Stihl E 140, E 180 C, E 160 Service Manual

STIHL E 140, 160, 180

STIH)

2003-01

1. Introduction 2

2. Specifications 3

2.1 Motor 3

2.2 Gear Drive 3

2.3 Cutting Attachment 3

2.4 Tightening Torques 4

3. Wiring Diagram/
Description 5

4. Removing and
Installing Electrical
Components 6

4.1 Power Cable 6

4.2 Trigger Switch 8

4.3 Capacitor (230 V only) 8

4.4 Overload Circuit Breaker 8
(E 160, E 180 C only)

4.5 Chain Brake Switch 9

5. Motor 10

5.1 Carbon Brushes 10

5.2 Rotor 11

5.3 Rotor Bearing 13

5.4 Fanwheel 13

5.5 Stator 14

6. Chain Drive 15

6.1 Chain Sprocket 16

6.2 Ring Gear and Pinion 16

6.3 Gear Housing 16

7. Chain Tensioner 17

7.1 Front Chain Tensioner 17

7.2 Side Chain Tensioner 17

7.3 Quick Chain Tensioner 18

8. Chain Brake 18

8.1 Removal 18

8.2 Installation 20

9. Chain Lubrication 21

9.1 Oil Tank 21

9.2 Oil Strainer 21

9.3 Oil Pump 21

10. Special Servicing Tools
and Aids 23

10.1 Special Servicing Tools 23

10.2 Servicing Aids 23

©1998,AndreasStihlAG&Co.,Waiblingen

CONTENTS

E140,E160,E180 1

This service manual contains
detailed descriptions of all servi­cing procedures for STIHL model
E140,E160andE180Celectric
chainsaws and can thus be used
as a basis for professional over­hauls and repairs on all versions
of these machines.

As the constructional features of
these electric saws are almost
identical, the servicing procedures
generally apply to all three
models. Differences are described
in detail and special reference is
made to the model concerned in
each case.

Caution: When carrying out re­pairs to electric saws it is essential
to observe all relevant national sa­fety regulations and ordinances.

We recommend that you make
use of the exploded views in the
illustrated parts lists while carrying
out repair work. Most of the illustra­tions show the installed positions
of the individual components and
assemblies.

Refer to the latest edition of the
parts list for the part numbers of
any spare parts you may require.
Microfilmed parts lists are always
more up to date than printed lists.

Afaultonthepowertoolmayhave
several causes. Consult the
troubleshooting charts for all
assemblies in the "Standard
Repairs, Troubleshooting" hand­book and the troubleshooting
charts immediately after the speci­fications in this manual.

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.

The 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:

•

=Actiontobetakenas

shown in the illustration
(above the text)

-= Actiontobetakenthat
is not shown in the
illustration
(above the text)

In the illustrations:

=Pointer

=Directionofmovement

Servicing instructions 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 electric
saw is mounted to the assembly
stand (1) 5910 890 3100.

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

It is secured with the sprocket co­ver nut (after removing sprocket
cover). On the E 180 C, remove
the quick chain tensioner and the
secure saw to stand with an M8
nut.

Always use original STIHL
replacement parts.

They can be identified by the
STIHL part number,

the logo
and the STIHL parts symbol

The symbol may appear alone on
small parts.

1. INTRODUCTION

100RA001

1

VA

2 E140,E160,E180

2.1 Motor E 140 E 160 E 180 C

Type: Universal motor
Rating (kW): 1.4 1.6 1.8
Rated voltage (V): 120; 230 230 120; 230
Frequency (Hz): 60 50 50 60 50
Rated current (A): 11.7 6.4 7.3 15,0 8.2
Fuse (slow-blowing) (A): 15 16 16 15 16
Overload protection: Thermal overload circuit breaker

Type of enclosure: IP 20
Class of protection: II
Coasting brake: Mechanical

2.2 Gear Drive

Type: Straight-toothed ring gear with pinion, single-stage
Output speed with
bar and chain,
off load (idle): 5900 rpm

1)

6300 rpm 6900 rpm

3)

at rated load: 5000 rpm

2)

5400 rpm 5400 rpm

4)

Lubrication: STIHL multipurpose grease

2.3 Cutting Attachment

Chain sprocket: 7-tooth 3/8" Picco

spur sprocket

Chain lubrication: Fully automatic, speed-controlled reciprocating oil pump

Oil tank capacity: 0.20 l (0.4 US pt)

1)

120 V : 6100 rpm

2)

120 V : 4900 rpm

3)

120 V : 6800 rpm

4)

120 V : 5000 rpm

2. SPECIFICATIONS

3

Plastoform screws are used in polymer 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 always use a torque wrench.

