Setup and Service Procedures for the MS 170, MS 180 Chain Saw

Transcription

Setup and Service Procedures for the
MS 170, MS 180 Chain Saw
© STIHL Inc., Virginia Beach, VA
2013
Introduction
confidential
The
MS 170, MS 180 chain saw has a 2-cycle engine
STIHL assigns a 4 digit series number to every product
The MS 170, MS 180 is assigned the 1130 series number
The
1130 series of saw was introduced to the market in
1995 as an 017, and then in 1998 the 018 was added
In 2002 the model designation changed from 017 to MS
170, and 018 to MS 180
2013
US/STR
1
Specifications
MS 170
Engine Displacement
30.1 cc (1.8 cu.in)
Engine Power
1.3 kW (1.7bhp)
Weight
3.9 kg (8.6 lbs)
Fuel Capacity
250 cc (8.5 oz.)
Chain Oil Capacity
145 cc (4.9 oz.)
Recommended OILOMATIC® Chain
Guide Bar Lengths Available
Engine
Idle Speed
Wide Open Throttle
2013
confidential
MS 180
31.8 cc(1.9 cu. in.)
1.5kW (2.0 bhp)
4.0 kg (8.8 lbs.)
3/8” PMM3
12” to 16”
2800 RPM
14,000 RPM (with bar and chain installed)
US/STR
Become Familiar With the Controls
confidential
Master
Control Lever™
A single lever
operating the choke,
throttle lock and on-off
switch
0 = Off
I = Ignition on
Warm Start
Cold Start
2013
US/STR
2
Starting Features
confidential
The
MS 170 is equipped with a
standard starter mechanism,
and with 2 bar nuts holding the
bar in place
The MS 180 C-B has the
Toolless Quick Chain Adjuster
(QCA) for fast and easy chain
and bar install and adjustment
The MS 180 C-BE also has the
Easy2Start™ starter
mechanism which allows
starting with less effort at a
lower cranking speed
2013
US/STR
Starting Features
confidential
The
MS 180 C-B has the standard starter mechanism, which
requires a brisk pull on the rope to it’s full extension to start
the engine
The MS 180 C-BE has the Easy2Start™ starter mechanism,
which allows starting by simply pulling out the rope slow and
easy, winding the auxiliary spring which then spins the motor
over to start it
Notice that the MS
180 C-BE has a
deeper recoil
housing and the
handle extends out
slightly farther for
clearance
2013
US/STR
3
confidential
Kickback!!!
Kickback occurs when the
moving saw chain near
the upper quadrant of the
bar nose contacts a solid
object or is pinched
The greater the force of
the kickback reaction, the
more difficult it becomes
for the operator to control
the saw
2013
US/STR
Chain and Bar Color Code Marking
confidential
STIHL
saw chain will have a green
or yellow tie strap to indicate if the
chain is low-kickback or other than
low-kickback
The bar will have two green or
yellow dots on the powerhead end
of the bar to identify if the bar is a
reduced kickback bar or not
2013
US/STR
4
Install the Bar and Chain
confidential
STIHL
recommends the use of reduced
kickback bars and low kickback chains on
all STIHL chain saws
Yellow bar and chain combinations are for
trained professionals with extraordinary
cutting needs
Be sure the bar and chain are within the
recommended length for the model of
saw being assembled
Always wear gloves when handling saw
chain to protect your hands from the
sharp cutters
2013
US/STR
Install Bar & Chain: Quick Chain Adjuster
confidential
Install
the tensioning gear and fasten the screw securely
The bar can be installed with the STIHL logo facing up or
down; periodically the bar should be flipped to spread the
wear over both edges of the bar
2013
US/STR
5
Install Bar & Chain
confidential
Make
sure the cutters on top of the bar are facing away from
the powerhead!
