Technical Information · issue 19 of 2010
New cut-off machines STIHL Cutquik® TS 410-A, TS 420-A
IssueTI 19/2010
Part changes (1)
| Was | Becomes | What the bulletin says |
|---|---|---|
| 0000 997 0912 | 0000 997 5510 | spring 0000 997 0912 with 6 coils is replaced by the new version 0000 997 5510 with 7 coils. |
Full text
Page 1 of 11
STIH)
Technical Information 19.2010
New cut-off machines STIHL Cutquik® TS 410-A, TS 420-A – Series 4238
Contents
1. Electronic water control
2. Specifications
3. Servicing accessories
4. Spare parts
5. Servicing
1. Electronic water control 1.1 Functional description
The new cut-off machines STIHL Cutquik®
TS 410-A, TS 420-A are equipped with the new, 1
innovative electronic water control.
Benefits:
. The optimum amount of water is always fed to
the cutting wheel during use
. The water supply is cut off automatically during
370TI052 KN
idling 2 3
. Easy operation via the ergonomically arranged
control panel The electronic water control consists essentially of
the following components:
. Time savings, e. g., due to less frequent refilling
of the STIHL pressurized water tank – Control panel (1)
– Generator (2) – behind the flywheel
Both the potential applications and uses as well as – Solenoid valve (3) – with integral control
the other product features are equivalent to those of
the cut-off machines STIHL Cutquik® TS 410, 420.
TI_19_2010_30_01_01.fm englisch / English
)m~ge 2 Technical Information 19.2010
The generator ensures that power is supplied to the 1.1.1 Before starting work
solenoid when the engine is running. . While the engine is switched off: Familiarize
Using the buttons of the ergonomically arranged yourself with the sequence of motions
control panel, the user can adjust both the water
flow rate as well as manually activating and
deactivating the water control.
370TI053 KN
. All of the control panel buttons can be operated
with the thumb of the right hand – the right hand
always remains on the rear handle during
operation
. The left hand always remains on the handlebar
1.1.2 Control Panel
When the engine is running, it is possible to activate
/ deactivate the electronic water control and adjust
the water flow.
3
370TI054 KN
1 Button (+):
Activate the electronic water control or increase
water flow to cutting wheel
2 Button (–):
Activate the electronic water control or decrease
water flow to cutting wheel
3 Deactivate electronic water control; no water is
fed to the cutting wheel
TI_19_2010_30_01_01.fm Page 2 of 11
Technical Information 19.2010 Page 3
1.1.3 Using the Electronic Water Control 1.1.4 Maintenance and Care
. Start the engine in accordance with the To protect the solenoid valve, a screen is installed in
Instruction Manual the water connection.
. Blip the (+) button or (–) button with the thumb of If too little water or no water is fed to the cutting
the right hand – the right hand always remains wheel during use with the electronic water control
on the rear handle during operation, the left activated:
hand always remains on the handlebar – no
water is fed to the cutting wheel during idling
During use, the set amount of water is fed to the
cutting wheel.
. Adjust water flow if necessary – to do so, blip the
(+) button or (–) button with the thumb of the
right hand until the correct water quantity is
attained – the right hand always remains on the
rear handle during operation, the left hand
1 2
370TI055 KN
always remains on the handlebar
If the engine is idling, no water will be fed to the
cutting wheel – the electronic water control,
however, remains activated, so when work . Remove the coupling sleeve (1)
continues, the last quantity of water set before the . Unscrew "water connection with screen" (2) and
idle phase will be fed to the cutting wheel again rinse under running water – the screen remains
automatically. on the water connection
2. Specifications
2.1 Weight
dry, without cutting wheel
without electronic water control
TS 410: 9.4 kg
TS 420: 9.6 kg
with electronic water control
TS 410-A: 9.9 kg
TS 420-A: 10.1 kg
TI_19_2010_30_01_01.fm
)m~ge 4 Technical Information 19.2010
3. Servicing accessories 3.2 Existing special tools
The existing special tools are listed in the Service
Manual for STIHL Cutquik® TS 410, 420.