Fastener Thread For component Torque Remarks

size Nm lbf.ft

Self-tapping screw IS-B6.3x32 LH hand guard/motor housing 4.5 3.3
Slotted nut M5 L Drive pinion/rotor shaft 8.0 5.9 1)
Plastoform screw IS-P3x10 Cover plate/sprocket cover 1.0 0.75
Plastoform screw IS-P4.5x25 Commutator cover/motor housing 3.0 2.2
Plastoform screw IS-P4.5x45 Stator/motor housing (1200 W) 3.0 3.0
Plastoform screw IS-P4.5x55 Stator/motor housing (1400, 1600 W) 3.0 3.0
Plastoform screw IS-P4x19 Oil pump/gear housing 2.5 1.8
Plastoform screw IS-P4x19 Handle housing/motor housing 2.0 1.5
Plastoform screw IS-P4x19 Cable clamp/motor housing 1.5 1.1
Plastoform screw IS-P5x20 Spiked bumper/handle housing 4.0 3.0
Plastoform screw IS-P5x20 Gear housing/motor housing 3.0 2.2
Spline screw IS-M6x25 Brake band/gear housing 6.0 4.4

Use the following procedure to fit a ’P’ screw in an existing thread:

–PlacethePscrewintheholeandrotateitcounterclockwiseuntilitdropsdownslightly.
–Tightenthescrewclockwisetothespecifiedtorque.

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

1) Secure slotted nut with Loctite 242.

Note: Screws/nuts secured with adhesive are easier to release if they are heated beforehand with a hot air blo­wer (hairdryer).

Be careful with polymer components!

Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm,

DG screws max. 500 rpm

2.4 Tightening Torques

4

The trigger switch (1) is equipped
with a mechanical starting lockout
(interlock button) which helps pre­vent unintentional switch-on.

The saws feature a thermal over­load circuit breaker (3) to protect
the electric motor from mechanical
overload.

This overload circuit breaker inter­rupts the power supply to the saw
if the operator continues cutting for
an extended period with an over­tensioned chain, uses excessive
feed force, "lugs down" the motor
speed or if the chain is suddenly
stopped by being pinched in the
cut.

Before restarting the saw and con­tinuing work it is necessary to pull
the guide bar out of the cut and
wait for a short period until the
overload circuit breaker has coo­led down. The overload circuit
breaker can then be reset by pres­sing in the button as far as
the stop.

This is not a fault. The remedy in
such a case is to work with less
feed effort. Under no circumstan­ces should the overload circuit
breaker be bypassed, even if the

owner explicitly requests such a
modification.

Chain brake

The brake lever is unlatched when
the "Quickstop" chain brake is
activated, either manually or by
inertia. The power supply is inter­rupted immediately by the chain
brake switch (4) and the spring-loa­ded brake band is clamped around
the brake drum at the same in­stant.
This causes the saw chain to be
brought to a standstill and locked
in position. The chain brake is
disengaged by moving the hand
guard toward the front handle.

Coasting brake

The coasting brake supplements
the chain braking system. It brings
the rotating chain to a standstill
when the operator releases the
trigger switch.
In the idle condition, an additional
spring clamps the brake band aro­und the brake drum.
When the trigger switch is squee­zed, the brake band is first disen­gaged from the brake drum via a
linkage. Only then does the switch
close and start the motor.

3. WIRING DIAGRAM/DESCRIPTION

100RA002

2

3

2

1

2

1

1

2

K

1 2 3

4

5

6

5

7

VA

1Triggerswitch
2Capacitor(230Vonly)
3Overloadcircuitbreaker(E160,E180Conly)
4Chainbrakeswitch
5Brushholderwithcarbonbrush
6Rotor
7Stator

5

Important: The electrical safety of
the saws should be checked after
every repair by performingahigh­voltage insulation test. Tests of
this kind may only be carried out
by electricians or specially trained
personnel.

Always unplug the machine from
the mains supply.

- Remove the quick chain
tensioner, if fitted - see 7.3.

•

Unscrew nut.

- Remove the chain sprocket
cover.

Models with quick chain
tensioner

•

Take out screws (1).

•

Remove the spiked bumper (2).

All models

- Remove the chain sprocket -

see 6.1.

•

Unscrew oil filler cap and remo­ve together with cap retainer.

•

Take out the screws.

- Remove the handle housing.

•

Take out the O-ring.

- Placeasocket (e.g. 19mm)
under the handle housing so that
it supports the bearing bush from
outside.

•

Use drift (1) 1111 893 4700 to
press needle sleeve out of
bearing bush.

•

Take out the screws.

- Remove the strain relief cable
clamp.

100RA005

VA

100RA008

1

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100RA004

2

1

1

VA

100RA003

VA

4. Removing and Installing Electrical Components

4.1 Connecting Cord

100RA007

VA

100RA006

VA

100RA009

VA

6

•

Slacken off the screws.

- Pull the wires out of the switch.

•

Pull cable protector off the old
connecting cord.

Installation is a reversal of the
removal sequence.

- Slip the cable protector, thin end
first, over the new connecting
cord.

•

Check that cable protector is
correctly seated.

- Fit the strain relief clamp
and tighten screws to 1.5 Nm
(1.1 lbf.ft).

•

Fit a new O-ring on gear housing
pivot pin.

- Place a socket (e.g. 19mm)
under the handle housing so that
it supports the bearing bush from
inside.

•

Use press arbor (1) 4116 893
7205 to install needle sleeve in
the bearing bush.

•

Check condition of sealing ring
on oil tank and fit a new one if
necessary - see 9.1.

- Tighten the handle housing
mounting screws to 2.0 Nm
(1.5 lbf.ft).

100RA014

1

VA

100RA011

VA

100RA012

VA

100RA015

VA

100RA010

VA

100RA013

VA

7