Stihl Cutquik TS 410-A Manual

STIH)
Technical Information
TI_19_2010_30_01_01.fm englisch / English
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
The new cut-off machines STIHL Cutquik®
TS 410-A, TS 420-A are equipped with the new,
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
idling
.Easy operation via the ergonomically arranged
control panel
.Time savings, e. g., due to less frequent refilling
of the STIHL pressurized water tank
Both the potential applications and uses as well as
the other product features are equivalent to those of
the cut-off machines STIHL Cutquik®TS 410, 420.
1.1 Functional description
The electronic water control consists essentially of
the following components:
– Control panel (1)
– Generator (2) – behind the flywheel
– Solenoid valve (3) – with integral control
1
370TI052 KN
23
19.2010

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The generator ensures that power is supplied to the
solenoid when the engine is running.
Using the buttons of the ergonomically arranged
control panel, the user can adjust both the water
flow rate as well as manually activating and
deactivating the water control.
1.1.1 Before starting work
.While the engine is switched off: Familiarize
yourself with the sequence of motions
.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.
1Button (+):
Activate the electronic water control or increase
water flow to cutting wheel
2Button (–):
Activate the electronic water control or decrease
water flow to cutting wheel
3Deactivate electronic water control; no water is
fed to the cutting wheel
370TI053 KN
1
2
3
370TI054 KN

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1.1.3 Using the Electronic Water Control
.Start the engine in accordance with the
Instruction Manual
.Blip the (+) button or (–) button 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 – 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
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
continues, the last quantity of water set before the
idle phase will be fed to the cutting wheel again
automatically.
1.1.4 Maintenance and Care
To protect the solenoid valve, a screen is installed in
the water connection.
If too little water or no water is fed to the cutting
wheel during use with the electronic water control
activated:
.Remove the coupling sleeve (1)
.Unscrew "water connection with screen" (2) and
rinse under running water – the screen remains
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
21
370TI055 KN

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3. Servicing accessories
3.1 New special tools
3.1.1 Power adapter 4238 400 8500
The power adapter 4238 400 8500 permits fast
troubleshooting (see b5.1, b5.2).
3.1.2 Spacer 4238 894 1100
The flywheel must be removed with the previous
puller 1135 890 4500 (to be changed to
5910 890 4504) and the new spacer 4238 894 1100
(see b5.3), in order to avoid damaging the
generator beneath it.
3.2 Existing special tools
The existing special tools are listed in the Service
Manual for STIHL Cutquik®TS 410, 420.
4. Spare parts
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
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®
TS 410-A, TS 420-A, only the new clutch
4238 160 2002 should be used as a replacement
part.
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
Possible customer complaint
– No water flow or water flow too low
– Water flow cannot be adjusted via the control
panel buttons
– System leaks
370TI075 KN
370TI057 KN

Technical Information 19.2010 Page 5
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Customer complaint
Customer complaint
remedied?
no
Check water connection / screen and
clean if necessary, see b1.1.4 Troubleshooting completed
Leaky solenoid valve, repair or
replace
Leak testing: Engine switched off,
connect machine to water supply
(e. g., pressurized water tank)
Disconnect machine from water
supply. Connect power adapter,
see b5.2
System free of leaks?
Solenoid valve / control defective,
repair or replace if necessary
Blip the (OFF) button on the control
panel, see b1.1.2
Control panel2) / button / wiring
harness defective, repair or replace
Blip the (+) button on the control panel
several times in succession,
see b1.1.2
yes
Can the clicking of the
solenoid valve be heard?
Does frequency1)
increase?
Generator / wiring harness defective,
repair or replace
Control panel2) / button / wiring
harness defective, repair or replace
no
yes
yes
yes
no
no
Blip the (–) button on the control panel
several times in succession,
see b1.1.2
Does frequency
decrease?
no
Can the clicking of the
solenoid valve be heard?
yes Control panel2) / button / wiring
harness defective, repair or replace
yes
no
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

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5.2 Connecting the Power Adapter
The power adapter 4238 400 8500 permits fast
troubleshooting. Connect the power adapter to the
generator connection on the solenoid valve and the
power source.
With the power adapter connected, all other
components of the electronic water control (control
panel, short circuit wire, solenoid) must be
connected except the generator. If a component is
replaced, then the power adapter must be
disconnected from the generator connection on the
solenoid valve and then reconnected after the
repair.
.Unscrew bolt (1)
.Remove cover (2)
.Disconnect the generator plug (3) from the
solenoid valve
.Connect the plug (4) of the power adapter (5) to
the solenoid valve
.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
solenoid valve should be heard (see b5.1).
5.3 Removing the Flywheel
With the cut-off machines STIHL Cutquik®
TS 410-A, TS 420-A, the flywheel must be removed
using the previous puller (1) 1135 890 4500 (to be
changed to 5910 890 4504) and the new spacer (2)
4238 894 1100 (see b3.1.2) in order to avoid
damaging the generator beneath it.
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.
1
370TI058 KN
2
3
370TI059 KN
4
370TI076 KN
5
6
370TI061 KN
1 2

