place the battery in direct sunlight or store it inside a vehicle in hot weather. Doing so may cause the battery to generate heat, rupture or ignite. Using the batteries in this manner may also result in a loss of performance and a shortened battery life.

In case of fire: stay clear of any vapors or gases generated, taking wind direction into account. If possible without danger, remove battery from the vicinity of the fire. In principle, cooling the battery or extinguishing the fire with water is possible. It is preferable to extinguish the fire with a multipurpose dry chemical fire extinguisher. As for any fire, evacuate the area and fight the fire from a safe distance. Once the fire has been extinguished, the area should be monitored (fire watch) in case of a flareup, until the battery has cooled sufficiently. Restrict access to the area until completion of clean-up. Do not

touch the burnt battery or any spilled liquids. Use inert absorbent to absorb spilled liquids.

Use and store the battery only within a temperature range from 14 °F (-10 °C) up to no more than 122 °F (+ 50 °C). Protect the battery from direct sunlight.

WARNING

Use STIHL batteries only with STIHL power tools, and charge them only with STIHL chargers. Replace battery with STIHL battery only. Use only genuine STIHL rechargeable batteries.

Charge the battery before use.

Do not immerse the battery in fluids.

WARNING

Do not open, drop, hit or damage battery. Never insert objects into the battery's cooling slots, since they may damage the battery. The battery contains safety features and devices which, if damaged, may cause the battery to generate heat, rupture or ignite. Never use or charge a malfunctioning, damaged, cracked or deformed battery.

Immediately discontinue use of the battery if, while using, charging or storing, it emits an unusual smell, feels hot or appears abnormal in any other way.

WARNING

Fluid may leak from the battery if it is damaged or is not used properly – avoid contact with the skin! Leaking battery fluid can cause skin irritation and chemical burns. In the event of accidental contact, immediately rinse thoroughly with mild soap and water. If fluid gets into your eye(s), do not rub your eye(s) but rinse water over the open eye(s) for 15 minutes at least. Also seek medical attention immediately.

WARNING

Never bridge (short circuit) the battery terminals with metallic objects, since this may damage the battery and possibly cause a fire. Keep a battery that is not in use away from metal objects (e.g. nails, coins, jewelry). Do not use metal containers for transporting batteries.

Store the battery out of reach of children in a cool and dry area away from direct sunlight and excessive heat or cold (14 °F – 122 °F (-10 °C – +50 °C)).

Protect STIHL batteries and the STIHL battery belt from flying sparks when cutting steel – risk of battery fire or explosion and/or damage to the belt.

Keep STIHL batteries away from conductive liquids, such as dirty water (e.g. from additives or solid matter) or slurry and from metal objects (e.g. nails, coins, jewelry, metal chips). The batteries can be damaged by a short circuit – risk of fire or explosion!

Charger Use only genuine STIHL chargers.

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Use only for charging geometrically matching STIHL batteries with a maximum capacity of 50 Ah and a maximum voltage of 42 V.

Never charge malfunctioning, leaking or deformed batteries.

Connect the charger only to a power supply with the voltage and frequency specified on the rating plate. Always plug the charger into a properly installed wall outlet. Do not use an extension cord unless absolutely neccessary (see below).

Never use a charger with damaged housing, damaged power supply cord or damaged plug. Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way.

Do not open or dissassemble charger – there are no user serviceable parts inside.

Store charger out of the reach of children.

Protect the charger from rain and dampness. Keep charger dry.

Use and store charger only indoors in dry rooms.

Operate charger at temperatures between 41 °F (5 °C) and 104 °F (40 °C).

Allow the charger to cool down normally – do not cover it.

Never bridge the contacts of the charger with metallic objects (e.g. nails, coins, jewelry) – which can cause a short circuit. The charger will be damaged by a short circuit.

In the event of smoke or fire in the charger, disconnect it from outlet immediately.

WARNING

To reduce the risk of electric shock or short circuit, do not insert any objects into the charger's cooling slots.

WARNING

The charger heats up during the charging process. Do not operate on an easily combustible surface (e.g. paper, cardboard, textiles) or in an easily combustible environment – risk of fire.

WARNING

Do not operate in a hazardous location, i.e. in a location where there are combustible liquids (fumes), vapors or dusts. Chargers can produce sparks, which may ignite the dust or vapors – risk of explosion.

Check the charger's power supply cord and plug regularly for damage. If the power supply cord or plug is damaged, immediately disconnect the plug from the wall outlet to avoid the risk of electric shock.

Never jerk the charger’s power supply cord to disconnect it from the wall outlet. To unplug, grasp the plug, not the cord.

