Stihl TS 460 User manual

STIHL TS 460 1
Service Manual
Cutquik TS 460
This Service Manual contains a Refer to the "Technical Information The STIHL Special Tools manual
detailed description of all repair Bulletins" for engineering changes lists all special servicing tools
work for the Cutquik TS 460. which have been introduced since currently available from STIHL.
publication of this service manual.
You should make use of the Technical information is Always use original STIHL
illustrated parts lists while carrying considered to be a supplement to replacement parts.
out repair work. They show the the parts list until publication of a Original STIHL parts can be identi-
installed position and the new edition. fied by the STIHL part number
assembly sequence of the the
STIHl logo
assemblies. Microfilmed parts lists Service manuals and technical and the STIHL parts symbol
(
((
(
are always more up to date than information bulletins describing
printed lists! engineering changes are intended The symbol may appear alone on
exclusively for the use of STIHL small parts.
A fault on the machine may have servicing dealers and staff and
several causes. Consult the must not be passed on to third
"troubleshooting charts" when parties.
tracing faults.
STIHl
STIHlSTIHl
STIHl
Andreas Stihl
D-71336 Waiblingen

STIHL TS 460 2
CONTENTS
1. Specifications 3
1.1 Engine 3
1.2 Fuel System 4
1.3 Ignition System 4
1.4 Cutting Wheel 5
1.5 Special Accessories 5
1.5.1 For User 5
1.5.2 For Service 5
1.6 Tightening Torques 6
2. Troubeshooting
Charts 7
2.1 Clutch,
Bearing with Guard 7
2.2 Engine 7
2.3 Ignition System 8
2.4 Rewind Starter 9
2.5 Fuel System 10
3. Cutting Wheel Drive
Assembly 12
3.1 Bearing with Guard 12
3.2 Testing of Radial and
Axial Truth of Running 16
3.3 V-Belt 18
3.4 V-belt Pulley/
Clutch Drum 18
3.5 Clamp 19
4. Clutch 20
4.1 Disassembly 20
4.2 Assembly and
Installation 21
5. Engine 22
5.1 Removing and Refitting
Exhaust Muffler 22
5.2 Cylinder and Piston 22
5.2.1 Removal 22
5.2.2 Installation 24
5.3 Piston Rings 27
5.4 Crankcase 27
5.4.1 Removing theCrankshaft 27
5.4.2 Installing the Crankshaft 29
5.5 Leakage Testing the
Crankcase 30
5.5.1 Preparations 31
5.5.2 Pressure Test 32
5.5.3 Vacuum Test 33
5.6 Replacing the Oil Seals 34
5.7 Removing and
Installing the Engine 35
5.8 Engine Housing 38
6. Ignition System 42
6.1 Repairing Component
Parts 42
6.1.1 Spark Plug 42
6.1.2 Ignition Module 44
6.1.2.1 Ignition Timing 44
6.1.2.2 Removing and Installing 44
6.1.3 Ignition Lead/Spark Plug
Terminal 45
6.1.4 Short Circuit Wire/
Ground Wire 47
6.1.5 Flywheel 48
7. Rewind Starter 50
7.1 Routine Maintenance 50
7.2 Rope Rotor 50
7.3 Replacing the Starter
Rope 51
7.4 Replacing the Rewind
Spring 52
7.5 Tensioning the Rewind
Spring 53
7.6 Pawl 53
7.7 Starter Cup 54
7.8 Replacing the Rope
Guide Bush 54
8. AV Handle System 55
8.1 Repair 55
9. Throttle Control 56
9.1 Throttle Trigger,
Throttle Trigger Interlock 56
9.2 Slide Control 57
9.3 Contact Springs 57
9.4 Throttle Cable 57
9.5 Handle 58
9.6 Handle Tube Bracket 58
9.7 Handle Grip 59
10. Fuel System 61
10.1 Air Filter 61
10.2 Construction
and Function of the
Carburetor with
Compensator 62
10.3 Removing and Installing
the Carburetor 63
10.4 Leakage Testing the
Carburetor 65
10.5 Servicing the
Carburetor 65
10.6 Carburetor Adjustment 71
10.7 Pickup Body 72
10.8 Fuel Tank 73
10.9 Expansion Tank 75
10.10 Tank Vent 75
10.11 Manifold 77
11. Special Servicing
Tools and Aids 78
11.1 Special Servicing Tools 78
11.2 Servicing Aids 80

