STIHL TS 480i, 500i Instruction Manual - FR Jones & Son
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STIHL TS 480i, 500i Instruction ManualEnglish
Contents
Guide to Using this Manual 2 Dear Customer,
Safety Precautions and Working Thank you for choosing a quality
Techniques 2 engineered STIHL product.
Sample Applications 10
Original Instruction Manual
It has been built using modern
Cutting Wheels 14 production techniques and
Composite Abrasive Wheels 14 comprehensive quality assurance.
Every effort has been made to ensure
Diamond Abrasive Wheels 14
your satisfaction and troublefree use of
Electronic Water Control 17 the product.
Assembling the cast arm and guard 19
Please contact your dealer or our sales
Tensioning the ribbed V-belt 22 company if you have any queries
Printing inks contain vegetable oils, paper can be recycled.
Mounting an Abrasive Wheel 23 concerning this product.
Fuel 24 Your
Fueling 25
Starting / Stopping the Engine 26
Air Filter System 28
STIHL Injection 29
Printed on chlorine-free paper
Spark Arresting Screen in Muffler 29
Dr. Nikolas Stihl
Spark Plug 29
Replacing the V-belt 30
Cut-off Machine Cart 31
Storing the Machine 32
Maintenance and Care 33
Minimize Wear and Avoid Damage 35
Main Parts 36
Specifications 37
Maintenance and Repairs 38
© ANDREAS STIHL AG & Co. KG, 2017
Disposal 39
EC Declaration of Conformity 39
0458-753-0121-B. VA5.B17.
0000006155_014_GB
{ This instruction manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process
with electronic systems.
TS 480i, TS 500i 1English
Symbols in text
Guide to Using this Manual Safety Precautions and
Working Techniques
WARNING Special safety precau-
Pictograms
Warning where there is a risk of an tions must be taken when
accident or personal injury or serious working with the cut-off
Pictograms that appear on the machine damage to property. machine, due to the very
are explained in this Instruction Manual. high rotational speed of
the abrasive wheel.
Depending on the machine and
NOTICE
equipment version, the following It is important you read
pictograms may appear on the machine. Caution where there is a risk of and understand the
damaging the machine or its individual Instruction Manual before
Fuel tank; fuel mixture of components. first use and keep the
gasoline and engine oil
manual in a safe place for
Engineering improvements future reference. Non-
Actuate decompression observance of the safety
valve instructions may result in
STIHL's philosophy is to continually
serious or even fatal
improve all of its products. For this
injury.
reason we may modify the design,
engineering and appearance of our Comply with national safety regulations
Actuate manual fuel products periodically. issued, e.g. by employers' liability
pump insurance associations, social security
Therefore, some changes, modifications
institutions, occupational safety and
and improvements may not be covered
health authorities or other organizations.
in this manual.
Water connection, shut- As for employers within the European
off cock Community, the provision 2009/104/EC
is binding – Safety and health protection
with the use of machines and devices by
employees at work
Tensioning nut for belt
Anyone using the power tool for the first
time: Let a shop assistant or expert
explain you the safe handling – or take
Pull starter grip part in a training course.
Minors are not allowed to work with the
power tool – except adolescents above
16 years of age, who were instructed
under supervision.
Children, animals and bystanders must
not be allowed near the machine.
2 TS 480i, TS 500iEnglish
When the power tool is not in use, put it The machine may only be used for Never use circular saw
down so that it does not endanger cutting. It is not suitable for cutting wood blades, carbide, rescue
others. The machine must be secured or wooden objects. or wood cutting attach-
against unauthorized access. ments or saws of any
Asbestos dust is extremely toxic - the
The user is responsible for avoiding machine must therefore never be used kind – these may cause
injury to third parties or damage to their to cut asbestos! fatal injuries! Instead of
property. uniformly removing parti-
Do not use the machine for any other cles as when cutting with
Hand-over or lend the engine-driven purpose because of the increased risk of an abrasive wheel, the
device to those persons only, who are accidents and damage to the machine. teeth of a circular saw
familiar with this model and its handling blade may snag in the
Do not modify the device – otherwise the
– always pass the instruction manual to material. This causes the
safety may be endangered. STIHL
them as well. machine to react in a
excludes all liability for personal injury
The use of noise emitting machines may and damage to property caused while highly aggressive manner
be restricted to certain times by national using unauthorized attachments. with uncontrolled and
or local regulations. extremely dangerous
Only use abrasive wheels or kickback.
The machine may only be operated by accessories which have been approved
people who are fit, in good physical by STIHL for this machine or which are Clothing and equipment
health and in good mental condition. technically equivalent. If you have any
questions in this respect, consult a
If you have any condition that might be Wear proper protective clothing and
servicing dealer. Only use high-quality
aggravated by strenuous work, check equipment.
abrasive wheels and attachments.
with your doctor before operating a
Otherwise there may be a risk of
power tool. Clothing must be sturdy
accidents or damage to the machine.
and snug-fitting, but allow
If you have a pacemaker: The ignition
STIHL recommends the use of genuine complete freedom of
system of this machine produces an
STIHL abrasive wheels and movement. Tightly fitting
electromagnetic field of very low
accessories. They are specifically clothes – overall, no
intensity. An effect on individual
designed to match your model and meet smock
pacemaker types cannot be excluded
your performance requirements.
entirely. STIHL recommends that you When cutting steel, always wear clothing
consult your doctor and the Do not use high-pressure cleaners to made of barely flammable material
manufacturer of your pacemaker in clean the machine. The hard water jet (e. g., leather or cotton with flame-
order to avoid health hazards. can damage parts of the machine. retardant finish) – no manmade fibers –
risk of fire due to flying sparks!
Never work with the machine while Do not spray the machine with water.
under the influence of alcohol, Clothing must be free from flammable
medication or drugs capable of impairing deposits (chips, fuel, oil, etc.).
your reaction speed.
Do not wear such clothes that can be
Postpone the work if the weather is bad caught by moving parts – no scarf, no
(snow, ice, wind) – higher risk of tie, no jewelry Tie up and confine long
accidents! hair.
TS 480i, TS 500i 3English
Wear safety boots with Transporting the machine Dust may collect on the engine unit. If
steel toe caps and non- dust gets mixed with fuel – risk of fire!
slip soles. Remove the dust from the engine unit
Always turn off the engine first. regularly.
Carry the device at the tubular handle
Look out for leaks! Never
only – abrasive wheel pointing to the
start the engine if fuel has
WARNING rear – hot muffler away from the body.
been spilled or is leaking
Do not touch hot device parts, in – Fatal burns may result!
