Stihl TS 400 Cutquick Manual

Technical Information
New cut-off saw STIHL TS 400 - type 4223
37.95
1. General description
The new STIHL TS 400 combines established
elements with innovative elements. The compact
external appearance, the easy-to-service design
and the pacesetting STIHL technology make this
an all-purpose machine. It is the lightest cut-off
saw in the STIHL range and weighs only 18.6 lbs.
In terms of engine power, torque and robust
design, however, it also meets high professional
standards.
The TS 400 is additionally characterized by
numerous sophisticated points of detail which not
only ensure high technical reliability, but also
vastly improve the ease with which this machine
can be serviced and operated.
Its straightforward operation, convenient handling
and minimum service requirements make the
TS 400 eminently suitable for tough continuous
duty as well as for occasional use.
TheTS400canbeusedforawholevarietyof
applications in the construction industry and rental
trade, by municipal authorities and by utility
companies, in the construction materials and steel
trade, by emergency rescue services and by fire
departments.

2. Equipment
The STIHL TS 400 is equipped with the newly developed long-term air filter system with compensator, the
STIHL quickstart system with ElastoStart and decompression valve, the AV handle system, semi-automatic
V-belt tensioner, fuel tank with integrated expansion reservoir, electronic magneto-ignition system with
speed limitation, and a new, light aluminium guard.
1
23
338TI001 K
3. Technical description
Air filter system and compensator
In combination with the compensator, the long-term
air filter system which has been specially
developed for the TS 400 permits long service
periods and therefore cuts service costs.
The entire intake of combustion air has been
optimally designed:
––Intake ports in the area with the least dust
––High-volume foam prefilter (1)
––Main filter (2) with large filter area, high
dust retention capacity and "self-cleaning" effect
due to the vertical folds
––Auxiliary filter (3) of flocked fabric to filter out
–fine dust
The filter cover is secured by a central wing nut
and can be removed quickly and easily to inspect
and service the prefilter.
Mechanical design of the compensator: The
metering chamber end cover of the carburetor
includes a connector which is linked with the intake
manifold by a hose. This ensures that the pressure
is the same on the clean-air side of the air filter
and at the control diaphragm.
Function: The air flow is reduced by a soiled air
filter, thus causing the pressure to drop not only in
the venturi valve of the carburetor, but also on the
outside of the control diaphragm. The control
diaphragm moves outwards and the needle valve
closes partly so that the supply of fuel is reduced.
This prevents the fuel mixture from becoming too
rich and eliminates the need for further adjustment
of the high-speed adjusting screw as the air filter
becomes increasingly soiled.
The purpose of the compensator is to keep the
proportion of fuel in the fuel/air mix constant,
regardless of the extent to which the air filter is
fouled. The rapid, tangible loss of engine power
due
to fouling of the air filter is delayed considerably in
machines with compensator. This also extends
the intervals between cleaning and the service life
of the air filter system. The optimum performance
is restored as soon as the prefilter has been
cleaned and/or the main filter replaced.
;;
321
Pa
Pa
Pr
Pi
4
1
2
3
4
Pi
Pa
Pr
= Luftfilter
= Vergaser
= Zylinder
= Kraftstofftank
= Innendruck
= Außendruck
= Druck im Regelraum
Air filter
Carburetor
Cylinder
Fuel tank
Internal pressure
External pressure
Pressure in the metering chamber
Technical Information 37.95 - Page 2

ElastoStart
Standard grip
The compensator is designed to reduce costs and
allows the machine to be used more effectively.
In addition, it ensures that the fuel/air mix remains
constant.
STIHL - Quickstart system for easy starting
The Elastostart is designed to reduce the sudden
peak forces (compression pressure) normally felt
during cranking. The forces which occur at the grip
after the first compression stroke are practically
uniform. The Elastostart consists of 3 separate
components:
•Grip
•Rubber element
•Starter rope
The rubber element is integrated in the starter grip.
A plastic plate is attached to both the top and
bottom of the rubber element in a vulcanization
process and 2 tapered plastic nipples are molded to
the starter rope. The distance between the two
nipples is greater than the length of the rubber
element in its relaxed state but less than the length
of the rubber element in the stretched condition.
The rope between the two nipples is accomodated
in a compressed condition inside the rubber element.
Duringthestartingprocessthetensileforce
applied by the operator pulling the rope is
transmitted via the grip (1) to the rubber element (2)
and from the lower nipple (3) to the rope (4).
However, as this tensile force is opposed by
compression pressure, the rubber element stretches
by an amount proportional to the compression
pressure. This means that the peak forces which
occur on each compression stroke (every revolution
of crankshaft) are cushioned.
The forces which occur at the grip after the first
compression stroke are practically uniform.
This enhances starting comfort.
The rubber element is protected from overload in
that it can only be stretched until the rope inside its
bore is fully tensioned. Cranking effort is then
transmitted to the rope through the grip and the
upper nipple (5).
Decompression valve
The decompression valve reduces the compression in the combustion chamber when starting and thus also
reduces the force required to pull the starter rope. This in turn reduces the physical effort required to start the
machine and makes it more convenient to operate. The valve is opened manually and closes automatically as
soon as the fuel/air mixture ignites for the first time.
Tensile force (pull)
Travel (hand)
Technical Information 37.95 - Page 3

