Stihl Cutquik 4238 Series Manual

STIH)
Technical Information
TI_35_2009_30_01_01.fm englisch / English
Cut-off machine STIHL Cutquik®TS 410, 420 – Series 4238
Contents
1. Guard with defined adjustment range
2. Belt guard, screw
3. Set of instruction labels
4. Summary
1. Guard with defined adjustment
range
1.1 Adjustment range
In STIHL Cutquik® TS 410, 420 cut-off machines,
the adjustment range (Aand Brespectively) of the
guard will be determined by the stop pin (1) installed
into the cast arm and by the lugs (arrows) molded
onto the guard (2).
Left: Adjustment range (A),
Guard mounted on the inboard side
Right: Adjustment range (B),
Guard mounted on the outboard side
370TI016 KN
B
A
1
2
1
2
35.2009

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1.2 Cast arm
The previous versions of the cast arm
4238 701 0201 (TS 410) and cast arm
4238 701 0200 (TS 420) are being replaced by the
new versions of the cast arm 4238 701 0203
(TS 410) and cast arm 4238 701 0202 (TS 420).
The new versions differ by a threaded hole (1) for
installing in the stop pin (see b1.4) and additional
holes (2) for fastening the limit stop (see b1.5).
Spare parts
The previous versions of cast arm 4238 701 0201
(TS 410) and cast arm 4238 701 0200 (TS 420)
without a threaded hole and without additional holes
are no longer available. The new versions of cast
arm 4238 701 0203 (TS 410) and cast arm
4238 701 0202 (TS 420) can also be used for older
machines.
1.3 Guard
The previous versions of the guard dia. 300 mm
(12") (4238 700 8102) and the guard dia. 350 mm
(14") (4224 700 8102) are being replaced by the
new versions of the guard dia. 300 mm (12")
(4238 700 8105) and the guard dia. 350 mm (14")
(4224 700 8108).
The new versions differ from the previous versions
by casted lugs (arrows), together with the stop pins
(see b1.4) installed into the cast arm (see b1.2)
to determine the adjustment range (see b1.1) of
the guard.
Spare parts
The previous versions of the guard dia. 300 mm
(12") (4238 700 8102) and the guard dia. 350 mm
(14") (4224 700 8102) remain available for older
machines.
Service notes
The previous versions of the guard dia. 300 mm
(12") (4238 700 8102) and the guard dia. 350 mm
(14") (4224 700 8102) may only be installed in
machines with the previous guards.
The new versions of the guard dia. 300 mm (12")
(4238 700 8105) and the guard dia. 350 mm (14")
(4224 700 8108) may only be installed in machines
with the new guards.
2
2
3701TI017 KN
1
Left: Previous versions of the guard
Right: New versions of the guard
3701TI018 KN

Technical Information 35.2009 Page 3
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1.4 Stop pin
With the introduction of the new guards
(see b1.3), the stop pin (1) 4224 691 0100 and
the limit stop (see b1.5) are introduced. The stop
pin (1) installed into the cast arm (2), together with
the lugs molded onto the guard (see b1.3)
determine the adjustment range (see b1.1).
Tightening torques
1.5 Limit stop
With the introduction of the new guards
(see b1.3), the limit stop (1) 4238 691 0200 and
the stop pin (see b1.4) are introduced. The limit
stop (1) is fastened to the cast arm with the pan
head self-tapping screw IS-P4x16 (2)
(9074 478 3025).
Tightening torques
1.6 Rubber buffer
The stop pin (1, see b1.4) and lugs cast onto the
guard (see b1.3) determine the adjustment range
(see b1.1), the rubber buffer (2) 4224 790 9300
and the screw IS-M5x6-10.9 (3) (9022 341 0910)
have been eliminated.
Spare parts
The previous versions of the rubber buffer
4224 790 9300 and the screw IS-M5x6-10.9
(9022 341 0910) remain available for machines with
the previous guards.
Stop pin / cast arm 5 Nm
Limit stop / cast arm 1.8 Nm
2
370TI019 KN
1
370TI020 KN
12
Left: Previous versions of the cast arm,
rubber buffer and screw
Right: New versions of the cast arm with
guard and the stop pin
3
2
3701TI071 KN
1