To reduce the risk of eye
particular the muffler surface – risk of
injuries, wear tight-fitting
burns!
safety goggles conform- Bayonet filler cap
ing to standard EN 166. Never transport the engine-driven
Make sure that the safety device with attached abrasive wheel –
goggles fit correctly. risk of breakage!
Wear a face shield and make sure it fits In vehicles: Properly secure the machine
correctly. A face mask alone is not to prevent turnover, fuel spillage and
sufficient to protect the eyes. damage.
Wear "personal" hearing protection –
e. g., ear defenders. Refueling
Wear a hard hat wherever there is any
risk of falling objects. Petrol is an extremely Never use a tool to open or close the
flammable fuel – keep bayonet filler cap. The cap can be
While working, dust (for example, clear of naked flames and damaged and fuel may escape.
crystalline material from the object to be fire – do not spill any fuel
parted-off), vapor and smoke may be Secure the bayonet filler cap tightly after
– no smoking.
produced – danger for health! refueling.
Switch off the engine before refueling.
Always wear a dust mask if dust is
Never refuel the machine while the Cut-off machine, spindle bearing
generated.
engine is still hot – the fuel may spill over
If fumes or smoke are anticipated (e. g., – risk of fire!
when cutting composite materials), wear Faultless spindle bearings provide for
respiratory protection. Open the fuel filler cap carefully so that concentricity and axial running of the
any excess pressure is relieved diamond-tipped abrasive wheel – if
Wear sturdy protective gradually and fuel does not splash out. necessary, get it checked by a
gloves made of a resist- competent dealer.
ant material (e. g. The machine may only be refueled in a
leather). well ventilated place. If fuel has been
spilled, clean immediately the engine-
driven device – prevent your clothes
STIHL can supply a comprehensive from being contaminated with fuel,
range of personal protective clothing otherwise change clothes at once.
and equipment.
4 TS 480i, TS 500iEnglish
Abrasive wheels that there are no damaged or missing Storing abrasive wheels
segments and that the spindle bore is
Store abrasive wheels in dry and frost-
not damaged.
free manner, place them on plane
Selecting the abrasive wheels
Never use cracked, chipped or bent ground, at constant temperature – risk of
Abrasive wheels must be approved for abrasive wheels. breakage and splintering!
hand-held cutting. Do not use other
Substandard and/or unapproved Always protect the abrasive wheel
abrasive wheels and attachments –
diamond abrasive wheels can shimmy against sudden contact with the ground
danger of accident!
during cutting. This shimmying can or objects.
Abrasive wheels are suitable for cause such diamond abrasive wheels to
different materials: Observe the be abruptly braked or become stuck in Before starting
identification of the abrasive wheels. the cut – Danger of kickback! Kickback
can result in fatal cuts! Diamond
STIHL generally recommends wet Inspect the cut-off machine for safe-to-
abrasive wheels that shimmy constantly
cutting. operate state – observe the respective
or even only intermittently must be
Observe the outer diame- replaced immediately. chapters in the instruction manual:
ter of the abrasive wheel. – Check the fuel system for leaks,
Never straighten diamond abrasive
wheels. especially the visible parts, e. g.,
filler cap, hose connections, manual
Do not use abrasive wheels, which has fuel pump (only in machines with a
fallen to the ground – damaged abrasive manual fuel pump). In case of
Spindle hole diameter of wheels may break – risk of accident! leakage and damage, do not start
the abrasive wheel and the engine – risk of fire! Have the
Observe the expiration date where resin
shaft of cut-off machine machine serviced by a servicing
abrasive wheels are concerned.
must match. dealer before using it.
Fitting abrasive wheels
– The abrasive wheel must be
Check the spindle hole for damage. Do Inspect the spindle of the cut-off suitable for the material to be cut. It
not use abrasive wheels with damaged machine. Do not work with a device must be in good condition and fitted
spindle bore – risk of accident! whose spindle is damaged – risk if correctly (direction of rotation,
The permissible speed of accident! secure).
the abrasive wheel must Note the arrows indicating the direction – Inspect the abrasive wheel guard
be equal to or greater of rotation on diamond abrasive wheels. for tight seat – if loose, contact your
than the maximum spin- specialist dealer.
dle speed of the cut-off Position the front pressure plate – rigidly
machine. – Refer to the tighten the clamping screw – rotate the – Both the throttle trigger and its
chapter "Specifications". abrasive wheel by hand and take sight throttle trigger lockout to move
check for concentricity and axial smoothly – the throttle trigger has
Before fitting a used abrasive wheel, running. automatically to return to its idle run
check that it is not cracked, chipped, position.
undercut or uneven, and does not
display any signs of core fatigue or – Stop switch must move easily to
overheating (discoloration); check also STOP or 0
TS 480i, TS 500i 5English
– Check that the spark plug boot is Holding and controlling the machine Cut-off machine cart
secure. A loose boot can lead to
STIHL cut-off machines can be mounted
flying sparks which may ignite the
The cut-off machine may only be used onto a STIHL cut-off machine cart.
escaping fuel/air mixture – risk of
fire! for hand-held cutting or when mounted
on a STIHL cut-off machine cart. Guard
– Never attempt to modify the controls
or safety devices in any way Hand-held cutting
The adjustment range of the guard is
– Keep the handles clean, dry and determined by a stop pin. Never push
free of oil as well as dirt – important the guard over the stop pin.
for safe guiding of the cut-off
machine.
– For wet applications, provide
sufficient water
002BA549 AM
The machine should only be used if it is
in good working order – risk of accident!
002BA550 AM
Always hold the machine firmly with both
Starting the engine hands: Right hand on the rear handle –
even if you are left-handed. To ensure
Move at least 3 meters away from the reliable control, wrap your thumbs tightly Set the abrasive wheel guard correctly:
place at which the machine was refueled around the handlebar and handle. Guide particles of material away from
and never start the machine in enclosed the user and machine.
spaces. Note the direction of flight of the
On even ground, ensure a firm and removed particles of material.
secure footing and hold the engine-
driven device firmly – the abrasive wheel During operation
must not touch any objects or the ground
180BA022 KN
and must not be in cutting action. In the event of impending danger or in
The abrasive wheel may begin to rotate an emergency, switch off the engine
as soon as the machine is started immediately by moving the stop switch
When a cut-off machine with an abrasive to STOP or 0.
