Stihl TS 510 Manual

The Stihl TS 510 is a professional-grade cut-off saw designed for heavy-duty cutting of concrete, asphalt, stone, and metal. It features a powerful engine, a robust cutting system with a diamond blade, safety mechanisms including a throttle lockout and a safety guard, and ergonomic handles for operator comfort. Below are key sections for safety, features, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Powerful 2-stroke engine, Diamond cutting blade, Throttle trigger with lockout, Front and rear handles, Safety guard, Blade mounting flange, Fuel tank, and Air filter system.

Feature	Description
Engine Type	2-stroke, single-cylinder gasoline engine
Displacement	Approx. 50.2 cc
Power Output	High power output for demanding cuts
Cutting Depth	Max. cutting depth with standard blade
Blade Size	Typically uses 12-inch (300mm) diamond blades
Throttle Lockout	Prevents accidental throttle activation
Safety Guard	Protects operator from debris and blade
Anti-Vibration System	Reduces operator fatigue
Fuel Mix	Requires gasoline and 2-stroke oil mixture (e.g., 50:1)
Weight	Approx. weight without blade

Safety Instructions

Read and understand all instructions before use. Always wear appropriate PPE.

1. Personal Protective Equipment (PPE): Wear safety glasses, hearing protection, gloves, sturdy boots, and long pants.
2. Work Area Safety: Keep bystanders and pets at a safe distance. Ensure firm footing.
3. Tool Inspection: Check for damage before each use. Do not operate if damaged.
4. Fuel Safety: Refuel in a well-ventilated area with engine off and cool. No smoking.
5. Kickback Awareness: Be aware of potential kickback; always grip saw firmly with both hands.

WARNING! Failure to follow safety instructions can result in serious injury or death. The blade rotates at high speed and can cause severe cuts.

Assembly & Preparation

Unpack and inspect all parts. Assemble according to instructions.

1. Attach the Handle: Secure the rear handle to the main body using provided bolts.
2. Mount the Blade: Ensure the saw is off. Place blade on spindle, secure with flange and nut. Tighten with wrench.
3. Install Safety Guard: Attach the guard over the blade, ensuring it rotates freely and covers the upper blade area.
4. Fuel Mix: Prepare correct fuel/oil mixture as specified in manual. Fill fuel tank.
5. Check Controls: Verify throttle trigger, lockout, and stop switch function properly.

CAUTION! Ensure all fasteners are tight. Do not force components during assembly.

Technical Specifications

• Model: TS 510
• Engine: 2-stroke, air-cooled
• Displacement: 50.2 cc
• Power Output: High performance for professional use
• Fuel Tank Capacity: Approx. volume
• Recommended Fuel: Unleaded gasoline min. 89 octane mixed with STIHL 2-stroke oil
• Oil Mix Ratio: 50:1 (Gasoline : Oil)
• Idle Speed: Factory set
• Max. Blade Diameter: 12 inches (300 mm)
• Weight (without blade): Approx. weight in lbs/kg
• Sound Power Level: dB(A) as per testing standards
• Vibration Levels: Front/Rear handle values

Controls and Components

Main Controls: Throttle trigger with lockout, Stop switch (On/Off), Choke lever, Primer bulb, Decompression valve (if equipped).

Components: Engine, Cutting attachment (blade), Safety guard, Front handle, Rear handle with controls, Fuel tank cap, Air filter cover, Muffler, Spark plug.

Operation: Set choke for cold start. Press primer bulb. Engage throttle lockout before pulling throttle trigger. Use stop switch to shut off engine.

Starting & Operation

Starting Procedure (Cold Engine):

1. Place saw on firm, level ground. Ensure blade is clear of obstructions.
2. Set stop switch to "On" (I) position.
3. Set choke lever to closed position (if engine is cold).
4. Press primer bulb several times until fuel is visible.
5. Hold front handle firmly with left hand. Place right foot in rear handle bracket.
6. Pull starter rope briskly until engine fires. Move choke to open position.
7. Pull starter rope again to start engine. Allow to warm up at idle.

Tip: For warm restart, do not use choke. Set choke to open position.

Cutting Techniques

Designed for straight, precision cuts in hard materials.

1. Planning: Mark cut line clearly. Check for hidden wires or pipes.
2. Stance: Stand with feet shoulder-width apart, firm footing. Do not overreach.
3. Grip: Hold front handle with left hand, rear handle with right hand. Thumbs wrapped.
4. Starting Cut: Lower spinning blade gently onto material at start of cut line.
5. Cutting: Apply steady, moderate forward pressure. Let blade do the work; do not force.
6. Blade Care: Avoid twisting blade in cut. For deep cuts, use multiple passes.
7. Dust Control: Be aware of dust generation. Use water for dust suppression if required and approved for the tool.

WARNING! Never use blade for prying or lifting. Always cut at full throttle. Do not cut overhead.

Maintenance & Care

Regular maintenance ensures performance and longevity. Perform with engine off and cool.

Task	Frequency	Procedure
Air Filter Cleaning	Daily or as needed	Remove cover, clean filter with compressed air or soapy water. Dry completely before reinstalling.
Spark Plug Check	Every 50 hours	Remove, check electrode gap, clean or replace if worn.
Fuel Filter	Annually or as needed	Replace fuel filter in tank.
Blade Inspection	Before each use	Check for cracks, warping, or segment wear. Replace damaged blades immediately.
Fastener Check	Before each use	Ensure all nuts, bolts, and screws are tight.
Exterior Cleaning	After use	Wipe down with a dry cloth. Keep air intake and cooling fins clean.

CAUTION! Use only STIHL approved parts and accessories. Do not modify the tool.

Storage

For storage longer than 30 days:

1. Drain fuel tank completely and run engine until it stops to empty carburetor.
2. Remove spark plug, add a few drops of engine oil into cylinder, pull starter rope slowly to distribute, reinstall plug.
3. Clean entire saw thoroughly.
4. Store in a dry, secure, and well-ventilated place, out of reach of children.
5. Protect from dust and moisture.

Regulatory Information

This power tool complies with relevant machinery directives and standards. It features spark arrestor muffler. Noise and vibration values are measured according to EN ISO standards. STIHL is a registered trademark. For genuine parts, accessories, and service, contact an authorized STIHL servicing dealer.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No fuel, flooded, spark plug faulty, choke setting wrong	Check fuel level and mix. Wait if flooded. Check/replace spark plug. Verify choke setting.
Engine starts but dies	Clogged air filter, fuel filter, carburetor issues	Clean/replace air filter. Check fuel filter. May require carburetor adjustment by dealer.
Loss of power	Dirty air filter, clogged muffler, old fuel	Clean air filter and muffler screen. Use fresh fuel mix.
Excessive vibration	Loose components, unbalanced/damaged blade	Tighten all fasteners. Inspect blade for damage and balance; replace if necessary.
Blade cuts poorly or slowly	Dull blade, wrong blade for material, insufficient rpm	Replace with sharp, appropriate diamond blade. Ensure engine runs at full throttle.
Overheating	Clogged cooling fins, dirty air filter, incorrect fuel mix	Clean cooling fins and air filter. Use correct fuel/oil ratio.

Service: For repairs beyond basic maintenance, contact an authorized STIHL servicing dealer.

Support: Visit www.stihl.com for dealer locator and more information.