WRONG
WRONG
CORRECT
2013
US/STR
Quick Chain Adjuster (QCA)
confidential
The
QCA allows the user to adjust the
chain tension without tools
Loosen the wing nut
Rotate the
adjusting wheel
Tighten the wing nut
2013
US/STR
6
Install Bar & Chain
confidential
If
the saw does not have a QCA simply remove the 2 bar nuts,
install the bar and chain, making sure the adjusting pin is in the
hole in the bar
2013
US/STR
Install Bar & Chain
confidential
Install
the cover and the 2 nuts leaving them just snug against
the cover
2013
US/STR
7
Chain Adjustment
confidential
The
1130 saws have a front
chain tensioner
Most STIHL chain saws have a
side chain tensioner that is more
convenient to use
Saws come with a combination
wrench, commonly referred to as
a “Scrench”, to make bar and
chain service easy to do
2013
US/STR
Install Bar & Chain
confidential
Adjust
the chain tension with the “Scrench” by holding up on
the nose of the bar, tightening the chain tension screw, then
tightening the nuts
2013
US/STR
8
Correct Chain Tension
confidential
With
the chain brake
disengaged, pull the
chain through from the
top side and it should
rotate freely without any
slack appearing
If the chain goes from
tight to loose the
sprocket and chain may
not be of the same pitch,
or the sprocket and chain
may have excessive
wear and no longer have
the same pitch
2013
US/STR
Correct Chain Tension
confidential
Regardless
of bar
length, check for
correct chain tension
by pulling up on the
chain at the center of
the bar
The
tension is correct
when the bottom of the
drive link will just clear
the bar groove
2013
US/STR
9
Cutterless Chain for Service
confidential
For
any chain saw, to properly tune the carb or verify running
RPM at idle and wide open throttle a bar and chain should be
installed
Cutterless chains are available to provide a safe way for the
service technician to do this without fear of the chain coming
into contact with anything
2013
US/STR
Chain Brake
confidential
All Current Models of STIHL Chain Saws are Equipped with
the STIHL Quickstop® Chain Braking System
The chain is stopped and locked when the hand guard is
pushed toward the guide bar nose by the left hand – or when
the brake is activated by enough inertia in certain kickback
situations
Brake
Brake
Band
Band
Engaged
Disengaged
2013
US/STR
10
Starting the 1130 Saw
confidential
Fill
the tank with 89
octane brand name fuel
with STIHL two-stroke oil
mixed at a 50:1 ratio, or
use STIHL MotoMix
Add
bar oil to the oil tank
for chain lubrication
2013
US/STR
Starting the 1130 Saw
confidential
Push
down on the interlock
on the top of the handle and
then squeeze the throttle all
the way open and hold it
Place
the Master Control
Lever™ in the full choke
position, down to the #1
position
2013
US/STR
11
Instruction Manual Directions for Safely
Starting a Chain Saw
(Never Drop Start a Chain Saw!)
2013
confidential
US/STR
First Time Start-Up
confidential
When
the engine starts, commonly referred
to as a “false start”, move the Master
Control Lever™ up to #2, to open the
choke and then pull the rope again
The engine should start and run at fast idle
Quickly “blip” the throttle to release the
engine from the fast idle position
2013
US/STR
12
First Time Start-Up
confidential
If
a saw is left in the fast idle position with the chain brake
engaged for even a very short period of time it may overheat
the clutch and chain brake components and possibly ruin the
tank housing as well
To
stop the engine raise the Master Control Lever™ to the 0
(off) position, #4 in the picture
2013
US/STR
First Time Start-Up: Warm Up
confidential
After
the engine has started and the chain brake has been
released, slowly squeeze the throttle about half way open and
then slowly release it back to idle
Do this several times, for at least 20 seconds, to completely
purge any remaining air from the carburetor circuits and to
allow the chain lubrication pump time to prime the system with
bar and chain oil
Never
allow any chain saw engine to run at full throttle without
a load, regardless if it is new or broken-in, for more than a few
seconds
2013
US/STR
13
Bar & Chain Oiler Check