The engine-driven device is operated by wheel rotating is moved in the direction
a single person only – do not allow any Check for correct idling so that the
of the arrow, a force is produced which
person to stay within the working area – abrasive wheel is no longer driven when
causes the machine to tip sideways.
nor with starting. the throttle trigger is released and
The object to be parted-off has to be comes to a complete halt.
Do not drop-start the engine – start as firmly supported. Always guide the
described in the Instruction Manual. Check idling periodically. Have the
device towards the workpiece – never in
machine repaired by a STIHL servicing
After releasing the throttle trigger, the reverse.
dealer if the abrasive wheel turns when
abrasive wheel keeps on running for a the machine is idling.
while – danger of injury due to slowing
down!
6 TS 480i, TS 500iEnglish
Keep clear the working area – bear in Your power tool produces Check the work area. Avoid danger due
mind obstacles, holes and pitches. toxic exhaust fumes as to damage to pipes and electric power
soon as the engine is lines.
Take care with slickness, moisture,
snow, on slopes, on uneven terrain, etc. running. These gases The machine must not be used in the
– risk of slipping! may be colorless and vicinity of flammable substances and
odorless and may contain combustible gases.
Don not work while standing on a ladder unburnt hydrocarbons
– not at unstable places – not over your and benzene. Never work Do not cut into pipes, metal tanks or
shoulder height – not with one hand only with the engine-driven other containers if you are not sure that
– risk of accident! device in closed or poorly they do not contain any volatile or
vented rooms – even not inflammable substances.
Ensure you always have a firm and safe
footing. with devices equipped Never leave the machine unattended
with a catalyst. with the engine running. Stop the engine
Never work alone – stay always in
Ensure proper ventilation when working before leaving the machine unattended
earshot to other persons, who can
in trenches, hollows or similar locations (e. g. for breaks).
render first aid in case of emergency.
– risk of fatal injury from breathing toxic Before putting the cut-off machine down
Keep out further persons from the fumes! on the ground:
working area – maintain sufficiently large
distance to additional persons to protect With sick feeling, headache, eye defect – Switch off the engine
them from noise and flying objects. (for example, shrinking field of vision),
hearing impairment, dizziness, fading – Wait until the abrasive wheel has
Pay increased attention and caution with powers of concentration, stop working come to a standstill or brake the
your ear defenders put-on – the immediately – such symptoms may be abrasive wheel until it comes to a
perception of noise of potential danger caused, among others, by high exhaust standstill by carefully touching a
(shouts, signal sounds, etc.) is gas concentration – risk of accident! hard surface (e. g., concrete slab)
restricted.
No smoking when working with or near Repeatedly inspect the
Take a break before it is too late. the machine - risk of fire! abrasive wheel – replace
Work calmly and carefully – in daylight the wheel if there are visi-
If the engine-driven device has been ble cracks, buckling or
conditions and only when visibility is exposed to stress due to improper use
good. Work with particular care, do not other damages (for
(e. g. impact of force by blow and crash), example, overheating)
endanger others. test the device for safe-to-operate due to breakage – risk of
condition before continuing work, in accident!
every case – see also "Before start-up".
Check the fuel system for leaks and In the event of changes in cutting
make sure the safety devices are behavior (e. g., increased vibration,
working properly. Do not continue reduced cutting performance), stop work
operating the machines if damaged. In and eliminate the causes of the
case of doubt, have the unit checked by changes.
your servicing dealer.
Never touch a rotating abrasive wheel
with your hand or any other part of your
body.
TS 480i, TS 500i 7English
Reactive forces
The most frequently occurring reactive
forces are kickback and pull-in.
Danger of kickback –
002BA552 AM
002BA556 AM
Kickback can result in
fatal injuries.
– Whenever possible, do not use the – Support an uncovered pipe stable
upper quarter of the abrasive wheel and solid, if necessary, use wedges
for cutting. Use extreme caution – always bear in mind a proper
when entering the abrasive wheel in support and ground – material may
a cut, do not twist or push into the crumble away,
cut
– Always work with water and wet
cutting when using diamond
002BA551 AM
abrasive wheels
– Depending on the version, resin
abrasive wheels are only suitable
Kickback occurs when the cut-off for dry cutting or only for wet cutting.
machine is suddenly thrown up and back Always use wet cutting with
002BA555 AM
in an uncontrolled arc towards the composite resin abrasive wheels
operator. that are suitable only for wet cutting
Kickback occurs if, for example, the Pulling away
– Avoid wedge effect, the severed
abrasive wheel
part must not brake the abrasive
– gets jammed – primarily in its upper wheel
quarter, or
– Always be aware that the object to
– is abruptly braked through friction be cut may move and other factors
contact with a solid object may cause the cut to close and jam
the abrasive wheel.
Reducing the risk of kickback
002BA553 AM
– The object to be cut must be
– Work cautiously and methodically
secured and supported so that the
– Hold the cut-off machine firmly with kerf remains open during and after
both hands and maintain a secure cutting The cut-off machine pulls forwards,
grip away from the user, when the abrasive
– Objects to be cut must therefore be wheel touches the object to be cut from
fully supported and must be above.
secured against rolling away,
slipping off or vibrations
8 TS 480i, TS 500iEnglish
Working with the cut-off machine Always decide the cutting direction When applying abrasive wheels made
before positioning the cut-off machine. from synthetic resin, which are suited for
Do not change the cutting direction. wet cuts only, take such wet cuts only –
The abrasive wheel must Never push or hit with the device into the for example, use the STIHL water
be guided straight in the cutting gap – do not let the cut-off connector.
cut, without wedging. machine fall into the cutting depth – risk
Never exert lateral pres- When using abrasive wheels made from
of breakage!
sure on the abrasive synthetic resin, which are suited for dry
wheel. Diamond abrasive wheels: If cutting cuts only, take such dry cuts only. If
performance begins to deteriorate, however composite resin abrasive
Do not use for lateral check the sharpness of the diamond wheels of this type become wet, their
grinding or scrubbing. abrasive wheel, resharpen as needed. cutting performance is reduced and they
To do this, briefly cut through abrasive become dull. If composite resin abrasive
material, e. g., sandstone, aerated wheels of this type become wet while
concrete or asphalt. working (e. g., due to puddles or water in
pipes), do not increase the cutting
At the end of the cut, the cut-off machine
pressure, but continue working with the
is no longer supported by the abrasive
same pressure – risk of breakage! Use
wheel in the cut. The user has to absorb
up such composite resin abrasive
the weight force – risk of loss of control!
wheels immediately.
When cutting steel: glow-
ing metal particles may Cut-off machine cart
002BA554 AM
cause fires! Clear a path for the cut-off machine cart.
