Stihl 019 T User Manual

1. Introduction 2

2. Specifications 3

2.1 Engine 3

2.2 Fuel System 3

2.3 Ignition System 4

2.4 Cutting Attachment 4

2.5 Special Accessories 4

2.5.1 For User 4

2.5.2 For Service 4

2.6 Tightening Torques 5

3. Clutch, Chain Drive, Chain Brake and Chain Tensioner 6

3.1 Chain Sprocket 6

3.2 Clutch 7

3.3 Chain Brake 7

3.3.1 Checking Function 7

3.3.2 Disassembly 8

3.3.3 Assembly 9

3.4 Chain Tensioner 11

3.5 Bar Stud 11

4. Engine 12

4.1 Removal 12

4.2 Assembly 13

4.3 Exhaust Muffler/ Spark Arresting Screen 14

4.4 Leakage Test 15

4.4.1 Preparations 15

4.4.2 Pressure Test 16

4.4.3 Vacuum Test

(for diaphragm) 17

4.4.4 Vacuum Test

(for oil seal) 17

4.5 Oil Seals 19

4.6 Cylinder 20

4.7 Piston 22

4.8 Piston Ring 23

4.9 Crankshaft 23

5. Ignition System 25

5.1 Spark Plug Boot 25

5.2 Ignition Module 26

5.2.1 Ignition Timing 26

5.2.2 Removing and Installing 26

5.3 Flywheel 27

5.4 Ground Wire/ Short Circuit Wire 28

5.5 Contact Spring 29

6. Rewind Starter 30

6.1 General 30

6.2 Fan Housing 30

6.3 Rewind Spring 31

6.3.1 Replacing 31

6.3.2 Tensioning 32

6.4 Starter Rope (ElastoStart) 32

6.5 Starter Grip (ElastoStart) 33

7. AV Handle System 34

8. Master Control/ Handle System 36

8.1 Interlock Lever/ Throttle Trigger 36

8.2 Switch Shaft 36

8.3 Handle Molding 37

8.4 Handlebar 37

8.5 Top Handle 37

9. Chain Lubrication 39

9.1 Pickup Body 39

9.2 Oil Tank/Suction Hose 39

9.3 Oil Pump 40

9.4 Worm 41

10. Fuel System 42

10.1 Air Filter 42

10.2 Pickup Body 42

10.3 Tank Vent 43

10.4 Fuel Tank/ Fuel Hose 43

10.5 Carburetor 44

10.5.1 Leakage Test 44

10.5.2 Removing and Installing 45

10.5.3 Adjustment 45

10.6 Throttle Cable 46

10.7 Spacer Flange/ Diaphragm 47

11. Special Servicing Tools and Aids 48

11.1 Special Servicing Tools 48

11.2 Servicing Aids 50

STIHl

STIHlSTIHl

STIHL 019 T 1

1. INTRODUCTION

This service manual contains detailed descriptions of all the repair and servicing procedures specific to this series of chainsaws There are separate handbooks for servicing procedures on standardized parts and assemblies that are installed in several STIHL power tool models. Reference is made to these handbooks in the appropriate chapters of this manual.

You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies.

Always use the latest edition of the parts list to determine the part numbers of any replacement parts required. Microfilmed parts list are always more up to date than printed lists.

A fault on the machine may have several causes. Consult the troubleshooting charts for all assemblies in the "Standard Repairs, Troubleshooting" handbook.

Refer to the "Technical Information" bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until a revised edition is issued.

Special servicing tools mentioned in the descriptions are listed in the last chapter of this manual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL. Symbols are included in the text and pictures for greater clarity. The meanings are as follows:

In the descriptions:

• = Action to be taken as shown in the illustration (above the text)

- = Action to be taken that

is not shown in the illustration (above the text)

In the illustrations:

P = Pointer

= Direction of movement

Service manuals and all technical information bulletins describing engineering changes are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties.

Servicing and repairs are made considerably easier if the powerhead is mounted to the assembly stand (1) 5910 890 3100.

This enables the powerhead to be swivelled to the best position for the ongoing repair and leaves both hands free.

It is secured with the bar mounting stud after removing the chain sprocket cover and tensioner.