Mechanical design and function
The housing (1) and piston (2) are the most
important elements of the decompression valve.
The piston can move axially in the housing.
A cone is fitted at the bottom end.
Three spring-loaded balls (3) offset at angles of
120 degrees hold the piston in its upper and lower
limit position. The complete decompression valve
is screwed into the cylinder.
Before starting, the piston (2) is forced into the
lower limit position and the cone lifts off the
housing (1). The decompression valve is now
open.
The pressure in the cylinder does not rise above
the closing pressure of the decompression valve
until a combustible fuel/air mix has ignited. The
piston (2) is then forced upwards and the hole (1)
is sealed by the cone.
337TI002
1
2
3
337TI003
1
2
3
The V-belt tensioner has already proved its worth
in the STIHL TS 460 and has improved the operating
convenience. All that is required in
order to tension the V-belt is to turn the tensioning
nut to the tensioning position. When that has been
done, the V-belt is correctly tensioned automatically
by the force of a spring. Retensioning the belt is
even simpler and quicker: only three hex bolts
need be unscrewed and then retightened on the
V-belt guard. There is no need to adjust the
tensioning nut. The constant spring force prevents
the V-belt from being tensioned excessively and
thus protects it against premature wear.
338TI002 K
Technical Information 37.95 - Page 4

The fuel tank has a capacity of 1.56 pints.
The large filler port is located on the top of the
housing so that it can be filled easily and without
tilting the machine.
Aexpansion reservoir has been integrated into
the fuel tank for ventilation purposes. If an excess
pressure builds up in the fuel tank, fuel flows into
the reservoir via a port and connecting hose. It is
drawn back into the fuel tank as soon as a negative
pressure is restored. The difference in pressure
between the fuel tank reservoir and the outside
atmosphere is balanced out via a valve (1) and
filter (2).
The AV system comprises five rubber buffers
secured to the crankcase and isolates the handle
system from the power unit and all other assemblies
connected to the crankcase. This is designed to
reduce the vibrations transmitted to the handles.
New cutting wheel attachment with aluminium
guard;
New water attachment for wet cutting
The STIHL TS 400 features a new cutting wheel
attachment with aluminium guard which is one of
the essential reasons for the machine’s low overall
weight. The adjusting lever of the wheel guard can
be fitted on the shroud in two positions, thus
ensuring that the guard’s full range for
adjustment is maintained for both inboard and
outboard mounting.
The new water attachment for wet cutting is mounted
atthesideandsecuredtothehandlebartoprovidea
clear view of the kerf and is a major advantage for
freehand cutting. (The part numbers of the
attachment kits are listed in Section 5.)
A=Compensator reservoir
B=Fuel tank
2
1
AB
338TI003 K
4. Cutting wheels
All cutting wheels approved for use with the TS 350, TS 360, TS460, TS 510 and TS 760 can also be used
with the TS 400. STIHL cutting wheels can be used to cut the following materials:
Composite wheels Diamond wheels
Asphalt Asphalt 1)
Concrete Concrete 2)
Stone Stone (hard rock) 3)
Ductile cast pipes
Railway tracks
Steel Abrasive concrete
Green concrete
Clay bricks and pipes
Technical Information 37.95 - Page 5