If the cart is pushed over objects, the
abrasive wheel may become wedged in
Do not stand in line with the abrasive
Keep water and sludge away from alive the cut and shatter!
wheel. Ensure sufficient freedom of
movement, especially in construction electrical cables – risk of electric shock!
trenches there must be sufficient space Vibrations
Drag the abrasive wheel into the
for the user and for the part being cut to workpiece – do not push it into the
fall. material. Do not correct severing cuts Prolonged use of the power tool may
Do not lean too far forwards and never with the cut-off machine. Do not re-cut – result in vibration-induced circulation
bend over the abrasive wheel when the remove left webs or breaking edges (for problems in the hands (whitefinger
guard has been pulled back. example, with a hammer). disease).
Don’t work above shoulder height. When applying diamond-coated No general recommendation can be
abrasive wheels, take a wet cut – for given for the length of usage because it
The cut-off machine may only be used example, use the STIHL water depends on several factors.
for cutting. It must not be used as a lever connector.
or shovel. The period of usage is prolonged by:
Depending on the version, resin
Do not press down on the cut-off – Hand protection (wearing warm
abrasive wheels are only suitable for dry
machine gloves)
cutting or only for wet cutting.
– Work breaks
TS 480i, TS 500i 9English
The period of usage is shortened by: To reduce the risk of fire due to ignition
outside the cylinder, move the stop Sample Applications
– Any personal tendency to suffer
switch to STOP or 0 before turning the
from poor circulation (symptoms:
engine over on the starter with the spark
frequently cold fingers, tingling
plug boot removed or the spark plug Water must always be used for wet
sensations).
unscrewed. cutting when working with diamond
– Low outside temperatures. abrasive wheels
Do not service or store the machine near
– The force with which the handles a naked flame – risk of fire due to the
are held (a tight grip restricts fuel.
circulation). Extend service life and increase cutting
Check fuel cap regularly for tightness. speed
Continual and regular users should
Use only spark plugs that are in perfect Always ensure a supply of water to the
monitor closely the condition of their
condition and have been approved by abrasive wheel.
hands and fingers. If any of the above
STIHL – see "Specifications".
symptoms appear (e.g. tingling
Binding dust
sensation in fingers), seek medical Inspect ignition lead (insulation in good
advice. condition, secure connection). The abrasive wheel must be supplied
with at least 0.6 liters of water per
Check that the muffler is in perfect
Maintenance and repairs minute.
working condition.
Do not use the machine if the muffler is Water attachment
The machine must be serviced regularly. damaged or missing – risk of fire! –
Do not attempt any maintenance or – Water attachment on the machine
Hearing damage!
repair work not described in the for all types of water supplies
Instruction Manual. All other work should Never touch a hot muffler – risk of burns!
– Pressurized water tank 10 l for
be carried out by a servicing dealer. Check the rubber buffers underneath binding dust
STIHL recommends that maintenance the machine – the housing must not rub
– water tank usable on the cut-off
and repair work be carried out only by against the ground – risk of damage!
machine cart for binding dust
authorized STIHL dealers. STIHL The condition of the antivibration
dealers receive regular training and are elements influences vibration behavior – Use composite resin abrasive wheels
supplied with technical information. inspect antivibration elements with or without water – depending on
Use only high-quality spare parts. periodically. version
Otherwise, there may be a risk of
accidents or damage to the machine.
Depending on the version, resin
Contact a servicing dealer if in doubt.
abrasive wheels are only suitable for dry
STIHL recommends the use of genuine cutting or only for wet cutting.
STIHL spare parts. Such parts have
been optimized for the machine and the Composite resin abrasive wheels
user's requirements. suitable only for dry cutting
Before starting any maintenance or During dry cutting, wear a suitable dust
repair work and before cleaning the mask.
machine, always stop the engine – risk
of injury!
10 TS 480i, TS 500iEnglish
If fumes or smoke are anticipated (e. g., Severed parts
when cutting composite materials), wear
With openings, recesses, etc., the
respiratory protection.
sequence of the cuts is important.
Composite resin abrasive wheels Always make the last cut so that the
suitable only for wet cutting abrasive wheel does not become
jammed and so that the operator is not
180BA027 AM
Use abrasive wheel only endangered by the severed or
with water. separated part.
If necessary, leave small ridges that hold
N Work along the cutting line. When
the part that is to be separated in
making corrections, do not tilt the
position. Break these ridges later.
abrasive wheel, but always set the
To bind dust, the abrasive wheel must Before finally separating the part, abrasive wheel against the
be supplied with at least 1 liter of water determine: workpiece anew – the cutting depth
per minute. To avoid a reduction in for each operation should not
cutting performance, the abrasive wheel – how heavy the part is
exceed 5 to 6 cm. Cut thicker
must be supplied with not more than – how it can move after separation material in multiple operations
4 liters of water per minute.
– whether it is under tension
After using the abrasive wheel, the Cutting plates
wheel should be allowed to continue When breaking out the part, do not
spinning at operating speed for endanger assistants.
approx. 3 to 6 seconds without water in N Secure the plate (e. g. on a non-slip
order to spin off the water remaining on Cut in several passes surface, sandbed)
it.
– Water attachment on the machine
for all types of water supplies
– Pressurized water tank 10 l for
binding dust
– water tank usable on the cut-off
machine cart for binding dust
Observe with diamond and composite N Grind a guide groove (A) along the
resin abrasive wheels N Mark cutting line (A) line marked
Objects to be cut
– Must be fully supported
– Must be secured so it cannot roll or
slip off
– Must be prevented from vibrating
TS 480i, TS 500i 11English
N Grind a guide groove along the line
marked
N Make cut deeper along the guide
groove – observe the recommended
cutting depth for each operation –
for small corrections of direction, do
180BA028 AM
002BA528 AM
not tilt the abrasive wheel, but
always position it anew instead – if
necessary, leave small ridges that
N Make the cut (B) deeper hold the part that is to be separated N Determine and mark direction of cut
in position. Break these ridges after
N Leave a "hinge" (C) N Determine sequence of cuts
the last planned cut
N First sever the plate at the cut ends Outer diameter is smaller than the
so that no material breaks away Cutting concrete pipe maximum cutting depth
N Break plate
002BA558 AM
002BA557 AM
A
N Make one cut from the top to the
The procedure is dependent on the bottom
N Make curves in multiple operations
– make certain that the abrasive outer diameter of the pipe and the Outer diameter is greater than the
wheel does not tilt maximum possible cutting depth of the maximum cutting depth
abrasive wheel (A).