3.1 New special tools
4. Spare parts
3.1.1 Power adapter 4238 400 8500
The spare parts lists will be available for market
launch and are already contained on the DVD
STIHL Service Communication System (01/2010).
4.1 Clutch
In the new cut-off machines STIHL Cutquik®
TS 410-A, TS 420-A, the new clutch 4238 160 2002
is used. In the new version, the previous tension
370TI075 KN
spring 0000 997 0912 with 6 coils is replaced by the
new version 0000 997 5510 with 7 coils.
In the new cut-off machines STIHL Cutquik®
The power adapter 4238 400 8500 permits fast
TS 410-A, TS 420-A, only the new clutch
troubleshooting (see b 5.1, b 5.2).
4238 160 2002 should be used as a replacement
part.
3.1.2 Spacer 4238 894 1100
5. Servicing
The safety instructions in the instruction manual
must be observed if the machine has to be started
up during servicing.
5.1 Troubleshooting Plan for the Electronic
Water Control
370TI057 KN
Possible customer complaint
The flywheel must be removed with the previous – No water flow or water flow too low
puller 1135 890 4500 (to be changed to – Water flow cannot be adjusted via the control
5910 890 4504) and the new spacer 4238 894 1100 panel buttons
(see b 5.3), in order to avoid damaging the
generator beneath it. – System leaks
TI_19_2010_30_01_01.fm Page 3 of 11
Technical Information 19.2010 Page 5
Customer complaint
Check water connection / screen and yes
Customer complaint Troubleshooting completed
clean if necessary, see b 1.1.4 remedied?
Leak testing: Engine switched off,
no Leaky solenoid valve, repair or
connect machine to water supply System free of leaks?
replace
(e. g., pressurized water tank)
yes
Disconnect machine from water
no Solenoid valve / control defective,
supply. Connect power adapter, Can the clicking of the
repair or replace if necessary
see b 5.2 solenoid valve be heard?
yes
Blip the (+) button on the control panel no Control panel2) / button / wiring
several times in succession, Does frequency1)
harness defective, repair or replace
see b 1.1.2 increase?
yes
Blip the (–) button on the control panel no Control panel2) / button / wiring
Does frequency
several times in succession, harness defective, repair or replace
decrease?
see b 1.1.2
yes
Blip the (OFF) button on the control yes Control panel2) / button / wiring
Can the clicking of the
panel, see b 1.1.2 harness defective, repair or replace
solenoid valve be heard?
Generator / wiring harness defective,
repair or replace
1) : Frequency increases until the solenoid valve is all the way open; when the solenoid valve is all the way open, no more clicking can
be heard
2) : If the electronics detect a defective control panel, then the solenoid valve is opened all the way during use, thus ensuring the flow
of water
TI_19_2010_30_01_01.fm
)m~ge 6 Technical Information 19.2010
5.2 Connecting the Power Adapter
The power adapter 4238 400 8500 permits fast 4
troubleshooting. Connect the power adapter to the
generator connection on the solenoid valve and the
power source.
With the power adapter connected, all other 6
components of the electronic water control (control
panel, short circuit wire, solenoid) must be 5
connected except the generator. If a component is
370TI076 KN
replaced, then the power adapter must be
disconnected from the generator connection on the
solenoid valve and then reconnected after the
repair. . Connect the plug (4) of the power adapter (5) to
the solenoid valve
2 . Plug power adapter (6) into a properly installed
power outlet – voltage source and operating
voltage of power adapter must match
Once the power adapter is connected, clicking of the
1 solenoid valve should be heard (see b 5.1).
