Related Manuals for Stihl 4180 Series
Summary of Contents for Stihl 4180 Series
- Page 1 STIH) STIHL Basismotor 4180 2007-11 FC 90 HL 100 FC 95 HT 100 FC 100 HT 101 FC 110 HT 130 FS 90 HT 131 FS 100 KM 90 FS 110 KM 100 FS 130 KM 110 KM 130...
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Page 2: Table Of Contents
Ignition Timing Accelerator Pump 8.2.2 Removing and Adjusting Idle Speed Installing 6.4.1 Basic Setting Testing the Ignition Tank Vent System 6.5.1 Checking Operation Ignition System 6.5.2 Replacing Tank Vent Troubleshooting © ANDREAS STIHL AG & Co. KG, 2007 Series 4180 Powerhead... -
Page 3: Introduction
*= Situation applies up to revised edition is issued. serial No. Always use original STIHL The special tools mentioned in the replacement parts. descriptions are listed in the last In the illustrations: They can be identified by the chapter of this manual. -
Page 4: Safety Precautions
Safety Precautions If the power tool is started up in the course of repairs or maintenance work, observe all local and country- specific safety regulations as well as the safety precautions and warnings in the instruction manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. -
Page 5: Specifications
FC 100, 110 HT 130 KM 90 HT 100, 101 HT 131 HL 100 KM 130 KM 100, 110 Engine STIHL single cylinder four-stroke engine with mixture lubrication Displacement: 28.4 cm 31.4 cm 36.3 cm Bore: 38 mm 40 mm 43 mm... -
Page 6: Tightening Torques
Tightening Torques DG and P (Plastoform) screws are used in polymer and light metal 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 impairing the strength of the screwed assembly, providing the specified tightening torque is observed. - Page 7 Fastener Thread size For component Torque Socket head screw IS-DG5x24 Starter cover/tank/engine pan M8x1 Starter cup/crankshaft 17.0 Socket head screw IS-M5x30 Valve cover/cylinder Screw plug M11x10 Screw plug/gearbox 10.0 Spark plug IS-M10x1 Spark plug Socket head screw IS-DG4x18 Ignition module/cylinder Socket head screw IS-DG5x32 Spacer flange/cylinder...
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Page 8: Troubleshooting
Troubleshooting Clutch Condition Cause Remedy Attachment stops under load at full Clutch badly worn Install new clutch throttle Clutch drum badly worn Install new clutch drum Attachment runs when engine is Engine idle speed too high Readjust with idle speed screw idling (counterclockwise) Clutch springs stretched or fatigued Install new clutch... -
Page 9: Rewind Starter
Rewind Starter Condition Cause Remedy Starter rope broken Rope pulled out too vigorously as Fit new starter rope far as stop or over edge, i.e. not vertically Normal wear Fit new starter rope Rewind spring broken (starter rope Spring overtensioned – no reserve Fit new rewind spring does not rewind) when rope is fully extended... -
Page 10: Ignition System
Ignition System Warning: Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The ignition system. The high voltages which occur can cause serious or fatal accidents. Condition Cause Remedy Engine does not run No spark Check operation of slide control and ignition module;... -
Page 11: Carburetor
Carburetor Condition Cause Remedy Carburetor floods; engine stalls Inlet needle not sealing. Foreign Remove and clean or replace inlet matter in valve seat or cone needle, clean fuel tank, pickup damaged body and fuel hose if necessary Inlet control lever sticking on Free off inlet control lever spindle Helical spring not located on nipple... - Page 12 Condition Cause Remedy Engine will not idle, Throttle shutter opened too wide by Reset idle speed screw idle speed too high idle speed screw Intake stub leaking Seal or replace intake stub Engine stops while idling Idle jet bores or Clean jet bores and ports and blow ports blocked clear with compressed air...
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Page 13: Engine
Engine – Always check and, if necessary, repair the following parts before looking for faults on the engine: – Air filter – Fuel system – Carburetor – Ignition system Condition Cause Remedy Engine does not start easily, stalls Check compression Check combustion chamber for at idle speed, but operates normally excessive build-up of combustion... - Page 14 Condition Cause Remedy Engine overheating Insufficient cylinder cooling. Air Thoroughly clean all cooling air inlets in fan housing blocked or openings and the cylinder fins cooling fins on cylinder very dirty Series 4180 Powerhead...
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Page 15: Rewind Starter/Shroud
– Lift away the rewind starter. with STIHL special lubricant. Carefully pull out the starter rope Reassemble in the reverse several times and allow it to rewind sequence. - Page 16 – Fit the pawl and washer. Engage the spring clip (1) out of the spring clip in the groove on the groove in the starter post. Coat bore in rope rotor with STIHL starter post. special lubricant, b 12. : Remove the washer (2) and pawl...