Plan first, then cut. Several cuts are
Cutting pipes, round and hollow bodies N Secure pipe against vibrations, needed – correct sequence is important.
slipping and rolling away
N Turn guard at rear stop
N Secure pipes, round and hollow N Note weight, tension and direction
bodies against vibrations, slipping of fall of the part to be severed
and rolling away
N Note direction of fall and weight of
the severed part
N Determine and mark the cutting line,
avoid reinforcement, especially in
the direction of the severing cut
N Determine sequence of severing
cuts
12 TS 480i, TS 500iEnglish
1 2
180BA024 AM
002BA560 AM
002BA563 AM
N Always start at the bottom, use the N Second lateral cut in the marked N Always make severing cuts so that
upper quarter of the abrasive wheel area – never cut into the area of the the abrasive wheel is not pinched
for cutting last cut, to ensure a firm hold on the
part of pipe to be cut
Only make the last top cut once all
bottom and lateral cuts have been
made.
180BA025 AM
002BA561 AM
N Use wedges and/or leave ridges
N Use the upper quarter of the that are broken after cutting
002BA559 AM
abrasive wheel for cutting the
opposite lower side. 4
N Last cut always from the top 3
(approx. 15 % of the pipe
circumference)
180BA026 AM
Concrete pipe – cut recess
002BA562 AM
Sequence of cuts (1 to 4) is important: N If the severed part remains in the
recess after cutting (due to wedges,
N First lateral cut on the top half of the N First, cut hard-to-reach areas ridges used), do not make any
pipe further cuts – break the severed part
TS 480i, TS 500i 13English
Cutting Wheels Composite Abrasive Wheels Diamond Abrasive Wheels
Abrasive wheels are exposed to
extremely high loads especially during
freehand cutting.
Therefore only for use of approved and
correspondingly labeled abrasive
wheels with hand-held machines as per
EN 13236 (diamond) or EN 12413
(composite resin). Note maximum
permissible speed of the abrasive wheel
– risk of accident! Types: For wet applications.
The abrasive wheels, which have been – for dry applications The proper selection and use of
developed by STIHL in cooperation with diamond abrasive wheels ensures
– for wet applications
renowned manufacturers of abrasive economical use and avoids accelerated
wheels, are of high quality and tailored The proper selection and use of wear. The product code which appears
precisely to the respective intended use composite resin cutting wheels ensures
– on the label and
as well as the engine performance of the economical use and avoids accelerated
cut-off machine. wear. The product code which appears – on the packaging (table with
recommendations for use) is an aid
They are of consistently outstanding – on the label and
to selection
quality.
– on the packaging (table with
STIHL diamond abrasive wheels are
recommendations for use) is an aid
Transport and storage suitable, depending on the version, for
to selection
cutting the following materials:
STIHL composite resin cutting wheels
– Do not expose abrasive wheels to – Asphalt
are suitable, depending on the version,
direct sunshine or other thermal for cutting the following materials: – Concrete
stresses during transport and
storage – Asphalt – Stone (hard stone)
– Avoid jolting and impacts – Concrete – Abrasive concrete
– Stack abrasive wheels flat on a level – Stone – Fresh concrete
surface in the original packaging in – Ductile cast iron pipes – Clay brick
a dry place where the temperature
is as constant as possible – Steel; STIHL composite resin – Clay pipe
cutting wheels are not suitable for
– Do not store abrasive wheels in the Do not cut any other materials – Risk of
cutting railway tracks
vicinity of aggressive fluids accident!
Do not cut any other materials – risk of
– Store abrasive wheels in a frost-free Never use diamond abrasive wheels
accident!
place with side plating as they jam in the cut
and can result in extreme kickback –
Risk of accident!
14 TS 480i, TS 500iEnglish
Product codes
D-B10
0000-GXX-1235-A0
An excessively high radial run-out
deviation (A) overloads individual
diamond segments, which overheat in
The product code is a combination of the process. This can lead to stress
letters and numbers, consisting of up to cracks in the parent wheel or to
four characters: annealing of individual segments.
– the letters denote the main field of Deviations in axial run-out (B) result in
application of the abrasive wheel higher thermal loading and wider cuts.
– the numbers denote the
performance class of the STIHL
diamond abrasive wheel
Axial and radial run-out
A faultless spindle bearing of the cut-off
machine is necessary for a long service
life and efficient functioning of the
diamond abrasive wheel.
Using the abrasive wheel on a cut-off
machine with a faulty spindle bearing
can lead to deviations in radial and axial
run-out.
TS 480i, TS 500i 15English
Troubleshooting
Abrasive wheel
Defects Cause Remedy
Ragged edges or cut surfaces, crooked Deviation in radial or axial run-out Contact a servicing dealer1)
cut
Heavy wear on the sides of the segments Abrasive wheel gyrates Use a new abrasive wheel
Ragged edges, crooked cut, no cutting Abrasive wheel is dull; built-up edges with Sharpen abrasive wheels for stone by
performance, generation of sparks abrasive wheels for stone briefly cutting through abrasive materials;
replace abrasive wheel for asphalt with a
new one
Poor cutting performance, high segment Abrasive wheel is turning in the wrong Mount abrasive wheel so that it turns in
wear direction the right direction
Breakdowns or tears in the parent wheel Overloading Use a new abrasive wheel
and segment
Undercut Cutting in the wrong material Use new abrasive wheel; observe sepa-
rating layers of various materials
1)
STIHL recommends STIHL servicing dealer
16 TS 480i, TS 500iEnglish
Undercut Built-up edges increase vibration,
reduce cutting performance, and cause Electronic Water Control
formation of sparks.
At the first signs of built-up edges, STIHL cut-off machines may be
immediately "sharpen" the diamond equipped with an electronic water
abrasive wheel – to do this, briefly cut control system.
through abrasive material such as e. g. The electronic water control makes it
sandstone, aerated concrete or asphalt. possible to feed the optimum amount of
Addition of water prevents the formation water to the abrasive wheel. No water is
of built-up edges. fed to the abrasive wheel during idling.
Do not cut into the base course
(frequently chipped stones and gravel) Before starting work
when cutting roadway pavement –
cutting in chipped stones and gravel is
N Familiarize yourself with the
revealed by light-colored dust –
sequence of motions while the
excessive undercut may occur as a
engine is switched off
result – Danger of shattering!