STIHL TS 460 3
1. Specifications
1.1 Engine STIHL single-cylinder two-stroke engine
with special impregnated cylinder bore
Displacement: 72.4 cm³
Bore: 48.0 mm
Stroke: 40.0 mm
Power output: 3.5 kW (4.75 bhp)
Max. permissible speed 9.600 r.p.m.
Idle speed: 2,500 r.p.m.
Bearings: Crankshaft supported in heavy-duty
deep groove ball bearings,
needle cages on small and
big ends
Connecting rod length: 70 mm
Rewind starter: Single pawl system with
automatic rope rewind
mechanism
Reserve pull on rope rotor: min. 1/2 turn of rope rotor
Starter rope: 4.5 mm dia., 1000 mm long
Clutch: Centrifugal clutch without linings
Diameter: 80 mm
Clutch engages at: 3,200 r.p.m.
Crankcase leakage test
at gauge pressure: pü= 0.5 bar
under vacuum: pu= 0.5 bar
Silencing: Intake air silencer and
exhaust muffler

STIHL TS 460 4
1.2 Fuel System Carburetor: All position diaphragm
carburetor with integral
fuel pump
Standard setting
High speed adjusting screw H: Back off 1 turn
Low speed adjusting screw L: Back off 1 turn
(starting with the screws
tight against their
seats)
Carburetor leakage test at
gauge pressure: pü= 0.8 bar
Fuel tank capacity: 0.95 I (950 cm 3)
Fuel mixture: Regular brand-name gasoline
(leaded or unleaded) and STIHL
two-stroke engine oil
Octane number: min. 90 RON
Mix ratio: 1:50
with STIHL two-stroke engine oil 50:1
1:25
with other brand-name
two-stroke engine oils
Air filter: Felt prefilter, large main filter
(paper filter cartrigde)
and auxiliary filter
1.3 Ignition System Type: Electronic magneto
ignition (breakerless)
Air gap: 0.2-0.5 mm
Ignition timing: 2.8-3.2 mm B.T.D.C.
at 8,000 r.p.m.
Spark plug (suppressed): Bosch WSR 6 F or
NGK BPMR 7 A
Electrode gap: 0,5 mm
Spark plug thread: M14x1.25
Length of thread: 9.5 mm
Heat range: 200

STIHL TS 460 5
1.4 Cutting Tools
Cutting wheel for stone 300x3.5x20 mm dia
Cutting wheel for steel 300x3.5x20 mm dia
Cutting wheel for stone 300x6.0x20 mm dia
Cutting wheel for asphalt 300x3.5x20 mm dia
Cutting wheel for stone 350x4.0x20 mm dia
Cutting wheel for steel 350x4.0x20 mm dia
Diamond cutting wheel for stone 300x2.6x20 mm dia
Diamond cutting wheel for asphalt 300x3.2x20 mm dia
Cutting depth approx. 100 mm (for 300 mm dia)
approx. 115 mm (for 350 mm dia)
1.5 Special Accessories
1.5.1 For User STIHL-Cutquik cart
Cutting depth limiter
Wet cutting attachment
Water attachment
1.5.2 For Service Electrician's repair kit