confidential
Carefully
hold the
tip of the bar over a
piece of wood or
cardboard
Run
the saw at half
throttle and verify
that a line of bar
and chain lubricant
is being slung off
the end of the bar
2013
US/STR
Factory Testing of All STIHL Products
confidential
Every
engine manufactured by STIHL has been started and
operated in a test cell
The test cell makes carburetor adjustments and verifies
that the engine runs properly at idle, acceleration, and at
full throttle under load
The test cell measures the running performance and
emissions and verifies that they are within acceptable
parameters
All the dealer needs to do is service the unit and verify it is
ready for the customer to operate it
It is extremely rare that a new unit will need any major
adjustments or repair
2013
US/STR
14
Fault Analysis: STIHL Engine Check
confidential
When
a unit is running poorly or not at all, using a systematic
approach to identify any and all faults present will allow the
Service Technician to quickly and efficiently determine what is
wrong
It
is just as
important to
know what
faults are not
present as well
as faults that
do need to be
addressed
2013
US/STR
DG Screws
confidential
STIHL
uses the DG type of
fastener in manufacturing because
they cut their own threads the first
time they are used
Notice that the ones holding into
plastic have a different pitch and
profile than the ones that hold into
For Metal
For Plastic
metal
It is imperative that the Service Technician keep track of which
screw is which and not screw them into the wrong base
material or the threads will be damaged
It is also best practice that when starting a DG screw into the
hole, slowly rotate it backwards until it “clicks” to index the
threads, then turn it clockwise to tighten it
2013
US/STR
15
1. Deflectors, Shrouds, Covers, Fasteners
confidential
Visually
look the unit over for damage, missing items, loose
fasteners, or anything else that is obvious
Damaged shroud may be a
safety hazard for the operator
Operated without
an air filter or cover
2013
US/STR
2. Warning Labels
confidential

Verify that warning labels
are present and readable
On a chain saw the only
label the service technician
should be concerned with
is the one on the chain
brake handle
If this label is damaged or
worn away, a universal
replacement label is
available from STIHL
White Chain Saw Label:
0000 967 3613
2013
US/STR
16
3. Cutting Attachment
confidential
Note
type and condition
Inspect for wear or damage
Bar, chain, and sprocket
within wear limits
2013
US/STR
3. Cutting Attachment
4. Belt Tension
confidential
If
the unit is a trimmer or a concrete saw:
Tap head eyelets worn, spool worn, retainer secure
Belt tension correct; belt worn or frayed
2013
US/STR
17
5. Operator Controls
confidential
The
interlock should
be sticking up out of
the handle, and it
must be depressed
flush with the handle
before the throttle
trigger will move
Be
sure the throttle
moves freely
2013
US/STR
confidential
The
throttle must be squeezed all the way open before the
Master Control Lever™ can be actuated to the full choke
position, then release the throttle and the Master Control
Lever™ should stay in the choke position
2013
US/STR
18
confidential
Now
raise the Master
Control Lever™ up one
notch with your thumb, and
it should stay in the warm
start, half choke position
Now
squeeze the trigger
and it should snap up to the
I position automatically
2013
US/STR
confidential
Finally
the Master
Control Lever™
should easily slide up
to the O position
Any
problem with the
Master Control
Lever™ should be
noted for repair
2013
US/STR
19
confidential
When
the chain
brake handle is
actuated back
and forth, there
should be an
audible “click”
In the forward
position the
sprocket must
not turn
In the back
position the
sprocket must
spin easily
2013
US/STR
6. Verify Anti-vibration Components
confidential
Most
STIHL chain saws and line
trimmers have an anti-vibration
system that should be inspected for
wear and damage
Some models do not have any antivibration components so this step
would not apply
2013
US/STR
20
6. Verify Anti-vibration Components
confidential
Hold