Always use original STIHL replacement parts. They can be

identified by the STIHL part number,

STIHL

the

STIHLSTIHL

parts symbol (The symbol may appear alone on small parts.

logo and the STIHL

STIHL 019 T 2

2. SPECIFICATIONS

2.1 Engine

STIHL single cylinder two-stroke engine with special impregnated cylinder bore

Displacement: Bore: Stroke: Engine power to ISO 8893:

35.2 cm 40 mm (1.57 in) 28 mm (1.10 in)

1.2 kW (1.6 bhp) Max. engine speed with bar and chain: Idle speed: Bearings:

12,000 rpm 2,800 rpm Crankshaft supported in heavyduty ball bearings, needle cages

on small and big ends Piston pin diameter: Connecting rod length: Rewind starter: Reserve pull on rope rotor: Starter rope:

8 mm (0.3 in)

51 mm (2 in)

Single pawl system

min. 1/2 turn

3.0 mm (0.12 in) dia.,

800 mm (31.5 in) long Clutch: Diameter: Clutch engages at:

Centrifugal clutch without linings

64 mm (2.52 in)

3,700 rpm Crankcase leakage test at gauge pressure: under vacuum:

0.5 bar (7.25 psi)

0.4 bar (5.8 psi)

(2.15 cu.in)

2.2 Fuel System

Carburetor: Standard setting High speed screw H: Low speed screw L: Carburetor leakage test at gauge pressure: Fuel tank capacity: Octane number:

Fuel mixture:

Mix ratio:

Air filter:

Diaphragm carburetor

Open approx. 1 turn

0.4 bar (4.8 psi)

0.29 1 (0.61 US pt)

min. 90 RON (US/CAN: pump

octane min. 87 unleaded)

Regular brand-name gasoline

and two-stroke engine oil

1:50 with STIHL 50:1 two-stroke

engine oil

25:1 with other brand-name

two-stroke, air-cooled engine oils

Felt element

STIHL 019 T 3

2.3 Ignition System

2.4 Cutting Attachment

2.5 Special Accessories

Type:

Air gap: Ignition timing:

Spark plug (suppressed):

Electrode gap: Spark plug thread: Length of thread:

Oilomatic chain: Chain sprocket: Chain speed:

Chain lubrication:

Oil delivery rate:

Oil tank capacity:

Electronic magneto ignition (breakerless) with integral trigger unit

0.25 mm (0.010 in)

1.6 - 2.3 mm (0.063-0.091 in) B.T.D.C. at 8,000 rpm NGK BPMR 7 A or CHAMPION RCJ6Y

0.5 mm (0.02 in) M14x1.25

9.5 mm (0.37 in)

9.32 mm (3/8") Picco-Micro-Mini 7-tooth 3/8" P spur sprocket

21.7 m/s (71.2 ft/sec) at 10,000 rpm Speed-controlled reciprocating oil pump. No oil feed at idle speed Adjustable 5 - 9 cm

/min

(0.17 - 0.30 fl.oz/min)

0.16 l (0.34 US pt)

2.5.1 For User

2.5.2 For Service

STIHL repair kit 6-tooth 3/8" P spur sprocket 8-tooth 1/4" spur sprocket ElastoStart

Carburetor parts kit

1132 900 5000 1123 640 2005 1123 640 2010 0000 190 3400

1132 007 1060

STIHL 019 T 4

2.6 Tightening Torques

Plastoform screws are used for polymer components and "DG" screws for lightmetal components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason it is essential to use a torque wrench.

Fastener

Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Spline screw Collar screw Spline screw Collar nut

Plastoform screw Screw

Use the following procedure when refitting a P or DG screw in an existing thread:

- Place the screw in the hole and rotate it counterclockwise until it drops down slightly.

- Tighten the screw clockwise to the specified torque.

Thread size

IS-DG 4x20 IS-DG 5x24 IS-DG 5x24 IS-DG 5x24 IS-DG 5x24 IS-DG 5x24 IS-DG 5x24 IS-DG 5x24 IS-DG 8x18 IS-M5x52 M8x1 M12x1 L M14x1.25 IS-P4x12 IS-DG 3.5x12

For component

Ignition module/cylinder Handle molding/front handle Fan housing/engine housing Engine pan/cylinder Handle molding/handle Muffler/cylinder Spacer flange/cylinder Engine housing/cylinder Bar mounting/engine housing Intake casing/carburetor/flange Flywheel Clutch Spark plug Hand guard, left/fan housing Support plate /diaphragm/ spacer flange

Torque Nm Ibf.ft

Remarks

4.5 3.3

3.5 2.6

4.0 3.0

8.0 5.9

4.0 3.0

7.0 5.2

8.0 5.9

16.0 11.8

5.0 3.7

28.0 21.0

50.0 37.0

25.0 18.5

1.7 1.3

2.0 1.5

This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the joint.

Note: Power screwdriver speed for use in polymer: Plastoform screws max. 600 rpm,

DG screws max. 500 rpm. Use only screws specified in parts list. Do not use screws with underhead locking teeth on polymer components.

STIHL 019 T 5

3. CLUTCH, CHAIN DRIVE, CHAIN BRAKE AND CHAIN TENSIONER

3.1 Chain Sprocket

• Unscrew the nut.