Have a damaged power supply cord or plug repaired by an experienced electrician.

Do not use the power supply cord for any other purpose, e.g. for carrying or hanging up the charger.

Never use power supply cords that do not comply with regulations.

Make sure the power supply cord is located and/or marked so that it will not be stepped on, tripped over, come in contact with sharp edges or moving parts or otherwise be subjected to damage or stress.

An extension cord should not be used for your charger unless absolutely necessary. If an extension cord must be used, plug the charger into a properly wired 16 gauge (AWG 16) or heavier gauge extension cord with blades that are the same number, size and shapes as the blades on the charger.

To reduce the risk of electric shock: – Always connect the charger to a

properly installed wall outlet.

– Make sure the insulation of the

power supply cord and plug is in good condition.

Unplug the power supply cord from the outlet when charger is not in use.

Never store a battery in the charger.

Abrasive Wheels

WARNING

Before mounting the cutting wheel, make sure that the maximum operating wheel speed is above or equal to the maximum spindle speed of your cut-off

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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. During a break, always place your cut-off machine in a location where the 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.

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 including Kickback." 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 "Reactive Forces including Kickback."

Only use the abrasive wheel approved for the type of material to be cut. There are different types of abrasive wheels, each specially marked.

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

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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

Remove the battery from the cut-off machine before:

– Carrying out tests and adjustments

or cleaning work

– Fitting or changing the abrasive

wheel

– Mounting and removing

accessories

– Leaving the cut-off machine

unattended

– Transport – Storage – Performing repairs and

maintenance work

This avoids the risk of the motor starting unintentionally.

Transporting the STIHL Cutquik

WARNING

To reduce the risk of injury from unintended activation and/or contact with a moving wheel, always switch off the machine and move retaining latch to ƒ when you carry the unit for short distances. The abrasive wheel continues to rotate (coast down) for a short while after the trigger switch is released (flywheel effect). Bring the wheel to a stop by lightly contacting the bottom of the wheel on a hard surface or wa it u ntil the w heel com es t o a com ple te stop on its own.

When carrying the machine for more than a few steps, remove the battery from the cut-off machine.

By hand: When carrying your cut-off machine by hand, the cut-off machine must be in the proper position. Grip the front handle and place 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.

By vehicle: Properly secure your cut-off machine to prevent turnover 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.

Allow the cut-off machine and battery to dry out separately if they are wet after use. During transport, make sure that the cut-off machine and battery remain dry. Only transport the battery in clean and dry containers, do not use metallic transport containers.

Before Starting For wheel installation, follow the

procedure described in the appropriate chapter of your instruction manual.

WARNING

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

Keep the handles dry and clean for a proper grip.

WARNING

Before operation of your cut-off machine, be sure the controls (e.g. trigger switch, trigger switch lockout and retaining latch) and other safety devices

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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.

Trigger switch must be locked when the trigger switch lockout is not depressed.

The retaining latch must be easy to set to ‚ or ƒ.

Check contacts in battery compartment for foreign matter. Keep clean.

Fit the battery correctly – it must engage audibly.

Do not use malfunctioning or deformed batteries.

Starting

WARNING

Your cut-off machine is a one-person tool. Do not allow other persons in the general work area, even when starting. For specific starting instructions, see the appropriate section of your instruction manual.

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. Never attempt to start the cut-off machine when the abrasive wheel is in a cut.

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

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 also 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 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.

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8016BA002 KN

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. Cutting with your cutoff machine resting on the ground or other surface can cause excessive wear to the guide plate designed to protect the bottom of the front handle. Replace a damaged or badly worn guide plate immediately.

Grip: Never use the cut-off machine with one hand. Always hold the cut-off machine firmly with both hands. Place your left hand on front handle bar and

your right hand on rear handle and trigger switch. Left-handed 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 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 are created when cutting metal and some other materials. They can burn or cause clothing to catch fire. Always direct sparks away from the operator or any flammable surroundings. Flammable items can include dry vegetation and brush, particulary when weather conditions are hot and dry. Never cut metal or other sparkcreating materials while standing on a flammable surface, such as wood, dry vegetation 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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8016BA028 KN

After finishing work turn off the cut-off machine, set the locking lever to ƒ and remove the battery from the cut-off machine.

If the battery is not removed after finishing work, there is the risk that the plug-in contacts on the cut-off machine and battery become corroded. Such corrosion can cause irreparable damage to the cut-off machine and battery. Allow the cut-off machine and battery to dry out separately if they are wet after use.