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1.7 Reconfiguring the "cast arm with guard"
– from guard on the inboard side to
guard on the outboard side
The "cast arm with guard" is mounted on the inboard
side by the manufacturer.
The "cast arm with guard" can also be mounted on
the outboard side depending on requirements.
Assembly on the inboard side is recommended for
better balance.
.Remove the abrasive wheel
Remove water attachment
.Loosen the banjo bolt (1) with the combination
wrench – in the process, remove the square nut
from the guide on the inside of the guard
.Remove the water hose (2) with connector from
the adjusting lever (3)
.Remove the water hose (2) from the
guide (arrows) in the V-belt guard
Remove the adjusting lever
.Loosen the banjo bolt (1) with the combination
wrench and remove it together with the seal – in
the process, remove the square nut from the
guide on the inside of the guard
.Remove bolt (2)
.Turn the adjusting lever (3) upwards and
remove
Slacken the V-belt
.Loosen the nuts (1) – do not remove them
.Turn the tensioning nut (2) counterclockwise
with the combination wrench – approx. 1/4 turn,
max. to stop = 0
3
1
1
370TI021 KN
2
370TI022 KN
2
1
3
0
1
370TI023 KN
2
1
1

Technical Information 35.2009 Page 5
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Remove the V-belt guard
.Loosen screw (1) – in machines with the new
belt guard (see b2), the screw is secured on
the belt guard to prevent loss
.Raise the V-belt guard (2) slightly and pull off
towards front
.Remove the V-belt (3) from the front pulley (4)
Remove the "cast arm with guard"
.Remove the nuts (1)
.Remove the "starter cover with rewind
starter" (2)
.Remove the "cast arm with guard" (3) from the
studs
Preparing the "cast arm with guard" for
outboard mounting
.Remove stop pin (1)
1
370TI024 KN
2
4
3
370TI025 KN
370TI026 KN
3
1
1
1
2
370TI027 KN
1

Page 6 Technical Information 35.2009
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.Turn the guard so that it is in the position shown
(see picture)
.Install and tighten the stop pin (1)
.Move the adjusting lever (2) to position (A)
.Install the bolt (3) and tighten
.Loosen the bolt (4) of the limit stop (5)
.Remove the limit stop (5)
.Turn the "cast arm with guard" so that the guard
is on the outboard side
.Insert limit stop (5) – align the hole in the limit
stop with the hole in the cast arm
.Install the screw (4) and tighten
.Insert the square nut into the guide of the guard
and hold in place
.Install the shorter banjo bolt (6) and washer at
the adjusting lever and tighten with the
combination wrench
Mount "cast arm with guard" – guard on the
outboard side
.Position the oblong holes (1) in the "cast arm
and guard" onto to the studs (2), install the
ribbed V-belt over the front pulley
.Check that the belt adjustment moves easily
.The belt tensioner (3) must nest against the
lug (4)
.Fit the "starter cover with rewind starter" (5) over
the studs (2)
.Tighten the nuts (6) by hand
370TI028 KN
4 5
1
3 2
A
370TI029 KN
6
45
2
2
370TI030 KN
1
3
4
2
1
1
370TI031 KN
2
2
2
66
6
5

Technical Information 35.2009 Page 7
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.Push the V-belt guard (7) into place
.Install and tighten screw (8) – in machines with
the new belt guard (see b2), the screw is
secured on the belt guard to prevent loss
Connect water connection
.Insert the longer banjo bolt (1) through the
connector (2) of the water attachment – observe
the position of the connector
.Insert the square nut into the guide of the guard
and hold in place
.Install the support with the longer banjo bolt onto
the adjusting lever (3) – install the banjo bolt and
tighten with the combination wrench
.Insert the water hose into the guide in the V-belt
guard (arrow) from the shut-off cock towards the
guard – avoid tight radiuses
.Tension the ribbed V-belt
Check the adjustment range of the guard
.Rotate the guard forwards and backwards as far
as possible – adjustment range (A) must be
limited by the stop pin
370TI032 KN
8
7
1
370TI033 KN
3
2
1
A
370TI034 KN