STIHL TS 460 6
1.6 Tightening Torques
Fastener Thread For component Torque Remarks
size Nm Nm
Spline screw IS-M5x58x22 Cylinder/crankcase 10.0
Spline screw IS-M5x35x22 Crankcase/engine housing 10.0
Spline screw IS-M5x20 Spacer flange 7.0
Clutch 50.0
Spline screw IS-M5x20 Cast arm/engine housing 7.0
Hexagon nut M10X1 Starter cup 40.0
Collar nut M8x1 Flywheel 25.0
Spline screw IS-M5x14 Filter base/engine housing 7.0
Spline screw IS-M5x58x35 Connector/carburetor/flange 5.0
Spline screw IS-M5x14 Housing cover/engine housing 7.0 1)
Spline screw IS-M5x20 Ignition module 8.0 1)
Spline screw IS-M5x20 Fan cover 6.0
Spline screw IS-M5x14 Muffler/cylinder 10.0
Spline screw IS-M5x35 Muffler/engine housing 10.0 1)
Spline screw IS-M4x6 Deflector baffle/muffler 3.0
Spline screw IS-M5x14 Clamp 4.0
Spline screw IS-M4x6 Short circuit wire/ground 3.0
Spline screw IS-DG5x24 Handle molding/handle 3.0
Spline screw IS-M5x14 Annular buffer/engine housing 7.0
Spline screw IS-DG5x24 AV-molding/handle 3.0
Spline screw IS-M5x14 Annular buffer/handle tube bracket 7.0
Spline screw IS-M5x14 Support/handle tube bracket 7.0
Spline screw IS-M5x14 Handle tube/handle tube bracket 7.0
Spline screw IS-DG5x24 Handle tube/handle 6.0
Spline screw IS-M5x20 Shroud/engine housing 6.0
Spline screw IS-M5x20 Carburetor box cover 6.0
Spline screw IS-M5x20 Starter cover 6.0
M14x1.25 Spark plug 27.5
1) Washer must be fitted under screw head.

STIHL TS 460 7
2. TROUBLESHOOTING
CHARTS
2.1 Clutch,
Bearing with Guard
Condition Cause Remedy
Insufficient frictional contact -
clutch slips Clutch springs stretched or fatigued, spring hooks broken Fit new springs
Cutting wheel rotates
while engine is idling Engine idle speed too high Correct at idle speed adjusting screw
Clutch springs stretched or fatigued,
spring hooks broken Fit new springs
Cutting wheel does not
rotate at full throttle Small V-belt not tensioned Tension small V-belt
Clamp damaged Replace clamp
Small V-belt torn Replace small V-belt
2.2 Engine
Always check and, if necessary, repair the following parts before looking for faults on the engine:
- Air filter, fuel system, carburetor, ignition system
Condition Cause Remedy
Engine does not start easily, stalls
at idle speed, but operates normally
at full throttle
Oil seals in crankcase damaged Replace oils seals
Gaskets on spacer flange leaking Fit new gaskets
Cylinder base gasket leaking Replace gasket
Crankcase damaged (cracks) Replace crankcase
Engine does not deliver full power
or runs erratically Secondary air seepage through faulty gasket on spacer flange Replace gaskets
Piston rings worn or broken Fit new piston rings
Muffler carbonized Clean the muffler (inlet and
exhaust), fit new spark arresting
screen
Engine overheating Insufficient cylinder Thoroughly clean cylinder
cooling due to dirty cooling fins
cooling fins

STIHL TS 460 8
2.3 Ignition System
Warning: Exercise extreme caution while carrying out maintenance and repair work on the ignition system,
The high voltages which occur can cause serious or fatal accidents!
Ignition system in order.
Look for fault in fuel system and
carburetor.
yes
Replace ignition module. Does engine
now run after positive spark test?
Fit new flywheel.
Is spark test positive?
Use ohmmeter to check ignition lead
for break. If break is detected, fit new
ignition lead. Does spark test now
produce sparkover?
Does flywheel appear to
be in good condition?
Fit new spark plug.Is air gap correct?
Adjust air gap (0.2-0.5 mm).
Is spark test positive?
Insert screwdriver in place of spark plug in spark plug
terminal and hold about 4 mm away from
ground. Sparkover?
Replace faulty ignition lead of short
circuit wire. Repair contact spring.
Faulty insulation on ignition
lead or short circuit wire?
Clean spark plug and reset electrode gap.
Does spark test produce powerful spark?
Press terminal firmly onto spark
plug and fit spring if necessary.
Spark plug terminal firmly seated on spark plug?
Remove spark plug.
Is it in good condition?
no
no
no no
no
yes
no
no yes
yes no
no
no
no
yes
yes