1) All types and blends of asphalt commonly used for building construction and road
construction, including the respective aggregates, as well as green concrete and screed topping
2) Cast stones of all types commonly used for and building construction, including light
reinforced concrete
3) Natural stones of every hardness, including granite stones of the hardest wear class, cast stones
and concrete
5. Special accessories
The new attachment kits "Bearing with guard dia. 300 mm" 4223 007 1005 and "Water attachment"
4201 007 1038 have been used for the first time with introduction of the TS 400. The new attachment kit
"Bearing with guard" can be used for all STIHL cut-off saws and replaces the former version 4201 007 1035.
The attachment kit "Bearing with guard dia. 350 mm" will also be available with aluminium guard in the
foreseeable future.
The new water attachment can also be fitted to the TS 350, TS 360 and TS 460.
All the existing special accessories, such as the Cutquik cart with mudguard and the attachment kits
"Cutting depth limiter", "Water tank" and "Pressurized water tank" can also be used with the TS 400.
The new attachment kit 4223 007 1000 is required to secure the TS 400 on the Cutquik cart. This attachment
kit is not included with the Cutquik cart and must be ordered separately.
Designation Part No. Comments
Attachment kit "Bearing with guard dia. 300 mm" 4223 007 1005
Cutquik cart 4201 710 1403
Attachment kit "Cutquik cart TS 400" 4223 007 1000
Attachment kit "Cutting depth limiter" 4201 007 1049
Attachment kit "Water connection for wet cutting" 4201 007 1038
Attachment kit "Water tank" 4201 007 1048
Attachment kit "Pressurized water tank" 4201 007 1037
6. Technical data
6.1 Power unit
STIHL single-cylinder two-stroke engine with specially impregnated cylinder bore
Displacement: 64.1 cm (3.9 cu in)
Cylinder bore 49 mm (1.93 in)
Piston stroke: 34 mm (1.34 in)
Power to ISO 7293: 3.2 KW (4.4 HP)
Max. torque: 4.1 Nm (0.41 kpm)
at n = 6500 rpm
Max. spindle speed: 4800 rpm
Max. acceptable speed: 9700 rpm (electronic speed limitation)
Mean idle speed: 2500 rpm
Crankshaft: Three-part, drop-forged
Bearing: Heavy-duty deep grooved ball bearing for crankshaft, needle cage
for big-end bearing at crankpin and piston pin
Starter mechanism: Single-pawl system with automatic rewinding of the starter rope
Starter rope: Dia. 3.5 mm (1/8")
Clutch: Centrifugal clutch without linings, dia. 76 mm (2.99 in)
Clutch engages at: Approx. 3500 rpm
Leakage testing
of the crankcase
with excess pressure: Pexcess = 0.5 bar
with negative pressure: Pnegative = 0.5 bar
Technical Information 37.95 - Page 6

6.2 Fuel system
Carburetor: All-position diaphragm carburetor
with integral fuel pump
Adjustment
High-speed adjusting screw H: Approx. 1 turn open
Low-speed adjusting screw L: Approx. 1 turn open
(Adjustment starts with the screws closed)
Leakage testing of the carburetor
with excess pressure: Pexcess = 0.8 bar
Fuel tank capacity: 0.74 l (1.56 pt))
Fuel mix: Branded mid-grade gasoline (89 octane) and branded two-stroke engine oil
Mixing ratio: 1:50 for STIHL two-stroke engine oil 1:50
Air filter: Prefilter (foam)
Large main filter (paper)
Auxiliary filter (flocked plastic fabric)
6.3 Ignition system
Basic principle: Transistorized (contactless) magneto-ignition system with
integrated control unit and electronic speed limitation
Air gap: 0.15...0.3 mm (0.006 –0.012 in)
Ignition timing: 1.6 ... 2.2 mm (0.063 –0.087 in) before TDC at 8000 rpm
Spark plug (suppressed): Bosch WSR 6 F or
NGK BPMR 7 A
Electrode gap: 0.5 mm (0.02 in)
Spark plug thread: M 14 x 1.25
Thread length: 9.5 mm (0.37 in)
Heat range value: 200
Length of ignition lead: 370 mm (145/8in)
6.4 Tightening torques
DG screws are used in some cases in the TS 400. These screws cut a thread in the material when they
are screwed in for the first time. The material is then permanently threaded. The screws can then be remo-
ved and retightened ad libidum.
The strength of a screw connection is not impaired if the specified tightening torque is maintained.
It is therefore essential to use a torque wrench.
Connecting Thread For Tightening Comments
element size components torque
Nm
Groove-headed screw IS-DG4x14 Starter cover 1,8 1)
Socket-head screw IS-DG4x15 Handle moulding / handle 1,8
Socket-head screw IS-DG4x15 Mount, stop linkage 1,8
Socket-head screw IS-DGM5x20 Handlebar / handlebar mount 8,0
Socket-head screw IS-DG5x20 Tank housing, left / right 7,5
Nut M5 Filter base / carburetor 3,5
Socket-head screw IS-M5x16 Cover, tensioner / cast arm 4,5
Socket-head screw IS-M5x16 Handlebar / tank housing 8,0
Socket-head screw IS-M5x16 Air baffle / crankcase 4,5
Socket-head screw IS-M5x16 Muffler / crankcase 10,0
Socket-head screw IS-M5x16 Muffler / cylinder 10,0
Socket-head screw IS-M5x20 Cast arm / crankcase 10,0
Socket-head screw IS-M5x20 Filter base / tank housing 6,0
Socket-head screw IS-M5x20 Fitler case / filter base 4,0
Technical Information 37.95 - Page 7