the bumper spike
against the edge of the
workbench and put
pressure against the
handle assemble
There should be strong
resistance to movement
but there should be
some “give” to the antivibe rubber bushings
There should not be any
looseness to the handle
assembly
2013
US/STR
7. Inspect Starter System
confidential

Inspect rope, handle, and eyelet for wear or damage
Pull the rope to it’s full extended length and be sure it is
not about to break at the very end
2013
US/STR
21
8. Inspect Air Filter
9. Inspect Air Filter Housing
confidential
Remove
cover and the top
of the filter is the clean side
There should not be dirt or
debris on this side of the
filter or down in the throat of
the air intake
Remove the filter and the
bottom side is the dirty side
There should be a pinch
mark all the way around the
edge of the filter to seal it
Verify that the housing is not
cracked or damaged
2013
US/STR
10. Carburetor Mixture Screws
confidential
Most
STIHL products have
mixture adjustment screws on
the carburetor and will be
equipped with a limiter cap on
the H mixture screw and may
have one on the L screw also
The limiter cap allows the
operator to adjust the carb
leaner only to compensate
for operation in high
altitude
If a cap is missing it should
be considered as a fault and
it is possible the screw may
be set too lean
2013
US/STR
L mixture screw with
cone to guide the
screwdriver in place
H mixture screw
with limiter cap in
the up, or released
position to allow the
technician to make
adjustments
22
10. Carburetor Mixture Screws
confidential
The
1130 saws do not have
mixture screws or limiter caps
Notice that the H and L holes are
not threaded and are blocked off
internally
The only adjustment on a 1130
saw is to set the idle speed with
this screw
It also makes slight mixture
adjustments as the idle speed is
tuned
This carburetor uses a fixed
orifice jet to regulate the amount
of fuel available to the engine
and is not adjustable
2013
US/STR
10. Carburetor Screw Settings
confidential

4229 121 2701
Limiter
caps can be removed by
the service technician for carb
service
Removal of this style of limiter
cap is done with the 5910 890
4501 tool
Anytime a cap is removed best
practice is to replace it with a
new one
On the 1130 saws this step
does not apply
2013
US/STR
23
Hose Removal
confidential
The
5910 890 4501 tool also works well to remove fuel,
impulse, or vent hoses
Use
a side to side rocking
motion while pushing against
the hose to walk it off of the
fitting
2013
US/STR
11. Spark Plug Connection
confidential
Use
a twisting motion to remove the spark plug connection
and be careful not to pull the clip out of the high tension
lead
Inspect it for damage, hardness or cracks
2013
US/STR
24
12. Spark Test
confidential
Connect
a spark
tester and pull the
rope through as if
trying to start the
engine
If no spark is present
try again with a new
plug
A fouled or
defective spark
plug may not show
spark on the tester
even if the ignition
system is OK
2013
US/STR
12. Spark Test
confidential
If
there is still a no
spark condition with a
new plug, carefully
disconnect the ground
wire from the terminal
on the ignition module
and now see if spark
is present
If there is no spark the
module is faulty
If there is spark the
stop circuit is faulty
2013
US/STR
25
12. Ignition Shut-Off Function
confidential
If
spark is present then place the Master Control Lever™ in
the off position and pull the rope through and verify that no
spark is present
This verifies that the stop switch and connecting wiring is in
order
2013
US/STR
13. Spark Plug
confidential
Verify
that the correct plug is installed for an 1130 saw:

Bosch WSR6F STIHL Part Number 1110 400 7005
NGK BPMR7A STIHL Part Number 0000 400 7000
Other
units may use a different part number with a different
heat range, so always look it up!
Set all STIHL spark plugs at .020”
2013
US/STR
26
13. Spark Plug Appearance
confidential
Normal color,
normal electrode
wear due to high
run time
Normal color and
wear
Carbon buildup
due to high run
time
Both of these
plugs have served
their useful life
2013
Heavy
carbon buildup and oil
fouled
Mix ratio
incorrect.