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1.8 Reconfiguring the "cast arm with guard"
– from guard on the outboard side to
guard on the inboard side
.Remove the abrasive wheel
.Remove water attachment
.Remove the adjusting lever
.Slacken the V-belt
.Remove the V-belt guard
.Remove the V-belt
.Remove the "cast arm with guard"
Preparing the "cast arm with guard" for inboard
mounting
.Loosen the bolt (1) of the limit stop (2)
.Remove the limit stop (2)
.Turn the "cast arm with guard" so that the guard
is on the inboard side
.Insert limit stop (2) – align the hole in the limit
stop with the hole in the cast arm
.Install the screw (1) and tighten
.Remove stop pin (3)
.Turn the guard so that it is in the position shown
(see picture)
.Install and tighten the stop pin (3)
.Install the adjusting lever
.Mount "cast arm with guard" – guard on the
inboard side
.Install the V-belt
.Install the V-belt guard
.Connect water connection
.Tension the ribbed V-belt
Check the adjustment range of the guard
Rotate the guard forwards and backwards as far as
possible – adjustment range (A) must be limited by
the stop pin
370TI035 KN
1 2
370TI036 KN
12
3
370TI037 KN
3
370TI038 KN
A

Technical Information 35.2009 Page 9
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2. Belt guard, screw
The previous versions of the belt guard (1)
4238 700 8101 (TS 410) and the belt guard (2)
4238 700 8100 (TS 420) are being replaced by the
new versions of the belt guard (3) 4238 700 8107
(TS 410) and the belt guard (4) 4238 700 8109
(TS 420).
The new versions of the belt guard (3,4) are
fastened to the cast arm with the new screw
IS-M5x21 (5) (9022 319 1027). In the versions of
the belt guard (3,4), the new screw IS-M5x21 (5)
(9022 319 1027) is secured against loss. The
previous versions of the spline screw
IS-M5x30x22-10.9 (6) (9022 341 1070) and the
hollow rivet DIN7339-7.5x1x6.8 (7)
(9443 825 7130) are no longer needed.
Tightening torques
Spare parts
The previous versions of the belt guard
4238 700 8101 (TS 410) and the belt guard
4238 700 8100 (TS 420) are no longer available.
The new versions of belt guard 4238 700 8107
(TS 410) and belt guard 4238 700 8109 (TS 420)
can also be used for older machines. The previous
versions of spline screw IS-M5x30x22-10.9
(9022 341 1070) and hollow rivet
DIN7339-7.5x1x6.8 (9443 825 7130) remain
available for older machines.
Left: Previous versions of the belt guard
and the screw
Right: New versions of the belt guard and
the screw
Belt guard / cast arm 6 Nm
7
56
7
3701TI072 KN
1, 2 3, 4

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3. Set of instruction labels
3.1 Set of instruction labels 0000 960 0100
(only for TS 410)
TS 410 only, the previous versions of instruction
label (1) 0000 967 3521 and instruction label (2)
0000 967 3511 are being replaced by the new "set
of instruction labels" (3) 0000 960 0100.
Spare parts/service notes
The previous versions of instruction label (1)
0000 967 3521 and instruction label (2)
0000 967 3511 are no longer available. The new
"set of instruction labels" (3) 0000 960 0100 can
also be used with older STIHL Cutquik®TS 410 cut-
off machines.
Always attach both instruction labels in the new "set
of instruction labels" (3) 0000 960 0100.
3.2 Set of instruction labels 0000 960 0101
(only for TS 420)
TS 420 only, the previous versions of instruction
label (1) 0000 967 3521 and instruction label (2)
0000 967 3520 are being replaced by the new "set
of instruction labels" (3) 0000 960 0101.
Spare parts/service notes
The previous versions of instruction label (1)
0000 967 3521 and instruction label (2)
0000 967 3520 are no longer available. The new
"set of instruction labels" (3) 0000 960 0101 can
also be used with older STIHL Cutquik®TS 420 cut-
off machines.
Always attach both instruction labels in the new "set
of instruction labels" (3) 0000 960 0101.
Left: Previous versions of the instruction
labels
Right: New versions of the instruction labels
3
3701TI073 KN
21
Left: Previous versions of the instruction
labels
Right: New versions of the instruction labels
3
3701TI073 KN
21