Connecting Thread For Tightening Comments
element size components torque
Nm
Socket-head screw IS-M5x20 Shroud / tank housing 6,0
Socket-head screw IS-M5x20 Crankcase, left / right 10,0
Socket-head screw IS-M5x20 Fan cover / tank housing 6,0
Socket-head screw IS-M5x20 Starter cover / cast arm 6,0
Socket-head screw IS-M5x20 Cylinder / crankcase 10,0
Socket-head screw IS-M5x20 Ignition module / crankcase 8,0 2)
Socket-head screw IS-M5x25 Support / handlebar / tank housing 8,0
Socket-head screw IS-M6x16 AV element, cast arm / handlebar 6,0
Socket-head screw IS-M6x16 AV element, tank housing / cast arm 6,0
Socket-head screw IS-M6x16 AV element, tank housing /
crankcase, left 6,0
Grub screw M5x55 Tank housing / carburetor 4,0
Collar nut M8x1 Flywheel 30,0
Hex nut M8x1 Starter wheel 23,0
Driver M12x1L Clutch 40,0
M14x1,25 Spark plug 27,5
Hex nut M10L V-belt pulley / bearing 37,5
Decompression valve 14,0
When screwing the DG screws into a precut thread:
•Insert the screw in the hole and turn anticlockwise until it drops slightly into the hole.
•Turn the screw clockwise and tighten to the specified torque.
This procedure ensures that the screw engages in the existing thread and does not cut a new thread.
As this would weaken the screw connection.
1) Secure screw with adhesive Loctite 242/243.
2) A washer must be fitted under the head of the screw.
Note: Screws secured with adhesive must be heated with hot air before they can be unscrewed.
Particular care must be exercised on plastic parts!
6.5 Weight
Machine without fuel, complete
with attachment for cutting wheel,
dia. 300 mm (12")
(without cutting wheel): 8.9 kg (19.6 lb)
6.6 Dimensions
Length with cutting wheel
(dia. 300 mm/12"): 740 mm (29 in)
Width with handle: 300 mm (12 in)
Height to handle: 350 mm (14 in)
6.7 Accessories
Combination wrench
Locking pin
Screwdriver
Technical Information 37.95 - Page 8