Built-up edges, sharpen
If work continues with dull segments,
these may soften due to the high heat
generated – the parent wheel is
1307BA001 KN
annealed and its strength is
compromised – this can lead to stresses
that are clearly recognizable by
gyrations of the abrasive wheel. Do not
continue to use the abrasive wheel – N All of the control panel buttons can
Risk of accident! be operated with the thumb of the
Built-up edges take the form of a light right hand – the right hand always
gray deposit on the tops of the diamond remains on the rear handle while
segments. This deposit on the segments doing so
clogs the diamonds and blunts the N The left hand always remains on the
segments. handlebar
Built-up edges can form:
Control panel
– when cutting extremely hard
materials, e. g., granite
When the engine is running, it is
– with incorrect handling, e. g.,
possible to activate / deactivate the
excessive feed effort
electronic water control and adjust the
water flow.
TS 480i, TS 500i 17English
remains on the rear handle while If too little water or no water is fed to the
1 doing so, the left hand always abrasive wheel although the screen has
remains on the handlebar been cleaned, visit your servicing
dealer.
If the cut-off machine is idling after use,
3 no more water will be fed to the abrasive
wheel – the electronic water control,
370BA085 KN
however, remains activated. With
2 continued use, the last quantity of water
set will be fed to the abrasive wheel
1 Button (+): again automatically.
activate the electronic water control If the engine is stopped and restarted,
or increase water flow to abrasive the electronic water control is switched
wheel off.
2 Button (–):
For installation on the STIHL FW 20 cut-
activate the electronic water control
off machine cart
or decrease water flow to abrasive
wheel If the cut-off machine is mounted on the
STIHL FW 20 cut-off machine cart in
3 Deactivate electronic water control;
combination with the water tank, feed
no water is fed to the abrasive wheel
the maximum amount of water.
Using the electronic water control
Maintenance and care
N Start engine, see
If too little water or no water is fed to the
"Starting / Stopping the Engine"
abrasive wheel during use although the
N Tap on the (+) button or (–) button electronic water control has been
with the thumb of the right hand – activated:
the right hand always remains on
the rear handle while doing so, the
left hand always remains on the
handlebar – no water is fed to the
abrasive wheel yet during idling
During use, the set amount of water is
370BA086 KN
fed to the abrasive wheel.
N Adjust water flow if necessary – to 1 2
do so, tap on the (+) button or (–)
button with the thumb of the right N Remove the coupling sleeve (1)
hand until the correct water quantity
N Unscrew "water connection with
is attained – the right hand always
screen" (2) and rinse under running
water – the screen remains on the
water connection
18 TS 480i, TS 500iEnglish
Removing the adjusting lever Removing the V-belt guard
Assembling the cast arm and
guard
3 2
The "cast arm with guard" is mounted on
the inboard side by the manufacturer. 2
The "cast arm with guard" can also be 1 1
mounted on the outboard side
1307BA004 KN
370BA069 KN
depending on requirements.
Assembly on the inboard side is
recommended for freehand cutting on
account of the better balance. N Unscrew the banjo bolt (1) with the N Unscrew the screw (1) – screw (1) is
combination wrench and remove it secured on the V-belt guard (2) to
together with the seal – in the prevent loss
Outboard mounting
process, remove the square nut
N Raise the V-belt guard (2) slightly
from the inside of the guard from the
and pull it off to the front
N Disassemble the abrasive wheel guide
(see “Fitting / replacing an abrasive N Unscrew the screw (2)
wheel”)
N Turn the adjusting lever (3) upwards
Removing the water attachment and remove
3 Slackening the V-belt 4
1307BA005 KN
1 3
2
2
1 0
N Remove the V-belt (3) from the front
1307BA002 KN
pulley (4)
1
1 1
1307BA003 KN
N Unscrew the banjo bolt (1) with the
combination wrench – in the
process, remove the square nut N Unscrew the nuts (1) – do not
from the inside of the guard from the remove them
guide N Turn the tensioning nut (2)
N Remove the water hose (2) with counterclockwise with the
connector from the adjusting combination wrench –
lever (3) approx. 1/4 turn, as far as it will
go = 0
N Pull the water hose (2) out of the
guide (arrows) in the V-belt guard
TS 480i, TS 500i 19English
Removing the "cast arm with guard" 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
A and tighten up with the combination
1 wrench
370BA074 KN
4 5 3 2 Mounting "cast arm with guard" – guard
on the outboard side
3
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
2 1 N Screw in the bolt (3) and tighten up 1 2
1307BA006 KN
N Remove screw (4) from the limit
1 stop (5) 1
1 1
N Pull off the limit stop (5) 2 2
N Remove the nuts (1)
N Remove the "starter cover with
rewind starter" (2) 4 3
6
N Remove the "cast arm with
1307BA007 KN
guard" (3) from the studs
370BA075 KN
Preparing the "cast arm with guard" for
outboard mounting 4 5 N Press the oblong holes (1) in the
"cast arm and guard" on to the
N Turn the "cast arm with guard" so studs (2), guiding the ribbed V-belt
that the guard is on the outboard over the front pulley
side
N Insert limit stop (5) – align the hole
NOTICE
in the limit stop with the hole in the
370BA073 KN
cast arm The belt action must run smoothly.
1
N Screw in the bolt (4) and tighten up N The belt tensioner (3) must sit close
to the lug (4)
N Unscrew the stop pin (1)
20 TS 480i, TS 500iEnglish
N Fit the support with the longer banjo Inboard mounting
2 bolt on the adjusting lever (3) –
screw in the banjo bolt and tighten
2 2 with the combination wrench N Disassemble the abrasive wheel
(see “Fitting / replacing an abrasive
N Insert the water hose into the guide wheel”)
6 in the V-belt guard (arrow) from the
1307BA008 KN
5 water connection towards the guard N Remove the water attachment
6 6 – avoid tight radiuses N Remove the adjusting lever
Checking the adjustment range of the N Slacken the V-belt
N Fit the "starter cover with rewind
starter" (5) over the studs (2) guard N Remove the V-belt guard
N Tighten up the nuts (6) by hand N Remove the "cast arm with guard"
Preparing the "cast arm with guard" for
inboard mounting
7
1307BA009 KN
8
370BA080 KN
N Push the V-belt guard (7) into place A
1 2
N Screw in the bolt (8) and tighten up
N Remove screw (1) from the limit
Connecting the water connection
stop (2)
1307BA010 KN
3 N Pull off the limit stop (2)
1
N Rotate the guard forwards and
backwards as far as possible –
adjustment range (A) must be
370BA078 KN
2 limited by the stop pin
1
Continue as described in the chapter
“Tensioning the V-belt”.