STIHL TS 460 9
2.4 Rewind Starter
Condition Cause Remedy
Starter rope broken Rope pulled out too vigorously as
far as stop or over edge - i.e. not
vertically
Fit new starter rope
Normal wear Fit new starter rope
Rewind spring broken Spring overtensioned – no reserve
when rope is fully extended Fit new rewind spring
Very dirty or corroded Fit new rewind spring
Starter rope can be pulled out
almost without resistance
(crankshaft does not turn)
Guide peg on pawl or pawl is worn Fit new pawl
Spring clip fatigued or broken Fit new spring clip
Starter cup worn or damaged Fit new starter cup
Starter rope is difficult to pull and
rewinds very slowly Starter mechanism is very dirty (dusty conditions) Thoroughly clean complete starter mechanism
Lubricating oil on rewind spring
becomes viscous at very low
outside temperatures (spring
windings stick together)
Apply a few drops of kerosine
(paraffin) to spring, then pull
rope carefully several times
until normal action is restored

STIHL TS 460 10
2.5 Fuel System
Condition Cause Remedy
Carburetor floods; Inlet needle not sealing. Remove and clean or replace
engine stalls Foreign matter in valve seat
or cone damaged inlet needle, clean fuel tank, pickup body and fuel line if necessary
Inlet control lever sticking on Free off inlet control lever
spindle
Helical spring not located on Remove inlet control
nipple of inlet control lever lever and refit correctly
Perforated disc on diaphragm is Fit new metering diaphragm
deformed and presses constantly
against inlet control lever
Inlet control lever too high Set inlet control lever flush with
(relative to design position) bottom of metering chamber
Poor acceleration Idle jet "too lean" Back off low speed adjusting
screw slightly (see Carburetor
Adjustment)
Main jet "too lean" Back off high speed adjusting
screw slightly (see Carburetor
Adjustment)
Inlet control lever too low Set inlet control lever flush with
(relative to design position) bottom of metering chamber
Inlet needle sticking to valve seat Remove inlet needle,
clean and refit
Compensator hose to Clear compensator hose
manifold is blocked using air pressure; replace
manifold if necessary
Diaphragm gasket leaking Fit new diaphragm gasket
Metering diaphragm damaged Fit new metering diphragm
or shrunk

STIHL TS 460 11
Condition Cause Remedy
Engine will not idle, Throttle shutter opened too Reset idle speed adjusting screw
idle speed too high wide by idle speed adjusting screw correctly
Engine stalls at idle speed Idle jet bores Clean jet bores and ports with
or ports blocked compressed air
Idle jet "too rich" Screw down low speed
adjusting screw slightly
(see Carburetor Adjustment)
Setting of idle speed adjusting Set idle speed adjusting screw
screw incorrect - throttle shutter correctly
completely closed
Small plastic plate in valve jet Clean or renew valve jet
does not close
Engine speed drops quickly Air filter plugged Clean air filter
under load - low power Tank vent faulty Clean or replace tank
vent if necessary
Leak in fuel line between tank Seal or renew connections
and fuel pump and fuel line
Compensator hose to Seal connections or
manifold leaks replace manifold
Pump diphragm damaged Fit new Pump diphragm
or fatigued
Main jet bores or Clean bores and ports
ports blocked
Fuel pickup body dirty Fit new pickup body
Fuel strainers dirty Clean fuel strainers
See also 2.2

STIHL TS 460 12
3. CUTTING WHEEL
DRIVE ASSEMBLY
3.1 Bearing with Guard
Top: Top:
Relieve tension of V-belt Top: Removing the axial clamp ring
Removing the bearing 1 = Thrust washer
Bottom:
1 = Guard Bottom: Bottom:
2 = Mounting screws Pliers 0881 611 8200 Unscrewing the nut
- Check axial and radial truth of - Lift the bearing with guard out of - Lock the V-belt pulley. Unscrew
- running; see 3.2. -the V-belt. - the nut and draw the V-belt pulley
- off the shaft.
- Relieve tension of V-belt by - Draw the axial clamping ring off
- turning hexagon nut of clamp - the shaft. Important! The nut has a
- counterclockwise until arrow left-hand thread.
- points left (at the "0"). - Remove the thrust washer.
- Unscrew the mounting screws on
-the bearing and remove the guard.