Black, sooty
appearance
Caused by
rich fuel/air
mixture
US/STR
14. Muffler
confidential
Remove
the 2 muffler nuts and
deflector plate and inspect the
spark arrester screen
It must be present for all hand
held engines used in the United
States
The screen may be blocked
with carbon deposits
If necessary shine a light
through the screen to verify
2013
US/STR
27
Remove Starter Housing
confidential
Remove
fuel and oil tank caps
Rock the cap retainer to the side
Remove starter housing
Reinstall
the caps if necessary to prevent fuel or oil from
running out on the work area
2013
US/STR
15. Cylinder Leak Down Test
confidential

This test typically is not
necessary on a two-stroke
engine but can be done to verify
how well the rings are sealing
with the flywheel blocked so the
piston is slightly down from TDC
A leak down test should always
be done on a four-stroke engine
because the piston and rings
cannot be observed visually
The leak down test also verifies
that the intake and exhaust
valves are sealing properly
2013
US/STR
28
16. Inspect Exhaust Port and Piston
confidential
With
the muffler removed use
a flashlight and look through
the exhaust port to be sure
the port is not clogged up
with carbon deposits
Move the piston up and down
and inspect the surface of the
piston skirt for scoring or
damage
A piston in good condition
will still have the radial
machine marks across the
skirt indicating little or no
wear
2013
US/STR
16. Inspect Exhaust Port and Piston
confidential
Spray
some lubricant on
the rings and when the
flywheel is turned back
and forth slightly it will be
apparent if the rings are
free in the lands
Lower the piston to BDC
Inspect the intake side of
the cylinder wall for wear
or damage
2013
US/STR
29
17. Cooling System
confidential
Verify
that the cooling fins are in good condition and that the
air path to the flywheel and through the engine from the
flywheel is not blocked or restricted in any way
Verify that the flywheel fins are in good condition
2013
US/STR
18. Magneto Air Gap
confidential
Line
up the pole shoes in the
flywheel with the magneto
Observe the gap between the
ignition module and the
flywheel
The specification is .008”
It is not absolutely
necessary to measure this
with a gauge, just be sure
the flywheel is not rubbing
on the module and that the
gap does not look
excessively wide
2013
US/STR
30
19. Fuel Tank
confidential
If
the tank is empty look down in the tank to see if it appears
contaminated with debris or anything else that shouldn’t be
there
If the unit has fuel in it carefully remove the cap and wave your
hand over the opening while smelling for a sour odor that may
indicate old stale fuel
2013
US/STR
19. Fuel Tank
confidential
If
fuel is present carefully pour the fuel out in a pan and see if
there is trash or debris, or any evidence of other contaminants
such as water in the fuel
This
sample is
contaminated with
water and debris
Dispose of fuel properly
2013
US/STR
31
20. Fuel Filter
confidential
Use
the 5910 893 880 hook tool to fish the fuel filter out of the
tank for inspection
The filter body screen should be clear and in good condition,
and the element may have oil staining but should not be dark
or fouled or have any kind of coating on it
2013
US/STR
Pressure Vacuum Tester
confidential
0000
850 1300 Pump
With the knurled ring to
the right the gauge
indicates pressure
With the knurled ring to
the left the gauge
indicates vacuum
2013
US/STR
32
20. Fuel Filter
confidential
It
is a good idea to backflow a fuel filter with the pressure
pump to verify that it is not restricted
Hook up the tester and place the filter on a towel and pump
the tester 2 times
No pressure should build up and if the filter is wet with fuel
it should clearly flow out
2013
US/STR
21. Pressure Test Fuel Line
confidential
Connect
the pressure tester to the fuel line where the filter was
removed and gently pump it up no higher than 10 PSI
If it holds steady then the fuel line is OK, and the carb itself
passes the pressure test
If
the gauge does not
hold then either the fuel
line or the carb may be
leaking, so isolate the
fuel line and test it by
itself to determine
where the fault is
2013
US/STR
33
Remove Carb
confidential
Hold
the choke shutter closed and carefully remove the link
2013
US/STR
Remove Carb
confidential
Carefully
slide the fuel line off of the fitting
2013
US/STR
34
Remove Carb
confidential
Hold
the throttle wide open and carefully remove the link
2013
US/STR
Remove Carb
confidential
Gently
pry the Master Control Lever™ up on the left side
2013
US/STR
35
Remove Carb
confidential
Slide
the Master Control Lever™ to the left and let it hang
out of the way by the ground wire
2013
US/STR
Remove Carb
confidential
Hold
the fuel line down out of the way and slide the carb off
of the studs
2013
US/STR
36
21. Pressure Test Fuel Line
confidential
To
test the fuel line by itself, plug one end and test through the
other
It should hold steady at 10 PSI
2013
US/STR
22. Pressure Test Tank
confidential
Be
sure there is no fuel
in the tank before
applying any pressure to
the fuel tank!