Operating Instructions

WARNING

It is extremely important that the wheel guard is in place and set to suit the type of work and your stance. By adjusting the angle of the cut-off machine to the work piece, you can influence the direction of debris from the cutting process. Operate your cut-off machine 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.

In case of imminent danger or in an emergency, switch off the machine immediately and move the retaining latch to ƒ.

This cut-off machine can be used for work in the rain or wet. Allow the cut-off machine or battery to dry out separately if they are wet after use.

Do not submerge the battery. Do not leave the cut-off machine outdoors in the rain.

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 including Kickback" 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 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 including Kickback."

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. 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

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8016BA005 KN

piece can be easily broken afterwards. Do not cock, jam or wedge the wheel in the cut.

Always switch off the machine, move retaining latch to ƒ and be sure the wheel has stopped rotating before setting down the cut-off machine.

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. 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. 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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8016BA030 KN

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 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.

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8016BA006 KN

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.

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. Do not overreach.

9. Never sideload a wheel in the kerf.

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

11. Be especially alert for reactive forces, including kickback, when cutting with the front and upper quadrant of the wheel.

12. 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.

13. Use wet-cutting whenever feasible. In a pinch situation the water ca n act as a lubricant and reduce the energy of reactive forces.

14. 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.

15. 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

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.

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.

WARNING

Use only STIHL replacement parts for maintenance and repair. Use of parts manufactured by others may cause serious or fatal injury.

WARNING

Always move retaining latch to ƒ and remove the battery from the power tool and make sure that the wheel is stopped 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.

Regularly check the electrical contacts and ensure that the insulation of the power cord and plug of the charger is in good condition and show no sign of aging (brittleness).

Electrical components, e.g. power cord of charger, may only be repaired or replaced by a qualified electrician.

Clean plastic components with a cloth. Do not use aggressive detergents. They may damage the plastic.

Clean the ventilation slots if necessary. Keep the battery guides free from

foreign matter – clean as necessary. Clean off grinding dust after finishing

work. Do not clean your machine with a

pressure washer. The solid jet of water will damage parts of the machine.

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

Store composite 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 the power tool in a dry, locked location with retaining latch on ƒ, the battery removed and out of reach of children.

If the battery is not removed, there is the risk that the plug-in contacts on the cutoff machine and battery become corroded. Such corrosion can cause irreparable damage to the cut-off machine and battery. Allow the cut-off machine and battery to dry out separately if they are wet after use.

General Power Tool Safety Warnings

This chapter relays the prescribed wording of general safety advice for handheld motor-operated electric cut-off machines contained in UL 60745-1 and UL 60745-2-22.

The safety precautions and warnings on avoiding an electric shock given under "2) Electrical safety" do not apply to STIHL cordless electric power tools.

WARNING

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1) Work area safety

a) Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

b) Do not operate power tools in

explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

c) Keep children and bystanders away

while operating a power tool. Distractions can cause you to lose control.

2) Electrical safety

a) Power tool plugs must match the

outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

b) Avoid body contact with earthed or

grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c) Do not expose power tools to rain or

wet conditions. Water entering a power tool will increase the risk of electric shock.

d) Do not abuse the cord. Never use

the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

e) When operating a power tool

outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

f) If operating a power tool in a damp

location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

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3) Personal safety

a) Stay alert, watch what you are doing

and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

b) Use personal protective equipment.

Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c) Prevent unintentional starting.

Ensure the switch is in the offposition before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

d) Remove any adjusting key or

wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

e) Do not overreach. Keep proper

footing and balance at all times. This enables better control of the power tool in unexpected situations.

f) Dress properly. Do not wear loose

clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

g) If devices are provided for the

connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

4) Power tool use and care

a) Do not force the power tool. Use the

correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

b) Do not use the power tool if the

switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

c) Disconnect the plug from the power

source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

d) Store idle power tools out of the

reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for

misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

f) Keep cutting tools sharp and clean.

Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

g) Use the power tool, accessories

and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

5) Battery tool use and care

a) Recharge only with the charger

specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.

b) Use power tools only with

specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.

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c) When battery pack is not in use,

keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.

d) Under abusive conditions, liquid

may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.