7. Special tools and service accessories
7.1 Special tools
Designation Part No. Use Comments
Assembly stand 5910 890 3100 Installation of the machine for repair
Locking strip 0000 893 5903 Locking the crankshaft 1)
Press sleeve 1127 893 2400 Pressing in the rotary shaft seal
Assembly sleeve 1122 893 4600 Protecting the rotary shaft seal on the
clutch side
Extractor 0000 890 4400 Extracting rotary shaft seals
- Jaws (No. 3.1 + 4) 0000 893 3706
- Jaws (No. 6) 0000 893 3711
Extractor 1116 893 0800 Extracting the flywheel
Insert, size 21 long 5910 893 5616 Releasing / tightening the clutch
Crimping tool 5910 890 8210 Fitting connectors to electric leads
Assembly pin 1108 893 4700 Assembly of the piston pin
Strap retainer 0000 893 2600 Tensioning the piston rings
Wooden assembly block 1108 893 4800 Positioning the piston
Carburetor and
crankcase tester 1106 850 2905 Leakage testing (crankcase and carburetor)
- Connector 0000 855 9200
- Fuel line 1110 141 8600
Vacuum pump 0000 850 3501 Leakage testing (crankcase)
Sealing plate 0000 855 8106 Sealing the exhaust outlet for leakage tests
Test flange 1128 850 4200 Leakage testing
Setting gauge 1111 890 6400 Setting the air gap between ignition
moduleand flywheel
Insert, size 13 5910 893 5608 Nut for flywheel
Insert, size 17 5910 893 5610 Nut for starter wheel
Torque wrench 5910 890 0301/02 Screw connections (0.5 to 18 Nm) 2)3)
Torque wrench 5910 890 0311/12 Screw connections (6 to 80 Nm) 2)3)
Insert, 1-5 x 120 x 6.3 0812 542 2104 Tightening the socket-head screws
with star-shaped recess
Assembly tool 10 5910 890 2210 Inserting the snap rings in the piston boss
Assembly hook 5910 890 2800 Disengaging the clutch springs
Assembly tool 0000 890 2201 Flaring the rope guide bush
Screwdriver with
tee-handle QI-5 x 150 5910 890 2400 For all hex socket-head screws
Pliers A10 0811 611 8200 Outer circlip on thrust washer
Pliers C19 0811 641 8380 Inner circlip on spindle bearing
and crankshaft
Drift pin 1119 893 7200 Pressing the needle sleeve into and out
of the V-belt pulley
Drift pin 4119 893 7200 Forcing out the deep groove ball bearings
in the spindle bearing
Assembly tool ZS 5910 890 2220 Removing the crankshaft 4)
- Screw sleeve 5910 893 2420 Installing the crankshaft
Comments
1) Important: Only this locking strip may be used to lock the crankshaft of the TS 400. The piston will be
damaged if one of the stop bolts in the set of STIHL special tools is used.
2) A torque wrench must be used to tighten DG screws
3) Versions 5910 890 0302 and 5910 890 0312 are fitted with an optical/acoustic warning device
4) Refer to the reworking instructions, Section 7.1.1
Technical Information 37.95 - Page 9

7.1.1 Reworking instructions
The assembly tools 5910 890 2220 supplied from
STIHL will in future already feature three additional
holes of diameter 5.5 mm (7/32") for use with TS 400.
An existing assembly tool which does not have
these holes can be reworked in accordance with the
template drawn to scale on the last page of this
Technical Information.
To mark the holes, the template should be photoco-
pied, carefully cut out and placed on the underside
of the tool flange. The figure 13 must subsequently
be stamped on the top of the tool flange beside
each of the three new holes and above the new identi-
fication notch at the edge for identification purposes.
The diagram alongside shows a top view of the top
of the new tool flange version.
7.2 Service accessories
Designation Part No. Used for
STIHL multi-purpose grease 0781 120 1109 High-voltage arbor on ignition module
HTR ignition lead, 10 m 0000 930 2251
Set of gaskets 4223 007 1050
Sealing panel 0457 281 4103
338TI004 K
13
2
3
4
5
6
7
8
9
10
11
12
1
13
13
13
Technical Information 37.95 - Page 10

8. Repairs
The national safety regulations and the safety
instructions in the Owner’s Manual must be
observed if the Cutquik has to be started up during
repairs or maintenance work.
8.1 Repair times
The repair times specified are based on the times
required by duly trained professionals with a properly
equipped service shop.
The repair times are specified in tenths of an hour
(0.1 = 6 minutes).
Note:
The table of repair times for Cutquiks of series
TS 400 can be transferred to the STIHL table of
repair times.
Code Type of repair
1 Crankcase
2 Crankshaft and/or Bearings
3 Crankcase Gasket/Sealing
4 Crankshaft Seals
5 Cylinder and/or Piston
6 Ignition
7 Fuel Supply, Tank Vent
8 Wheel Guard
9 Carburetor
10 Arbor Housing
11 Handle Bar, Buffers, Handle Frame
12 Recoil Starter
13 Clutch
14 V Belt Pulley
15 Muffler
16 Air Filter/Filter Cover
17 Stop Switch
✂
TS 400
TS 460
2.5
2.5
1.5
1.2
1.0
0.5
0.5
0.3
0.7
0.6
0.5
0.5
0.5
0.4
0.4
0.3
0.4
0.5
0.5
0.5
Technical Information 37.95 - Page 11

Andreas Stihl - D1/MTK-sc
Technical Documentation
Waiblingen, April 25, 1995
© 1995 Andreas Stihl
13
13
12
13
12
338BB005 KN
12
12 = Typ 1128
13 = Typ 4223
Technical Information 37.95 - Page 12