5.3 Removing the Flywheel
370TI058 KN
. Unscrew bolt (1)
. Remove cover (2) 1 2
370TI061 KN
3
With the cut-off machines STIHL Cutquik®
TS 410-A, TS 420-A, the flywheel must be removed
370TI059 KN
using the previous puller (1) 1135 890 4500 (to be
changed to 5910 890 4504) and the new spacer (2)
4238 894 1100 (see b 3.1.2) in order to avoid
. Disconnect the generator plug (3) from the damaging the generator beneath it.
solenoid valve STIHL recommends also using the new spacer (2)
4238 894 1100 in combination with the previous
puller (1) 1135 890 4500 (to be changed to
5910 890 4504) for the cut-off machines
STIHL Cutquik® TS 410, 420 without electronic
water control, since this ensures straight positioning
of the puller.
TI_19_2010_30_01_01.fm Page 4 of 11
Technical Information 19.2010 Page 7
5.4 Removing the Shroud 5.6 Removing the Air Baffle
In addition to the previous description "Removing In addition to the previous description "Removing
the Shroud" in the Service Manual STIHL Cutquik® the Air Baffle" in the Service Manual
TS 410, 420, in machines with electronic water STIHL Cutquik® TS 410, 420, in machines with
control, the plug connection between the short electronic water control, the plug connection
circuit wire and the control panel must be between the short circuit wire and the control panel
disconnected. as well as the short circuit wire plug on the solenoid
valve must be disconnected.
1
2
1
370TI062 KN
370TI058 KN
. Loosen screw (1) – screw (1) remains in cap (2)
. Remove bolt (1)
. Remove cap (2).
. Remove cover (2)
4
3
370TI063 KN
370TI064 KN
3 4
. Remove plug connector (3) from guide
. Disconnect the plug (3) of the short circuit wire
. Unplug connector (3) between short circuit wire
from the solenoid valve
and control panel
. Remove the shroud, see b 5.4
. Remove bolts (4)
. Remove the filter cover
. Remove the support foot
5.5 Removing the Control Panel
. Remove the air baffle with the short circuit wire
Do not attempt to pry out the control panel with
shroud installed.
. Remove the shroud, see b 5.4
. Remove control panel from the snap mount
TI_19_2010_30_01_01.fm
)m~ge 8 Technical Information 19.2010
5.7 Removing the Generator 5.8 Cable Routing
To ensure that plug connections remain sealed, fuel,
2 oil, grease or other lubricants must never be used
when unplugging and plugging in the connectors.
Fuel, oil, grease or other lubricants can cause the
seal to swell.
1 Do not unplug connections by pulling on the wires,
but instead by pulling on the connector
370TI058 KN
5.8.1 Generator
. Unscrew bolt (1)
. Remove cover (2)
4 5
3
A
1
2
4
3
370TI066 KN
. Insert the lug (1) of the black wire (2) as far as it
will go (A) into the retainer (3) – crimped side
370TI059 KN
facing the bolt head
. Press and/or insert the black wire (2) and yellow
. Disconnect the generator plug (3) from the wire (4) into the marked locations (arrow)
solenoid valve
. Route the yellow wire (4) under the retainer (3)
. Remove the fan cover in the direction of the generator (5)
. Remove the flywheel, see b 5.3 . Insert the retainer (3) into recess "crankcase
half, fan side"
. Bolt down the lug (1)
6
. Bolt down the generator (5)
6
370TI065 KN
5 4
. Unscrew bolt (4) and remove lug (5)
. Remove bolts (6)
. Remove generator (7)
TI_19_2010_30_01_01.fm Page 5 of 11
Technical Information 19.2010 Page 9
5.8.2 Solenoid Valve 5.8.3 Air Baffle
A
4
1
A
1 5 2
2
6
370TI068 KN
370TI067 KN
3
Generator wire Short circuit wire
Route the cable starting at the generator in the . Insert the blue shrink tube (1) into the air baffle
direction of the solenoid valve (see b 5.8.1). as far as it will go (A)
. Insert bushing (1) . Press in and/or insert short circuit wire (2) in the
marked locations (arrows)
. Insert shrink tube as far as it will go (A)
. Press in and/or insert wires (2) in the marked . Slide the bushing (3) over the black shrink tube
locations (arrows)
. Connect the generator plug (3) to the solenoid
valve
Short circuit wire
Route the short circuit wire starting at the air baffle
in the direction of the solenoid valve (see b 5.8.3).
