Stihl TS 440 Service Manual
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Stihl TS 440 Service Manual

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STIHL TS 440
Service Manual
2019-03

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Summary of Contents for Stihl TS 440

  • Page 1 STIHL TS 440 Service Manual 2019-03...

  • Page 3: Table Of Contents

    Removing the connector, brake band and brake lever 10.5 Installing new brake lever, new brake band and new V belts This service manual is protected by copyright. All rights reserved, especially the rights to reproduce, translate and process with electronic systems. TS 440...

  • Page 4: About This Service Manual

    Preparations for Repair Spare parts Preparing the cut-off machine If spare parts which have not been approved by STIHL are installed, the functions of components can no longer be performed or safety devices can be deactivated. People Empty fuel tank into a container suitable for fuel.

  • Page 5: Ribbed Belt

    Tighten nut (8). The V belt (5) is relaxed. Extension for flex ratchet wrench – Removing the rear V belt Prepare for repair, @ 3.1 Undo screw (1). Remove guard (2). Remove screws (3). Remove “starter cover with rewind starter” (4). TS 440...

  • Page 6: Installing The Rear V Belt

    Slowly undo the nut (8). The V belt (5) is tensioned. Slowly release brake lever (7). Turn the center belt pulley 3 turns. The tension is evenly distributed. Installing the rear V belt If the front V belt (6) is removed: Install front V belt (6), @ 4.5 TS 440...

  • Page 7: Removing The Front V Belt

    Remove “starter cover with rewind starter” (4), @ 4.2. Remove the rear V belt (5), @ 4.2. Slowly undo the nut (12). The V belt (6) is tensioned. Turn the center belt pulley 3 turns. The tension is evenly distributed. TS 440...
  • Page 8 10 Nm / 89 lbf. in. to the “19 mm auxiliary tool” (13). Tighten nut (12) (20 Nm / 177 lbf. in.). Install the rear V belt (5), @ 4.3. Attach “starter cover with rewind starter” (4), @ 4.3. Attach guard (2), @ 4.3. TS 440...

  • Page 9: Clamping Arms

    Removing the rear clamping arm Prepare for repair, @ 3.1 Remove guard, @ 4.2. Remove “starter cover with rewind starter”, @ 4.2. Remove the rear V belt, @ 4.2. Remove E–clip (1). Undo nut (2). The clamping arm (3) snaps downward. TS 440...

  • Page 10: Installing The Rear Clamping Arm

    Remove the rear V belt, @ 4.2. Remove the front V belt, @ 4.4. Remove the middle belt pulley, @ 6.2. Undo nut (10). Remove screws (11). Remove the holding-down clamp (12). Pull off clamping arm (7) and remove torsion spring (8). TS 440...

  • Page 11: Installing The Front Clamping Arm

    Screw on and tighten nut (10). Install middle belt pulley, @ 6.3. Install the front V belt, @ 4.5. Install the rear V belt, @ 4.3 Install “starter cover with rewind starter”, @ 4.3. Fit guard, @ 4.3. TS 440...

  • Page 12: Belt Pulleys

    Pull off the belt pulley (3). Block belt pulley (6) with locking pin (arrow) Installing the middle belt pulley 4130 893 7800. Unscrew the nut (4) (left-hand thread). Push on the belt pulley (3). Remove washer (5). Slide on the washer (2). TS 440...

  • Page 13: Installing The Front Belt Pulley

    Screw on and tighten nut (4) (40 Nm / 354 lbf. in.) (Left-hand thread) Remove locking pin (arrow) 4130 893 7800. Install the front V belt, @ 4.5. Install the rear V belt, @ 4.3. Attach starter cover with rewind starter, @ 4.3. Fit guard, @ 4.3. TS 440...

  • Page 14: Connecting Piece With Guard

    Release hose clip (1) on water connector. Pull out white plug (8). Pull off hose (2) and hose clip (1). Pull grommet (9) out of the support (arrow) Undo screw (3). Undo the nuts (5). Actuate the brake lever (6) and hold it there. TS 440...

  • Page 15: Installing The Connector

    Actuate the brake lever (6) and hold it there. Remove locking pin (10) 4130 893 7800. Slowly release brake lever (6). Push the grommet (9) into the support (arrow). Plug white plug (8) into electronic module. The plug (8) engages. TS 440...