The pressure test
verifies that the tank
does not have a leak in
any location, such as a
grommet, seam, cap or
hose
Apply about 8 PSI max and it must hold steady
If it leaks down at all use soapy water in a spray bottle
to locate where the leak is
2013
US/STR
37
23. Vacuum Test Tank Vent
confidential
Reverse
the tester into
vacuum mode and pump
hard and fast to see the
needle indicates that
some negative pressure
is present in the tank
Stop pumping and watch
the gauge and the
needle should move
back up towards zero
rapidly
If the needle does not
leak back to zero quickly
the tank vent must be
replaced and then re-test
2013
US/STR
24. Inspect Intake Side Of Piston
With
the carb removed
look through the inlet port
and rotate the crankshaft
to inspect the intake side
of the piston
The machine marks
should be present on a
piston in good condition
Scoring or a dull gray
appearance would
indicate lack of
lubrication, dirt ingestion,
or possibly other
problems that would
prevent the engine from
running properly
2013
US/STR
confidential
38
25. Impulse Signal Present
confidential
Most
two-stroke engines have a
passageway between the
crankcase and the fuel pump side of
the carburetor to cause the fuel
pump diaphragm to flex back and
forth with the pressure/vacuum that
is created by the piston moving up
and down
It is rare that there is no impulse
signal, but always verify that it is
present because no impulse signal
will cause a hard to diagnose,
unusual running behavior that will
appear to be carburetor related
2013
For this blower engine the
impulse signal comes out
through the flange here:
US/STR
25. Impulse Signal Present
confidential
For
the 1130 saw, remove the white plastic sealing ring, use
the tapered adapter and connect the tester to the impulse port
By hand, rotate the flywheel back and forth and the needle on
the gauge should bounce back and forth indicating the
impulse signal is present
2013
US/STR
39
26. Vacuum and Pressure Test of Crankcase
confidential
A
two-stroke engine needs an air tight crankcase since the air
fuel mix is coming through the crankcase on the way to the
combustion chamber
Test to verify that there are no leaks at places like gaskets or
RTV silicone sealed mating surfaces, and that crankshaft seals
are not leaking under pressure or vacuum
Block off the exhaust port
by slipping a rubber block
off plate in between the
cylinder and the adapter
plate, then install spacers
and snug up the nuts
while pulling the rubber up
to get a complete seal
2013
US/STR
confidential
The
Service Manual for each
model describes how to do
this test and gives the part
number for the adapters
For
the 1130 saw the special
adapter for the carb side is
part number 1118 850 4200
Be
sure the spark plug is
installed and tight
2013
US/STR
40
confidential
Use
the tester to pull a 0.5 bar vacuum; it should hold steady
or not leak back to 0.3 bar within 20 seconds
Rotate the crankshaft back and forth while the crankcase is
under vacuum to verify that the seals are holding properly
Pump 0.5 bar of pressure into the engine and it should hold
steady for at least 20 seconds
2013
US/STR
Pressure Test Results
confidential
If
the unit fails the pressure test check obvious things first, such
as the rubber sealing plate on the exhaust and the spark plug,
by spraying with soapy water and looking for bubbles
If they are sealing properly then the engine may need to be
taken apart far enough to be able to check the crankshaft seals
and the seal between the cylinder and the crankcase
If an engine leaks under vacuum but holds under pressure it is
most likely a crankshaft seal
2013
US/STR
41
27. Crankshaft and Bearing Condition
confidential
See
if the flywheel moves in and out or up and down
There should not be any loose play in the crankshaft
bearings
2013
US/STR
28. Carburetor
confidential
Pressure
test the carb no higher than 10 PSI and it should hold
steady
Open and close the butterfly and it should open smoothly
Verify that the throttle shaft does not have any excessive side
to side play
Inspect the carb for any physical damage
2013
US/STR
42
29. Other Observations; Final Running
confidential
This
is where any other observations about the unit not
specifically covered by one of the numbered items on the
STIHL Engine Check can be recorded
Once
repairs have
been made the last
part of the STIHL
Engine Check
document can be used
as a quality control
check to be sure the
engine starts easily
and is running to
specification
2013
US/STR
Final Check: Roll Out Test
confidential

With the engine warmed
up and idling, and the
chain brake engaged on
a saw, slowly roll the
engine over so one side
faces the ground
Now roll it back upright,
then roll the other side
towards the ground
Idle RPM should not
change more than 200300 RPM
If the idle changes the
engine may have an air
leak or other fault
2013
US/STR
43
confidential
This presentation has been prepared by:
Eddie Anderson
Technical Training Supervisor
STIHL Inc.
Virginia Beach, VA
[email protected]
2013
US/STR
44