. Insert bushing (4)
. Press in and/or insert short circuit wire (5) in the
marked location (arrow)
. Connect the plug (6) of the short circuit wire to
the solenoid valve
TI_19_2010_30_01_01.fm
)m~ge 10 Technical Information 19.2010
5.8.4 Shroud 5.9 Tightening torques
Plug connection short circuit wire / control
Part(s) Thread Tightening
panel
torque
Cap / tank housing P 6x19 6 Nm
Generator / M 4x12 3 Nm
crankcase
Solenoid valve / tank P 6x19 6 Nm
housing
Cap / shroud M 5x17 4.5 Nm
Ground wire / M 4x12 3 Nm
crankcase
Hose connector / G 3/8" 3 Nm
370TI069 KN
solenoid
. Press in and/or insert plug connection/wire in
the marked locations (arrows) Additional tightening torques are listed in the
Service Manual for the STIHL Cutquik®
TS 410, 420.
Control panel
5.10 Service notes
Service and repair procedures are included in the
Service Manual STIHL Cutquik® TS 410, 420.
370TI070 KN
Route the cable starting at the control panel in the
direction of the plug connection to the short circuit
wire.
. Press in and/or insert plug wires in the marked
locations (arrows)
TI_19_2010_30_01_01.fm Page 6 of 11
Technical Information 19.2010 Page 11
5.11 Repair times
The specified repair times apply for trained and The repair times are specified in minutes.
qualified personnel as well as for properly equipped
repair shops.
TS410-A
Code Type of Repair
TS420-A
2 Replace wheel guard 20
3 Replace wheel bearing bracket assembly. 25
4 Replace belt pulley on wheel arbor. 15
5 Replace wheel arbor shaft. 15
6 Replace arbor shaft bearing. 25
7 Replace belt pulley on clutch end. 25
8 Replace drive belt. 15
9 Replace front handlebar. 15
10 Replace cast arm from engine to wheel 25
11 Replace crankcase, crankcase gasket or re-seal crankcase. Includes air leak test. 160
12 Replace crankshaft main bearing(s). Includes air leak test. 170
13 Replace crankshaft seal(s). Includes air leak test. 70
14 Perform engine air leak test. 30
15 Replace cylinder and/or piston. Includes air leak test and repair of components causing failure. 90
16 Replace ignition module or flywheel. Includes stop circuit test. 25
17 Replace fuel tank line, vent line, or fuel pick-up body. 40
18 Replace intake or transfer port manifold or intake flange 35
19 Repair or replace carburetor. Includes fuel system testing. 45
20 Repair or replace rewind starter 15
21 Repair or replace clutch, clutch shoes or clutch springs. 20
22 Replace rear handle frame or handle housing 30
23 Replace muffler 25
24 Replace air filter or filter housing 15
25 Repair or replace stop switch. Includes circuit testing. 35
26 Replace fuel tank housing 60
27 Replace control panel. Includes electrical and run test. 25
28 Replace generator. Includes electrical and run test. 30
29 Replace solenoid valve. Includes electrical and run test. 20
30 Replace short circuit wire, air baffle. Includes electrical and run test. 25
40 Miscellaneous repairs and other repairs not listed. 15
45 Handling allowance only-no labor. 10
50 No Labor 0
© ANDREAS STIHL AG & Co. KG, 2010 Technical Documentation
D1/MTK-fr
TI_19_2010_30_01_01.fm Page 7 of 11
Page 8 of 11
Page 9 of 11
Page 10 of 11
Page 11 of 11
Extracted from the manufacturer's 2012 service catalogue. Most of these PDFs embed fonts with a shifted character map, so the text above was recovered rather than copied — read it as a faithful but imperfect transcription, and treat the page image above each block as the authority where the two disagree — the figures exist only there, because they are vector drawings that text extraction cannot keep.