  • Page 16: Brake Band

    Remove the holding-down clamp (2). Undo screw (3). Actuate the brake lever (5) and hold it there. Lift brake band (4) out of guide. Detach brake band (4) from lever (6) and remove it. Slowly release brake lever (5). TS 440...

  • Page 17: Installing The Brake Band

    Insert screw (3) and tighten. Insert holding-down clamp (2). Insert screws (1) and tighten. Install connector, @ 7.3. Install the rear V belt, @ 4.3. Install “starter cover with rewind starter”, @ 4.3. Fit guard, @ 4.3. TS 440...

  • Page 18: Brake Lever

    – Assembly hook – 5910 890 2800 – Pliers, curved – STIHL multi-purpose grease – 0781 120 1110 – Removing and dismantling the brake lever Preparing for repair, @ 3.1. Use assembly hook (6) 5910 890 2800 to detach the tension spring (1) and remove it.

  • Page 19: Assembling And Installing The Brake Lever

    Insert lever (5) into brake lever (3). Push brake lever (3) and lever (5) onto the pins on the connector. Fit the E-clips (4). Grease area around the lever (arrows). Total quantity of grease: 10 g (0.4 oz.). TS 440...

  • Page 20: Brake Service

    Socket 13 mm – 5910 893 5608 or equivalent tool – Socket 19 mm, long – 5910 893 5613 or equivalent – tool Pliers, curved – Flat nosed pliers – 13 mm box wrench, offset – 19 mm box wrench, offset – Flat screwdriver 5.5 mm – TS 440...
  • Page 21 Wet the thread of the shaft with Loctite 270 thread- locking adhesive (thread-locking adhesive, high strength) - 0786 111 2109. Screw on and tighten 40 Nm / 354 lbf. in.) nut (33) for pre-tensioning. (Left-hand thread) Remove locking pin (arrow) 4130 893 7800. TS 440...

  • Page 22: Removing The Connector, Brake Band And Brake Lever

    Release cover (11) at the tab (arrow) and remove it. Actuate top brake lever (7) and hold it there. Remove connector (13) and attached parts. Slowly release top brake lever (7). Remove screws (15). Remove the holding-down clamp (14). TS 440...
  • Page 23 Actuate top brake lever (7) and hold it there. Use assembly hook (28) 5910 890 2800 to detach Detach brake band (19) from lever (20) and remove the tension spring (24) and remove it. Slowly release top brake lever (7). TS 440...

  • Page 24: Installing New Brake Lever, New Brake Band And New V Belts

    Push brake lever (25) upward and hold it there. Hook in the tension rod (26). Push brake lever (25) downward. Hook tension spring (24) into the lever (20) and push it over the pin (arrow) with the aid of the assembly tube (30) 1117 890 0900. TS 440...
  • Page 25 Actuate top brake lever (7) and hold it there. Check correct functioning: Actuate top brake lever (7) Remove locking pin 4130 893 7800. and slowly release it. The brake band will be slackened and tensioned. Repeat process 3 times. Slowly release top brake lever (7). TS 440...
  • Page 26 Plug white plug (16) into electronic module. The distributed. plug (16) engages. Fit cover (11). The cover (11) audibly engages. Insert screw (10) and tighten. Push hose (9) and hose clip (8) onto water connection. Close hose clip (8). TS 440...
  • Page 27 Remove “19 mm auxiliary tool” (32). Once the rear V belt is mounted, turn the front belt pulley 3 turns. Slowly undo the nut (12). The rear V belt (5) is tensioned. Turn the belt pulley 3 turns. The tension is evenly distributed. TS 440...
  • Page 28 Actuate top brake lever (7) and hold it there. Remove locking pin (arrow) 4130 893 7800. Slowly release top brake lever (7). Place “starter cover with rewind starter” (4) in position. Insert screws (3) and tighten. Place guard (2) in position. Insert screw (1) and tighten. TS 440...

  • Page 29: Fly Wheel

    The cone of the crankshaft stub and of the flywheel Undo screw (3) and remove cap (4). must be clean and free from grease. Pull off the spark plug boot. Block the piston. Unscrew the spark plug (5). Screw on and tighten nut (6). TS 440...
  • Page 30 Check air gap with setting gauge 1127 890 6400 and adjust if necessary. Insert spark plug (5) and tighten. Attach spark plug boot. Place cap (4) in position, insert screw (3) and tighten. Fit fan cover (2). Insert screws (1) and tighten. TS 440...