STIHL TS 460 13
Top: Top:
1 = Woodruff key Top: 1 = Rubber washer
2 = Washer Flat head screws 2 = Disk
Bottom: Bottom: Bottom:
Removing the shaft Removing the flange Removing the bearing
- Remove the woodruff key from - Unscrew both flat head screws - Remove the disk and rubber
- the groove in the shaft. - and remove them together with - washer from the flange and
- the spring washers. - guard.
- Remove the washer from the
- shaft. Note: Note the number of spring - Remove the bearing from the
washers. - guard.
- Draw the shaft out of the deep
- groove ball bearings. - Remove the flange from the
- guard.

STIHL TS 460 14
Top:
1 = Countersunk screw Top:
Top: 2 = Limit stop Removing a
Removing the rubber ring 3 = Spline screw circlip
4 = Rubber vibration buffer
Bottom: Bottom:
1 = Rubber washer Bottom: Pressing out the deep groove ball
2 = Disk Pliers 0811 641 8380 bearings with drift pin 4119 893 7200
- Remove the rubber ring from the - Unscrew the countersunk screw - Remove the circlips from the
-bearing. - and remove the limit stop. - grooves before removing the
- deep groove ball bearings.
- Remove the rubber washer and - Unscrew the spline screw in
- disk from the bearing. - order to replace the rubber - Force both deep groove ball
- vibration buffer. - bearings and the ring out of the
- bearing with the drift pin.
Note: The limit stop and rubber
vibration buffer only feature in
machines for the USA.

STIHL TS 460 15
Top:
Flange Top: Top:
mounting screws 1 = Deep groove ball bearing Correctly positioned spring washers
2 = Ring
Bottom: Bottom:
Fitting the circlip Bottom: Longer collar on the
with pliers 0811 641 8380 Pressing in the deep groove ball bearings V-belt pulley
- Unscrew the flange mounting - Slide the first deep groove ball - Slide the same number of spring
-screws and remove the flage - bearing onto the shaft, then the - washers onto the flat head
- from the guard. - ring and the second deepgroove - screws as were removed during
- ball bearing. - disassembly, as shown in the
The parts are assembled in - drawing.
reverse order. - Position the deep groove ball
- bearings and press them in with - Slip the V-belt pulley onto the
Note: Particular care must be - the shaft until they contact the - shaft with the longer chamfered
taken when carrying out the - circlip. - edge first and tighten the nut with
following work. - a torque of 37.5 Nm.
- Draw the shaft out of the deep
- Place the circlip in one of the - groove ball bearings.
- bearing grooves. - Place the second circlip in the
- bearing groove.

STIHL TS 460 16
approx. 130 mm over one full
revolution of the wheel. Refer to
the table "Test procedure".
- Remove the test equipment after
completing the measurement.
3.2 Checking the Axial and
Radial Truth of Running
Top:
Fitting the test wheel
1 = Arresting grooves
1 =Test wheel 5910 851 6100 2 = Arresting lugs
2 = Gauge holder
5910 850 6000 Bottom:
Tightening the V-belt 3 = Dial gauge 0000 890 9100 Test equipment in position
- Place V-belt in V-belt of bearing, Since changes in the shaft
position guard and loosely screw diameter (due to scoring etc.) can
in mounting screws. affect the radial truth of running of
the cutting wheel, it is normally
- Turn hexagon of tensioning sufficient to inspect the shaft
device clockwise until spring around the cutting wheel mount.
force is eliminated. The axial truth of running, on the
- Tighten all three mounting other hand, depends on the state
screws starting with rear screw. of various components and must
therefore be determined by
measurement.
- Fit the test wheel and then
position the thrust washer so that
the arresting lugs engage in the
arresting grooves in the shaft.
-Tighten the screw.
- Secure the gauge holder with dial
gauge to the guard cover so that
the axial truth of running can be
determined for a diameter of