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
TS 480i, TS 500i 21English
Checking the adjustment range of the
guard Tensioning the ribbed V-belt
This machine is equipped with an
automatic spring-action V-belt
3 tensioning device.
370BA081 KN
1 2
2
N Turn the "cast arm with guard" so 1 0
that the guard is on the inboard side
N Insert limit stop (2) – align the hole 1 1
1307BA029 KN
in the limit stop with the hole in the
cast arm
N Screw in the bolt (1) and tighten up
A Prior to tensioning of the ribbed V-belt,
N Remove the nuts (3)
the nuts (1) must be loosened and the
arrow on the tensioning nut (2) must
370BA083 KN
point to 0.
N otherwise loosen the nuts (1) and
N Rotate the guard forwards and the tensioning nut (2) with the
backwards as far as possible – combination wrench
adjustment range (A) must be counterclockwise –
370BA082 KN
3 limited by the stop pin approx. 1/4 turn, as far as
possible = 0
Continue as described in the chapter
N Turn the guard so that it is in the “Tensioning the V-belt”.
position shown (see picture)
N Screw in and tighten the stop pin (3)
N Install the adjusting lever 1
1307BA011 KN
N Mount "cast arm with guard" – guard
on the inboard side 1 1
N Install the V-belt guard
N to tighten the ribbed V-belt, fit the
N Connect water connection
combination wrench over the
tensioning nut as illustrated
22 TS 480i, TS 500iEnglish
Removing an abrasive wheel
WARNING Mounting an Abrasive Wheel
The tensioning nut is spring-loaded –
hold the combination wrench securely. The engine must be switched off for
N Turn the tensioning nut clockwise fitting or replacement – move stop switch
to STOP or 0.
approx. 1/8 turn – the tensioning nut
will be engaged by the spring
Blocking the shaft
N Continue turning approx. 1/8 turn –
up to the stop 2
NOTICE
Do not turn the combination wrench
further by force.
The V-belt is automatically tensioned by
the force of the spring in this position.
Remove the combination wrench
370BA053 KN
N
from the tensioning nut
N Tighten up the nuts (1)
N Use the combination wrench to
Retensioning the V-belt 1 loosen and remove the hexagon
head screw (2)
The V-belt is retensioned without the aid N Remove the front thrust washer (3)
370BA014 KN
of the tensioning nut. from the shaft together with the
abrasive wheel
1 N Slide the locking pin (1) through the
bore in the V-belt guard
N Turn the shaft with the combination
wrench until the locking pin (1)
1307BA012 KN
1 1 engages in the bore behind the
guard
N Loosen the nuts (1) – V-belt is
retensioned automatically by the
force of the spring
N Tighten up the nuts (1) again
TS 480i, TS 500i 23English
Fitting an abrasive wheel
WARNING Fuel
Never use two abrasive wheels at the
same time. The uneven wear creates a The engine requires a mixture of
risk of breaking and an injury hazard! gasoline and engine oil.
WARNING
Avoid direct skin contact with and
breathing in of gasoline fumes.
STIHL MotoMix
STIHL recommends using STIHL
MotoMix. This pre-blended fuel is free of
4 benzene and lead, stands out because
of a high octane rating, and always
provides the proper mixing ratio.
370BA054 KN
STIHL MotoMix is blended with STIHL
HP Ultra two-stroke engine oil for
maximum engine life.
N Fit the new abrasive wheel (4)
MotoMix is not available in all markets.
WARNING
Mixing fuel
Note the arrows indicating the direction
of rotation on diamond abrasive wheels.
N Fit the front thrust washer (3). The NOTICE
catches of the front thrust
washer (3) must engage in the shaft Unsuitable fuels or a mixing ratio that
grooves deviates from the specification can lead
to severe engine damage. The engine,
N Screw in the hexagon bolt and seals, fuel lines and fuel tank may be
tighten it with the combination damaged if poor quality gasoline or
wrench – if using a torque wrench, engine oil is used.
refer to the "Specifications" for the
tightening torque Gasoline
N Draw the locking pin out of the V- Use only high-quality gasoline with an
belt guard octane rating of at least 90 ROC –
leaded or unleaded.
24 TS 480i, TS 500iEnglish
Engines with M-Tronic or STIHL Fuel mixture ages – mix only as much as
Injection deliver full engine performance needed for a few weeks. Do not store Fueling
using gasoline with an alcohol fuel mixture for longer than 30 days. The
component of up to 25% (E25). fuel mixture can become unusable faster
if exposed to light, sunlight or low or high
Engine oil temperatures.
Use only high-quality two-stroke engine STIHL MotoMix however can be stored
oil – ideally STIHL HP, HP Super or without trouble for up to 2 years. Preparing the machine
HP Ultra two-stroke engine oil, as they
are specially engineered for STIHL N Shake the canister containing the
engines. HP Ultra ensures maximum fuel mixture thoroughly before N Before fueling, clean the filler cap
performance and engine life. refueling and the area around it so that dirt
cannot fall into the tank
The engine oils are not available in all
WARNING
markets. N Always position the machine so that
Pressure can build up inside the canister the filler cap is facing upwards
Mix ratio – open carefully.
with STIHL two-cycle engine oil 1:50; N The fuel tank and the canister in WARNING
1:50 = 1 part oil + 50 parts gasoline which fuel mixture is stored should Never use a tool to open the bayonet
be cleaned thoroughly from time to filler cap. The cap can be damaged and
Examples time fuel may escape.
Quantity of STIHL two-cycle engine Residual fuel and the liquid used for
gasoline oil 1:50 cleaning must be disposed of in Opening the filler cap
Liters Liters (ml) accordance with regulations and without
harming the environment!
1 0,02 (20)
1.
5 0,10 (100)
10 0,20 (200)
2.
15 0,30 (300)
20 0,40 (400)
1307BA035 KN
25 0,50 (500)
N Pour oil into an approved safety fuel
canister first, then add gasoline and
mix thoroughly N Press the filler cap down as far as
possible by hand, then turn it
Storing fuel mixture counterclockwise (approx. 1/8 turn)
and remove
Store in approved safety fuel canisters
only in a dry, cool and secure place
protected against light and sunlight.
TS 480i, TS 500i 25English
Refueling If the cap can be removed or the
markings do not align, close the cap Starting / Stopping the
again – see sections "Closing the filler Engine
Take care not to spill fuel while fueling cap" and "Checking the lock".
and do not overfill the tank. STIHL
recommends use of the STIHL filling
Changing the fuel pickup body every
system for fuel (special accessory).
year
Closing the filler cap
3
The fuel pickup body is equipped with a
magnetic separator. 3
1.