  • Page 31: Generator

    Torque wrench – 5910 890 0302 or equivalent tool – Screwdriver T20 – 5910 890 2301 or equivalent tool – Wiring tool - 5910 890 4000 – STIHL press fluid – 0781 957 9000 – Loctite 242 (thread-locking adhesive, medium – strength) – 0786 111 2101 12.2...

  • Page 32: Installing The Generator

    Pass generator wire (6) through opening (arrow). Insert generator wire (6) and ground wire (8) into the cable holder (5). Coat cable holder (5) with STIHL press fluid. Press cable holder (5) into the opening (arrow). Pass generator wire (6) through grommet (7).
  • Page 33 The insulating hose (1) should be flush with the guide rib (9). Press the wires into the guides (arrows) with the aid of the wiring tool. Install the electronic module, @ 14.3. Install flywheel, @ 11.3. Fit fan cover, @ 11.3. TS 440...

  • Page 34: Electromagnet

    Remove the middle belt pulley, @ 6.2. Undo nut (2). Pull out white plug (9). Remove screws (1). Pull grommets (10) out of the guides. Remove the holding-down clamp (3). Pull wire of electromagnet out of the guide. Undo screw (4). TS 440...

  • Page 35: Installing The Electromagnet

    Screw on and tighten nut (2). Install middle belt pulley, @ 6.3. Install the front V belt, @ 4.5. Install the rear V belt, @ 4.3. Install “starter cover with rewind starter”, @ 4.3. Fit guard, @ 4.3. TS 440...

  • Page 36: Electronic Module

    Pull off terminal socket (4), black plug (5), white plug (6), blue plug (7) and black plug (8). Release electronic module (3) at the tab (arrow) and remove it. Release cover (2) at the tab (arrow) and remove it. TS 440...

  • Page 37: Installing The Electronic Module

    (6), blue plug (7) and black plug (8). The plugs engage. Press the wires into the guides (arrows) with the aid of the wiring tool. Fit cover (2). The cover (2) audibly engages. Insert screw (1) and tighten. TS 440...

  • Page 38: Solenoid Valve

    Pull off hose (2) and hose clip (1). Pull wires of black plug (7) and wire of terminal socket (8) out of the guides (arrows). Pull insulating hose (9) and plug connection out of the guide rib. Pull grommet (10) out of the guide rib. TS 440...

  • Page 39: Installing The Solenoid Valve

    (13). The black wires are routed underneath the plug connection. Push the wire of the terminal socket (8) and the wires of the black plug (7) into the guides (arrows) with the aid of the wiring tool. TS 440...

  • Page 40: Control Panel

    Remove switch shaft (6). Undo screw (8) and remove cap (7). Undo screw (12). Pull the short circuit and ground wires out of the guides (arrows). Remove switch (13). Unhook throttle rod (14) and hook it into air baffle. TS 440...

  • Page 41: Installing The Control Panel

    Insert screw (4) and tighten. tabs engage. Fit grommet (3). Push wires into the guides (arrows) with the aid of the wiring tool and pass plug (16) through the opening. Fit cap (2), insert screw (1) and tighten. TS 440...
  • Page 42 Connect plug connection (15). The plug engages. Press the plug connection (15) and wires into the guides (arrows). Fit cap (7), insert screw (8) and tighten. TS 440...

  • Page 43: Cable Routing

    – Screwdriver T27x200 – 5910 890 2415 or equivalent – tool Wiring tool - 5910 890 4000 – STIHL press fluid – 0781 957 9000 – 17.2 Removing control panel – electronic module wiring harness Prepare for repair, @ 3.1 Remove shroud, @ 16.2.

  • Page 44: Installing Control Panel - Electronic Module Wiring Harness

    Press the wires of the wiring harness (7) into the guides (arrows) with the aid of the wiring tool. The black wire must run underneath the blue wire. Pass wiring harness (7) between handlebar and engine housing. Press grommet (9) into the guide rib. TS 440...
  • Page 45 Align ferrite sleeves (13, 14) as shown in the drawing. Coat support foot (3) with STIHL press fluid. Insert support foot (3) into guides of air baffle (5). Fit filter cover (2) and place support foot (3) in position on tank housing.

  • Page 46: Interactive Tutorials

    18 Interactive Tutorials The following interactive video tutorial is available for repair work. Carrying Out a Brake Service – TS 440...
  • Page 48 RA_021_2015_01_01 englisch www.stihl.com...

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