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5.4 Removing the Shroud
In addition to the previous description "Removing
the Shroud" in the Service Manual STIHL Cutquik®
TS 410, 420, in machines with electronic water
control, the plug connection between the short
circuit wire and the control panel must be
disconnected.
.Loosen screw (1) – screw (1) remains in cap (2)
.Remove cap (2).
.Remove plug connector (3) from guide
.Unplug connector (3) between short circuit wire
and control panel
.Remove bolts (4)
5.5 Removing the Control Panel
Do not attempt to pry out the control panel with
shroud installed.
.Remove the shroud, see b5.4
.Remove control panel from the snap mount
5.6 Removing the Air Baffle
In addition to the previous description "Removing
the Air Baffle" in the Service Manual
STIHL Cutquik®TS 410, 420, in machines with
electronic water control, the plug connection
between the short circuit wire and the control panel
as well as the short circuit wire plug on the solenoid
valve must be disconnected.
.Remove bolt (1)
.Remove cover (2)
.Disconnect the plug (3) of the short circuit wire
from the solenoid valve
.Remove the shroud, see b5.4
.Remove the filter cover
.Remove the support foot
.Remove the air baffle with the short circuit wire
370TI062 KN
12
3
370TI063 KN
4
4
1
370TI058 KN
2
3
370TI064 KN

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5.7 Removing the Generator
.Unscrew bolt (1)
.Remove cover (2)
.Disconnect the generator plug (3) from the
solenoid valve
.Remove the fan cover
.Remove the flywheel, see b5.3
.Unscrew bolt (4) and remove lug (5)
.Remove bolts (6)
.Remove generator (7)
5.8 Cable Routing
To ensure that plug connections remain sealed, fuel,
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.
Do not unplug connections by pulling on the wires,
but instead by pulling on the connector
5.8.1 Generator
.Insert the lug (1) of the black wire (2) as far as it
will go (A) into the retainer (3) – crimped side
facing the bolt head
.Press and/or insert the black wire (2) and yellow
wire (4) into the marked locations (arrow)
.Route the yellow wire (4) under the retainer (3)
in the direction of the generator (5)
.Insert the retainer (3) into recess "crankcase
half, fan side"
.Bolt down the lug (1)
.Bolt down the generator (5)
1
370TI058 KN
2
3
370TI059 KN
4
5
7
370TI065 KN
6
6
1
3
370TI066 KN
4
2
5
4
A

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5.8.2 Solenoid Valve
Generator wire
Route the cable starting at the generator in the
direction of the solenoid valve (see b5.8.1).
.Insert bushing (1)
.Insert shrink tube as far as it will go (A)
.Press in and/or insert wires (2) in the marked
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 b5.8.3).
.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
5.8.3 Air Baffle
Short circuit wire
.Insert the blue shrink tube (1) into the air baffle
as far as it will go (A)
.Press in and/or insert short circuit wire (2) in the
marked locations (arrows)
.Slide the bushing (3) over the black shrink tube
A
3
370TI067 KN
4
1
2
5
6
A
370TI068 KN
1
2
3

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5.8.4 Shroud
Plug connection short circuit wire / control
panel
.Press in and/or insert plug connection/wire in
the marked locations (arrows)
Control panel
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)
5.9 Tightening torques
Additional tightening torques are listed in the
Service Manual for the STIHL Cutquik®
TS 410, 420.
5.10 Service notes
Service and repair procedures are included in the
Service Manual STIHL Cutquik®TS 410, 420.
370TI069 KN
370TI070 KN
Part(s) Thread Tightening
torque
Cap / tank housing P 6x19 6 Nm
Generator /
crankcase
M4x12 3Nm
Solenoid valve / tank
housing
P6x19 6Nm
Cap / shroud M 5x17 4.5 Nm
Ground wire /
crankcase
M4x12 3Nm
Hose connector /
solenoid
G3/8" 3Nm

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5.11 Repair times
The specified repair times apply for trained and
qualified personnel as well as for properly equipped
repair shops.
The repair times are specified in minutes.
© ANDREAS STIHL AG & Co. KG, 2010 Technical Documentation
D1/MTK-fr
Code Type of Repair TS410-A
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