- Pull off the chain sprocket cover.

- Disengage the chain brake by pulling the hand guard toward the front handle.

• Remove the E-clip (1).

• Remove the washer (2).

• Take the needle cage out of the sprocket.

- Clean and inspect the chain sprocket.

Important: If there are noticeable wear marks on the inside diameter of the clutch drum, check its wall thickness. If it is less than 80% of the original wall thickness, fit a new sprocket.

• If the clutch drum is still serviceable, use No. 120 emery paper or emery cloth (grain size approx. 120µm) to clean and roughen its friction surface.

Reassemble in the reverse sequence.

- Clean stub of crankshaft. Wash needle cage in clean white spirit and lubricate with grease - see 11.2.

- Replace damaged needle cage.

- Rotate chain sprocket and apply slight pressure at the same same until oil pump drive spring engages properly.

Note: If the clutch drum has to be replaced, also check the brake band

- see 3.3.2.

• Pull off the chain sprocket.

STIHL 019 T 6

3.2 Clutch

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

- Remove chain sprocket - see 3.1.

3.3 Chain Brake

3.3.1 Checking Function

The chain brake is one of the most important safety devices on the chainsaw. Its efficiency is measured in terms of braking time, i.e. the time that elapses between activating the brake and the saw chain coming to a standstill. The shorter the braking time, the better the efficiency and protection offered against being injured by the rotating chain.

• Pull boot (1) off the spark plug.

- Unscrew the spark plug (2).

• Unscrew the clutch from the crankshaft in the direction of the arrow (left-hand thread).

- Disassemble and reassemble the clutch - see "Standard Repairs, Troubleshooting" handbook.

• Screw clutch onto crankshaft and torque down to 50 Nm (37 Ibf.ft).

- Remove locking strip from cylinder.

Contamination (with chain oil, chips, fine particles of abrasion, etc.) and smoothing of the friction surfaces of the brake band and clutch drum impair the coefficient of friction. This, in turn, reduces the frictional forces and thus prolongs the braking time. A fatigued or stretched brake spring has the same negative effect.

- Start the engine.

- With the chain brake activated (locked), open throttle wide for brief period (max. 3 seconds) the chain must not rotate.

- With the chain brake released, open throttle wide and activate the brake manually - the chain must come to an abrupt stop.

Note: The braking time is in order if deceleration of the saw chain is imperceptible to the eye.

- Install spark plug and torque down to 25 Nm (18.5 Ibf.ft).

Important: If spark plug has a separate terminal nut, make sure that it is properly tightened down.

- Fit spark plug boot.

- Install the chain sprocket see 3.1.

• Push the locking strip (1) 0000 893 5903 into the cylinder.

STIHL 019 T 7

3.3.2 Disassembl

- Release tension of brake spring by pushing the hand guard forwards.

- Remove chain sprocket cover.

• Ease the cover out of its retainers.

• Use assembly tool (2) 1117 890 0900 to carefully disconnect the brake spring (1).

• Unhook the brake spring from the bell crank (3).

• Remove brake band from the chain sprocket and detach it from the bell crank.

Replace the brake band if:

- there are noticeable signs of wear (large areas on inside diameter and/or parts of outside diameter) and

- its remaining thickness is less than

0.6 mm (0.024").

• Take out the screw.

- Remove the hand guard from its seat on the fan housing.

• Remove the E-clip,

Important! Thickness of brake band must not be less at any point.

• If the brake band is still serviceable, use No. 120 emery paper or emery cloth (grain size approx. 120µm) to clean and roughen its entire friction surface (inside diameter).

• Lever the brake band out of the engine housing.

• Slip the strap off the bell crank pivot pin (1).

• Push the strap to one side and remove it from the hand guard pivot pin (2).

STIHL 019 T 8

3.3.3 Assembl

• Remove the washer.

- Clean chain brake seat in housing.

- If the groove of the brake spring anchor pin is worn, replace the housing.

- Lubricate sliding and bearing points of chain brake with STIHL multipurpose grease or, preferably, Molykote grease - see 11.2.

- Fit flat spring in position.

• Carefully ease the hand guard (1) and bell crank (2) off the pivot pins and lift them away together.

- Pull the bell crank out of the hand guard.

• Take out the flat spring.

- Inspect parts. Replace any worn or damaged parts.

• Slide bell crank into end of hand guard. The short arm of the bell crank must point to top of hand guard.

• Locate bearing boss of hand guard (1) on pivot pin.

- Fit other end over the housing.

STIHL 019 T 9

• Position bell crank (1) against pivot pin (2).

- Push hand guard and bell crank fully

onto the pivot pins.

• Place strap on pivot pin (1) and pull it in direction of arrow until it engages the groove.

