STIHL TS 400 Instruction Manual

The STIHL TS 400 is a professional-grade cut-off machine designed for heavy-duty concrete, asphalt, and masonry cutting. It features a powerful engine, ergonomic design, advanced safety systems, and compatibility with a range of cutting wheels. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Safety Information 3. Assembly & Preparation 4. Specifications 5. Controls and Components 6. Starting & Operation 7. Cutting Techniques 8. Maintenance & Care 9. Storage 10. Troubleshooting 11. Warranty & Support

Features at a Glance

Key components: High-performance 2-stroke engine, Ergonomic handle system, Quick-release wheel guard, Anti-vibration system, STIHL Quickstop® inertia chain brake, Tool-less depth adjustment.

Feature	Description
Engine	2-stroke, single-cylinder, air-cooled
Displacement	64.1 cm³ (3.91 cu. in.)
Power Output	3.1 kW (4.2 hp)
Fuel Tank Capacity	700 ml (23.7 fl. oz.)
Cutting Wheel Diameter	Max. 350 mm (14")
Weight (without cutting wheel)	9.8 kg (21.6 lbs)
Anti-Vibration System	Reduces operator fatigue
Quickstop® Inertia Chain Brake	Stops cutting wheel in event of kickback
Handle System	Ergonomic, adjustable side handle
Depth Adjustment	Tool-less, quick-set mechanism

Safety Information

Read and understand all instructions before use. Always wear appropriate PPE.

Personal Protective Equipment (PPE): Safety glasses, face shield, hearing protection, gloves, dust mask, steel-toed boots, and close-fitting clothing.
Work Area Safety: Keep work area clean and well-lit. Ensure bystanders are at a safe distance.
Tool Inspection: Inspect machine before each use. Do not operate if damaged or malfunctioning.
Kickback Awareness: Be aware of kickback forces; always maintain firm grip and proper stance.

WARNING! Failure to follow safety instructions can result in serious injury or death. This tool generates dust containing silica—use appropriate respiratory protection.

Assembly & Preparation

Unpack and inspect all components. Assemble on a clean, stable surface.

Attach the handle: Align handle with mounting points and secure with provided bolts.
Install cutting wheel: Ensure machine is off and spark plug disconnected. Place wheel on spindle, secure with flange and nut. Tighten with provided wrench.
Adjust wheel guard: Loosen knob, position guard for maximum protection, retighten.
Fuel mixture: Use STIHL HP Ultra 2-stroke oil mixed with unleaded gasoline at 50:1 ratio. Shake well before filling.
Chain oil: Fill chain oil reservoir with STIHL chain oil.

CAUTION! Never use a damaged or incorrect cutting wheel. Ensure all fasteners are tight before operation.

Specifications

Model: TS 400
Engine Type: 2-stroke, single-cylinder
Displacement: 64.1 cm³ (3.91 cu. in.)
Power Output: 3.1 kW (4.2 hp)
Idle Speed: 2,800 rpm
Max. Engine Speed: 9,500 rpm
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra oil)
Fuel Tank Capacity: 700 ml (23.7 fl. oz.)
Cutting Wheel Diameter: Max. 350 mm (14")
Cutting Depth (max.): 125 mm (4.9") at 90°
Sound Pressure Level: 106 dB(A)
Vibration Level (front/rear handle): 6.5/4.2 m/s²
Weight (without cutting wheel): 9.8 kg (21.6 lbs)

Controls and Components

Familiarize yourself with all controls before starting the engine.

Main Components: Throttle trigger lockout, Throttle trigger, Stop switch, Choke lever, Decompression valve, Primer bulb, Fuel tank cap, Chain oil tank cap, Side handle, Front handle, Wheel guard, Cutting wheel, Depth adjustment knob.

Operation: The throttle lockout must be depressed before the throttle trigger can be engaged. The stop switch stops the engine. The choke lever is used for cold starts. The decompression valve reduces compression for easier starting.

Starting & Operation

Follow these steps for safe starting and operation.