6) Service

a) Have your power tool serviced by a

qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

7) Safety instructions for abrasive cutting-off operations

Cut-off machine safety warnings a) The guard provided with the tool

must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. Position

yourself and bystanders away from the plane of the rotating wheel. The guard helps to protect operator from broken wheel fragments and accidental contact with wheel.

b) Use only bonded reinforced or

diamond cut-off wheels for your power tool. Just because an accessory can be attached to your power tool, it does not assure safe operation.

c) The rated speed of the accessory

must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.

d) Wheels must be used only for

recommended applications. For example: do not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.

e) Always use undamaged wheel

flanges that are of correct diameter for your selected wheel. Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage.

f) Do not use worn down reinforced

wheels from larger power tools. Wheels intended for a larger power tool are not suitable for the higher speed of a smaller tool and may burst.

g) The outside diameter and the

thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.

h) The arbour size of wheels and

flanges must properly fit the spindle of the power tool. Wheels and flanges with arbour holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

i) Do not use damaged wheels.

Before each use, inspect the wheels for chips and cracks. If power tool or wheel is dropped, inspect for damage or install an undamaged wheel. After inspecting and installing the wheel, position yourself and bystanders away from the plane of the rotating wheel and run the power tool at maximum no load speed for one minute. Damaged wheels will normally break apart during this test time.

j) Wear personal protective

equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and shop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.

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k) Keep bystanders a safe distance

away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken wheel may fly away and cause injury beyond immediate area of operation.

l) Hold the power tool by insulated

gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.

n) Never lay the power tool down until

the accessory has come to a complete stop. The spinning wheel may grab the surface and pull the power tool out of your control.

o) Do not run the power tool while

carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.

p) Regularly clean the power tool’s air

vents. The motor’s fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

q) Do not operate the power tool near

flammable materials. Sparks could ignite these materials.

8) Further safety instructions for

abrasive cutting-off operations

Kickback and related warnings Kickback is a sudden reaction to a

pinched or snagged rotating wheel. Pinching or snagging causes rapid stalling of the rotating wheel which in turn causes the uncontrolled power tool to be forced in the direction opposite of the wheel’s rotation at the point of the binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.

Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power

tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque reactions or kickback forces, if proper precautions are taken.

b) Never place your hand near the

rotating accessory. Accessory may kickback over your hand.

c) Do not position your body in line

with the rotating wheel. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.

d) Use special care when working

corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.

e) Do not attach a saw chain,

woodcarving blade, segmented diamond wheel with a peripheral gap greater than 10 mm or toothed saw blade. Such blades create frequent kickback and loss of control.

f) Do not "jam" the wheel or apply

excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.

g) When wheel is binding or when

interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel binding.

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h) Do not restart the cutting operation

in the workpiece. Let the wheel reach full speed and carefully reenter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.

i) Support panels or any oversized

workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

j) Use extra caution when making a

"pocket cut" into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

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.

Use clean water for binding dust.

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 also reduce the energy of reactive forces. In a pinch situation, the water can act as a lubricant.

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 135 fl. oz (4 L/min).

Use water properly:

1. Make certain water does not flow on wheel that is not running, since a composite wheel will absorb water and that will affect wheel balance.

2. 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

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. Even if wet cutting, an operator who is actively

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8016BA007 KN

180BA028 AM

cutting for more than two hours a day should wear at least a NIOSH-approved disposable respirator.

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

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

N Mark cutting line (A).

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 2 cm (0.8“). Thicker material must be cut in several passes.

Cutting slabs

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

surface, sandbed).

N Cut a guiding groove (A) along the

marked line.

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 Curves must be cut in several

straight passes, taking care to ensure that the cutting wheel does not become wedged.

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8016BA008 KN

002BA528 AM

8016BA009 KN

8016BA010 KN

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. 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

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

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.

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

N Always start at the bottom, use the

front and upper part of the abrasive wheel for cutting.

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N Use the front and upper part of the

8016BA011 KN

8016BA012 KN

8016BA013 KN

8016BA014 KN

8016BA015 KN

180BA026 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.

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

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180BA025 AM

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.

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.

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Sequence of cuts (1 to 4) is important:

N First, cut hard-to-reach areas.

N Always make severing cuts so that

the abrasive wheel is not pinched.

English

Cutting wheels Composite resin cutting

wheels

Cutting wheels are exposed to extremely high loads especially during hand-held cutting.

Only use abrasive wheels that comply with ANSI B 7.1 for hand-held machines and are correspondingly labeled. Note that the maximum permissible speed rating 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.

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 can help to ensure the correct choice.

STIHL composite resin cutting wheels are suitable, depending on the version, for cutting the following materials:

– Stone – Ductile cast pipes – Steel; STIHL composite resin

cutting wheels cannot be used to cut

railway tracks. – Stainless steel Do not cut any unauthorized materials –

risk of accident!

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

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.

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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 unauthorized 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.

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 a malfunctioning spindle bearing can lead to axial and radial runout.

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.

TSA 230

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 on 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

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

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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 into 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.

TSA 230

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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