• Then push it over the pivot pin (2).

• Attach brake band to the bell crank.

• Check that flat spring (1) is properly located on face (2) of bearing boss.

• Fit the washer.

• Secure strap with E-clip.

- Coat brake band with chain oil (STIHL Bioplus), see 11.2, to protect it from corrosion an cushion "snatching" during the first few brake applications.

• Fit the brake band and press it into the engine housing.

• Hook the brake spring onto the bell crank.

STIHL 019 T 10

3.4 Chain Tensione

3.5 Bar Stud

• Use the assembly tool (2) 1117 890 0900 to attach the brake spring (1) to the anchor pin.

• Push cover over chain brake until it snaps into position and then tap it home carefully with a plastic mallet.

- Remove the chain sprocket cover.

• Pull the cover out of the engine housing.

• Unscrew the nut (1) from the adjusting screw (2).

• Take the adjusting screw out of the cover (3).

- Remove the chain sprocket cover.

• Push the stud puller (1) 5910 893 0501 onto the stud as far as it will go.

• Unscrew the stud.

- Insert stud and torque down to 16 Nm (11.8 Ibf.ft).

Reverse the above sequence to install the chain tensioner.

• Fit hand guard (1) over boss (2) on the fan housing.

- Insert screw and tighten to

1.7 Nm (1.25 Ibf.ft).

STIHL 019 T 11

4. ENGINE

4.1 Disassembly

Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine.

Troubleshooting chart - see "Standard Repairs, Troubleshooting" handbook.

- Remove the clutch - see 3.2.

- Take the locking strip out of the cylinder.

• Open the grommet. • Take throttle cable out of retainer.

• Pull off the worm with drive spring.

- Remove throttle trigger - see 8.1.

• Take out the upper screw (1).

• Disconnect the short circuit wire (2).

• Pull intake pipe (1) out of the intake casing (2).

• Pull intake pipe with grommet out of engine housing.

- Remove the grommet.

• Remove throttle cable from grommet and pull it downwards and out of the handle.

• Take out screws from top of engine.

STIHL 019 T 12

4.2 Assembly

• Take out screws from underside of engine.

• Remove engine sideways from housing.

• Check that grommet is properly seated in the engine housing.

• Throttle cable sleeve must locate in retainer in air baffle.

• Place throttle cable in the grommet.

- Fit top and bottom engine mounting screws and torque down to 8.0 Nm (5.9 Ibf.ft).

• Push grommet, ledge facing up, over the lugs of the intake pipe.

• Fit engine and position throttle cable in the handle at the same time.

- Push throttle cable into retainer in handle.

• Push grommet with intake pipe into the engine housing until the ledge butts against the engine housing.

STIHL 019 T 13

4.3 Exhaust Muffler/Spark Arresting Screen

• Fit the intake pipe (1) in the intake casing (2).

• Fit the short circuit and ground

wires (pull them downward and out of handle as far as possible) in the grommet and close the grommet.

Spark arresting screen

• Take out the screw.

• Remove the cover plate.

Muffle

- Remove the engine - see 4.1.

• Take out the screws.

- Remove the muffler.

Reassemble in the reverse sequence.

- Tighten screws to 7.0 Nm (5.2 Ibf.ft).

- Install the engine - see 4.2.

- Connect short circuit and ground wires to ignition module.

- Fit throttle trigger - see 8.1.

- Fit the worm with drive spring in position.

- Install the clutch - see 3.2.

• Remove the spark arresting screen.

- Clean the spark arresting screen or fit a new one if necessary.

STIHL 019 T 14

4.4 Leakage Test

4.4.1 Preparations

Defective oil seals, diaphragms and gaskets or cracks in castings or the spacer flange cause leaks. Such faults allow supplementary air to enter the engine and thus upset the fuel-air mixture.

This makes adjustment of the prescribed idle speed difficult, if not impossible.

Moreover, the transition from idle speed to part or full throttle is not smooth.

The engine housing can be checked thoroughly for leaks with the carburetor and crankcase tester and the vacuum pump.

- Remove the carburetor - see 1 0.5.2.

- Set the piston to top dead center (T.D.C.). This can be checked through the spark plug hole.

- Remove the air baffle - see 10.6.

• Fit the sealing plate (1) 0000 855 8106 between muffler and cylinder.

Note: The sealing plate must completely cover the exhaust port.

- Tighten the screws moderately.

Important: Do not overtighten the screws since the sealing plate may otherwise be damaged.

• Fit the spark plug and tighten down to 25 Nm (18.5 Ibf.ft).

• Back off muffler mounting screws halfway.

• Fit new gasket on spacer flange.

STIHL 019 T 15

+ 35 hidden pages