STIHL TS 460 17
Test procedure Actual condition Possible causes Remedy
Radial truth of running:
Visual inspection Wear marks or scoring Mounting screw loose, Replace the
of the spindle (shaft) around the cutting wheel use of wrong cutting spindle (shaft)
mount wheels (diameter of
mount Ø > 20 mm
or > 22 mm)
Axial truth of running:
Check the axial truth of Axial eccentricity None
running with the STIHL ≤0,15 mm
test wheel or diamond
cutting wheel (over a > 0,15 mm
diameter of 130 mm) Damaged or uneven contact Dirt; thrust washers or Replace the
surfaces of the thrust washers cutting wheel fitted incorrectly; thrust washers
(especially the inner thrust application of force when
washer); contact surfaces not cutting or during transport
plane; genuine STIHL parts
have not been used
Spindle (shaft) Incorrect handling, Replace the
damaged use of force spindle (shaft)
Distinct radial play in the Deep groove ball bearings Replace the
bearing seat --> spindle damaged by exposure to dirt spindles and
bearing defective and/or bearing seat worn deep groove
down at the spindle ball bearings

STIHL TS 460 18
3.3
V
-belt 3.4
V
-belt Pulley
/
Clutch Drum
Top:
Removing the cover
Bottom:
Removing the V-belt
Top:
Assembly pin 1119 893 7200
Bottom:
Forcing out the needle sleeve
- Remove the V-belt, see 3.3.
- Remove the starter cup, see 7.7.
- Draw the V-belt pulley off the
crankshaft stub.
- Check the clutch drum: it must not
show any major signs of wear or
scoring. Replace the V-belt pulley if
necessar
y
.
- Remove the bearing with guard,
see 3.1.
- Remove the starter cover, see
7.2.
- Remove the cover.
- Remove the V-belt from the
V-belt pulley.
The parts are assembled in
reverse order.
- Check the needle sleeve and
force it off the V-belt pulley
from the clutch side using an
assembly pin if necessary.
Top:
Removing the V-belt pulley
Bottom:
Friction surface of the clutch drum

STIHL TS 460 19
3.5 Clamp
Top:
1 = Wheel
2 = Bushing
Bottom:
Properly positioned needle sleeve
Bottom:
Mounting screws
of clamp
Top:
Removing the throttle trigger interlock
Below:
Attaching the tension rod
Top:
Relieving tension of the clamp
- Remove bushing and wheel from
crankshaft stub.
The parts are assembled in
reverse order.
Note: Insert assembly pins on
thicker, beaded side of needle
sleeve and press in from side on
which the clutch drum is located
until they are flush with the inner
edge of the V-belt pulley.
- Remove the V-belt, see 3.3.
-Turn hexagon nut on clamp
counterclockwise until inner
spring is completely slack.
- Take out clamp mounting
screws, remove clamp.
- Remove throttle trigger interlock
from recess in housing.
The parts are assembled in
reverse order.
Note: Insert hooks of tension rod in
hole and put both parts together.
Tighten mounting screws to 4.0 Nm.

STIHL TS 460 20
4. CLUTCH
4.1 Removing and Disassembly
Top:
Socket 5910 893 5616
Bottom:
Clutch
Top:
Removing the cover washer
Bottom:
Assembly pin 5910 890
Top:
Removing a clutch spring
Bottom:
Component parts of clutch
Troubleshooting charts, see 2.1.
- Remove the V-belt, see 3.4.
- Unscrew clutch from
crankshaft stub using socket.
Caution! Clutch has a
left-hand thread.
- Remove cover washer
from crankshaft stub.
- Use assembly hook to remove
all the clutch springs.
- Pull the clutch shoes off
the carrier.
- Pull the retainers off the
clutch shoes.
- Clean all parts and stub of
crankshaft in white spirit.
Replace any damaged or
worn parts.