2.
1307BA036 KN
1
1307BA016 KN
N Fit the cap and turn it until it
2
engages in the bayonet catch
N Press the cap down as far as
possible by hand and turn it N Press throttle trigger lockout (1) and
clockwise (approx. 1/8 turn) until it then press throttle trigger (2)
engages N Hold both triggers down
1307BA015 KN
Checking the lock N Set the stop switch (3) to F
N Release the throttle trigger, stop
switch and throttle trigger lockout in
N Drain the fuel tank succession – starting throttle
position
N Pull the fuel pickup body out of the
tank with a hook and disconnect it
from the hose
1307BA037 KN
N Connect a new fuel pickup body to
the hose
N Return the fuel pickup body to the
N Grip the cap – the cap is closed tank
properly if it cannot be removed and
the markings (arrows) on the cap
and fuel tank are aligned
26 TS 480i, TS 500iEnglish
ground or any objects. There must dealer if the abrasive wheel turns while
not be anyone within the swivel the engine is idling. STIHL recommends
4 range of the cut-off machine STIHL servicing dealers.
N Make sure you have a firm footing
Switching off the engine
N Press the cut-off machine firmly
against the ground, holding the
handle with your left hand, thumb
wrapped round the handle
N Press the cut-off machine against
the ground with the right knee on the
shroud
1307BA019 KN
N Pull the starter grip slowly with your
right hand until you feel it engage –
5 then give it a brisk strong pull – do
1307BA017 KN
not pull out the starter rope all the N Move stop switch to STOP or 0
way
Additional hints on starting
N Press the button (4) of the NOTICE
decompression valve Do not let the starter grip snap back – it
If the tank has been drained completely
N Press the manual fuel pump may break! Guide it back into the
bulb (5) 7-10 times, even when the housing in the opposite direction so that N Refueling
bulb is filled with fuel it can rewind properly. N Press the manual fuel pump bulb
7-10 times – even if it is full of fuel
Starting Once the engine is running
N Restart the engine
N Let the engine run for a few seconds At very low temperatures or if the
- important: the abrasive wheel may machine is extremely cold
begin to rotate!
N Allow the engine to warm up longer
N Blip the throttle trigger and throttle after starting – important: the
trigger lockout so that the engine abrasive wheel may begin to rotate!
settles down to idle speed
1307BA018 KN
N Blip the throttle trigger and throttle
The cut-off machine is now ready for trigger lockout so that the engine
use. settles down to idle speed
N Place the cut-off machine carefully
on the ground, ensuring that the WARNING
abrasive wheel cannot touch the The abrasive wheel must not rotate
when the engine is idling. Have the
machine repaired by a STIHL servicing
TS 480i, TS 500i 27English
Replacing the air filter STIHL recommends the use of genuine
Air Filter System STIHL air filters. The high quality of
these parts will ensure trouble free
Only if there is a noticeable loss of operation, a long service life for the
Basic information engine power engine and extremely long filter life.
The average filter life is more than 1
year. Do not dismantle the filter cover or
fit a new air filter unless there is a
noticeable loss of engine power.
In the long-life air filter system with the
cyclone pre-separation system, dirty air
4
3
is drawn in and deliberately rotated. The
larger and heavier particles carried in
the air are thus expelled and extracted. 2
Only pre-cleaned air enters the air filter
system and the result is extremely long
filter life.
1307BA020 KN
1
1
N Undo the screws (1)
N Remove the filter cover (2) and
clean it
N Remove the main filter (3)
N Remove the auxiliary filter (4) –
ensuring that dirt does not enter the
intake area
N Clean the filter area
N Insert new auxiliary filter (4) and
new main filter (3)
N Refit filter cover (2)
N Retighten screws (1)
Only high-quality air filters should be
used, to protect the engine against
ingress of abrasive dust.
28 TS 480i, TS 500iEnglish
STIHL Injection Spark Arresting Screen in Spark Plug
Muffler
STIHL Injection regulates the fuel In some countries, the mufflers are fitted N If the engine is down on power,
quantity and ignition timing for all with a spark arresting screen. difficult to start or runs poorly at idle
operating states electronically. speed, first check the spark plug.
N If engine performance deteriorates,
STIHL Injection stands for easy, fast check the spark arresting screen in N Fit a new spark plug after about 100
starting, constant optimum engine the muffler operating hours – or sooner if the
performance, outstanding acceleration electrodes are badly eroded. Install
and automatic adaptation to changes in WARNING only suppressed spark plugs of the
operating conditions. type approved by STIHL – see
Wait until engine has cooled completely "Specifications".
before performing the following
operations. Removing the spark plug
2 N Switch off the engine – move stop
switch to STOP or 0
1
370BA031 KN
1
2
1307BA030 KN
N Remove screw (1)
N Pull the spark arresting screen (2)
upwards out of the muffler
N Clean the soiled spark arresting N Unscrew screw (1) and remove
screen cap (2) – screw (1) is secured in the
cap (2) to prevent loss
N If the screen is damaged or heavily
carbonized, fit a new one
N Refit the spark arresting screen in 3
reverse order of steps
4
1307BA031 KN
N Remove the spark plug boot (3).
N Unscrew the spark plug (4).
TS 480i, TS 500i 29English
Checking the Spark Plug N Use resistor type spark plugs with a
properly tightened adapter nut. Replacing the V-belt
Installing the spark plug
2
N Fit the spark plug by hand and
screw it in
1 0
000BA039 KN
N Tighten spark plug with combination
1 1
1307BA029 KN
A wrench
N Press the spark plug boot firmly
onto the spark plug
N Clean dirty spark plug.
N Position the cap for the spark plug N Undo the nuts (1)
N Check electrode gap (A) and
boot and screw it down Turn the tensioning nut (2)
readjust if necessary – see N
"Specifications". counterclockwise with the
combination wrench –
N Rectify the problems which have approx. 1/4 turn, as far as it will
caused fouling of the spark plug. go = 0
Possible causes are:
– Too much oil in fuel mix.
– Dirty air filter. 4
– Unfavorable running conditions. 3
1307BA022 KN
1
N Pull the water hose out of the guide
in the V-belt guard
000BA045 KN
N Unscrew the screw (3)
N Raise the V-belt guard (4) slightly
and pull it off to the front
WARNING
Arcing may occur if the adapter nut (1) is
loose or missing. Working in an easily
combustible or explosive atmosphere
may cause a fire or an explosion. This
can result result in serious injuries or
damage to property.
30 TS 480i, TS 500iYou can also read