Cold Start: Place machine on firm ground. Set stop switch to "I". Press decompression valve. Set choke lever to closed position. Press primer bulb 5-10 times. Pull starter rope sharply until engine fires. Move choke lever to open position. Pull starter rope again to start. Allow 30-second warm-up.
Warm Start: Follow steps above but leave choke lever open.
Operation: Grip handles firmly. Squeeze throttle lockout and trigger to increase speed. Begin cut with wheel at full speed. Do not force the tool; let the wheel do the work.
Stopping: Release throttle trigger. Allow engine to idle briefly. Move stop switch to "0".

WARNING! Never start the machine unless the cutting wheel is clear of all obstructions and you are in the proper operating stance.

Cutting Techniques

Proper technique ensures efficient cutting and operator safety.

Straight Cuts: Mark cut line. Set depth adjustment. Start cut at edge, allowing wheel to reach full depth gradually. Use a steady, even feed pressure.
Deep Cuts: Make multiple passes, increasing depth incrementally.
Dust Control: Use water attachment if available to suppress dust. Always wear a respirator.
Kickback Prevention: Do not cut above shoulder height. Never use the upper quadrant of the wheel. Be aware of material binding.

Tip: For reinforced concrete, use a diamond blade designed for the material. Allow the blade to cool periodically.

Maintenance & Care

Regular maintenance ensures optimal performance and longevity.

Daily: Clean air filter. Check for loose fasteners. Inspect cutting wheel for damage. Clean exterior with a dry cloth.
Weekly: Check spark plug condition and gap. Clean cooling fins. Inspect fuel filter.
Monthly: Check anti-vibration elements. Inspect throttle trigger and lockout for smooth operation. Clean carburetor air passage.
Chain Oil System: Check oil flow before each use. Refill as needed.
Spark Plug: Replace if electrodes are worn. Gap: 0.5 mm (0.020").

CAUTION! Always disconnect the spark plug boot before performing any maintenance. Use only STIHL-approved parts and lubricants.

Storage

Prepare the machine for storage to prevent damage.

Drain all fuel from the tank and run the engine until it stops to empty the carburetor.
Remove the cutting wheel and store separately.
Clean the entire machine thoroughly.
Store in a dry, secure location, out of reach of children.
For long-term storage, treat with STIHL fuel stabilizer or use fully synthetic fuel mix.

WARNING! Gasoline is highly flammable. Drain fuel in a well-ventilated area away from sparks or flames.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No fuel, flooded engine, dirty spark plug, choke position incorrect	Check fuel level. Wait if flooded. Clean/replace spark plug. Verify choke setting.
Engine runs poorly or stalls	Dirty air filter, clogged fuel filter, old fuel mixture, carburetor adjustment	Clean air filter. Replace fuel filter. Use fresh fuel mix. Have carburetor serviced by dealer.
Excessive vibration	Damaged or unbalanced cutting wheel, loose components	Inspect and replace cutting wheel if necessary. Tighten all bolts and handles.
Cutting wheel does not spin freely	Debris in guard, damaged spindle bearing	Clean guard area. Have bearing inspected by authorized service center.
Chain oil not flowing	Empty oil tank, clogged oil channel, incorrect oil viscosity	Refill tank. Clean oil channel. Use STIHL chain oil.
Machine overheats	Dirty cooling fins, incorrect fuel mixture, dull cutting wheel	Clean cooling fins. Use correct 50:1 mix. Replace or dress cutting wheel.

Note: For repairs beyond basic maintenance, contact an authorized STIHL servicing dealer.

Warranty & Support

STIHL Limited Warranty: Refer to the separate warranty statement included with your purchase for specific terms and duration.

Support: For technical assistance, genuine parts, and servicing, contact an authorized STIHL dealer. Locate a dealer at www.stihlusa.com or call 1-800-467-8445.

Safety & Training: STIHL offers professional training programs. Contact your dealer for information.

Manual Updates: Check the STIHL website for the latest version of this manual.