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Page 17: Starter Rope
Starter Rope – Remove the rewind starter, b 5.2 – Remove remaining rope from the rope rotor and starter grip. : Pull the rope back into the rotor – Thread the other end of the rope through the guide bush (2) from so that the knot locates in the outside. -
Page 18: Tensioning
5.4.1 Tensioning – Remove the rewind starter, b 5.2 : Hold the rope rotor steady. The rewind spring is correctly tensioned when the starter grip sits : Pull out the twisted rope with the firmly in the rope guide bushing starter grip and straighten it out. -
Page 19: Pawl
Pawl Replacing the Rewind Removing the Shroud Spring – Remove the rope rotor, b 5.3 The pieces of broken spring may still be under tension and may fly apart unexpectedly when you remove them. To reduce the risk of injury, wear a face shield and work gloves. -
Page 20: Fuel System
Fuel System Air Filter Dirty air filters reduce engine power, Install air filter housing (B) with stub increase fuel consumption and only with the connecting hose to the make starting more difficult. tank vent. The air filter must be cleaned when Unfiltered air would be sucked in if there is a noticeable loss of engine the connecting hose is not fitted. -
Page 21: Carburetor
Carburetor 6.2.1 Leakage test Troubleshooting, b 4.4 In the event of trouble with the carburetor, first check the fuel supply, b 6.6, and tank vent, b 6.5 The carburetor can be tested for leaks with the carburetor and crankcase tester 1106 850 2905. –... -
Page 22: Removing And Installing
6.2.2 Removing and Installing 6.2.3 Manual Fuel Pump – Remove the air filter, b 6.1 : Pull off the carburetor. – Remove the shroud, b 5.7. : Pull the fuel hoses (1 and 2) off – Leakage test, b 6.2.1 the elbow connectors. -
Page 23: Metering Diaphragm
6.2.4 Metering Diaphragm : Remove the flange. – Remove the flange, b 6.2.3 : Place the metering diaphragm (1) on the gasket. : Remove metering diaphragm (1) and gasket (2) from the The cutout in the metering carburetor body. diaphragm (2) must line up with the compensating bore in the If the gasket and diaphragm are carburetor and the gasket. -
Page 24: Inlet Needle
6.2.5 Inlet Needle 6.2.6 Fixed Jet 6.2.7 Pump Diaphragm – Remove the carburetor, b 6.2.2 – Remove the metering – Remove the metering diaphragm, b 6.2.4 diaphragm, b 6.2.4 : Take out the screws (1). : Loosen the collar screw (1). : Use a suitable screwdriver to : Remove the end cover (2). - Page 25 : Remove the gasket (1) and pump : Remove the gasket (1) and pump : Gasket (1) and pump diaphragm diaphragm (2). diaphragm (2). (2) are held in place by the cast pegs on the end cover (5). If the gasket and diaphragm are Reassemble in the reverse : Install the spring (4) and spring stuck together, separate them...
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Page 26: Accelerator Pump
Accelerator Pump Adjusting Idle Speed Standard Setting – Shut off the engine – Check the air filter and clean or replace if necessary. – Inspect the spark arresting screen (if fitted) and clean or replace if necessary. The limiter caps must not be The carburetor is equipped with an : Take out the screw (1). -
Page 27: Basic Setting
6.4.1 Basic Setting – Adjust engine idle speed with the The basic setting is carried out with aid of a tachometer, the high speed screw H and the low b 3.1; speed screw L as follows: note that there is an ignition spark on every revolution of FS 90;... -
Page 28: Tank Vent
Tank Vent 6.5.1 Checking Operation Correct operation of the carburetor is only possible if atmospheric pressure and internal fuel tank pressure are equal at all times. This is ensured by the tank vent. In the case of problems with the carburetor or fuel supply system, also check the tank vent. -
Page 29: Replacing Tank Vent
6.5.2 Replacing Tank Vent – Drain the fuel tank, b 6.6.1 Vacuum test Tank vent with return line : Push hose (1) onto stub on filter – Connect hose (2) to vacuum – Remove the faulty tank vent. pump 0000 850 3501 and test housing (3). -
Page 30: Fuel Supply
Fuel Supply 6.6.1 Cleaning the Fuel Tank 6.6.2 Fuel Hoses and Pickup Body The diaphragm pump draws fuel out Depending on the type of fuel tank, of the tank and into the carburetor two different fuel supply systems via the fuel hose. are installed: Any impurities mixed with the fuel One-part system (molded hose),... - Page 31 Reassemble in the reverse sequence. – Attach pickup body with molded hose to connector. Multi-part system Multi-part system : Carefully pry the tab (1) of the : Center the connector in the fuel connector upwards; take care not tank’s opening and turn it so that to damage the fuel tank.
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Page 32: Fuel Tank
6.6.3 Fuel Tank Engine – Drain the fuel tank. Always check and, if necessary, repair the fuel system, carburetor, – Remove the rewind starter, air filter and ignition system before b 5.2 looking for faults on the engine. – Remove the shroud, b 5.7 Lubricate all moving parts of the engine with oil. -
Page 33: Compression Pressure
Compression Pressure Checking / Adjusting Valve Clearance Check and adjust valve clearances only when engine is cold. – Remove the rewind starter, b 5.2 – Remove the shroud, b 5.7 : Rotate the crankshaft until the – Pull the boot off the spark plug. arrow (1) is in line with the screw –... - Page 34 : Fit locking screw (1) : Take out the screws (arrows). : Marks (arrows) on cam gear (2 4180 890 2700 in spark plug and 3) must line up with the : Carefully lift away the cam gear hole. notches (1 and 4) in the cylinder. cover (1).
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Page 35: Rocker Arms/Pushrods
Rocker Arms/Pushrods : Remove the rocker arm. Adjusting Valves – Remove the valve cover and cam gear cover, b 7.2 Valve clearance is adjusted with the locknuts (1 and 2). – Set piston to T.D.C., b 7.2 To increase valve clearance: Turn nut counterclockwise : Remove the locknut (1). -
Page 36: Cam Followers, Cam Gear
Cam Followers, Cam Gear – Remove the pushrods, b 7.3 : Permissible combinations are as : Install the pin (1). follows: : Pull out the pin (1). The marks must not move out of position while the cam gear is being Bore Length of pin : Remove the cam followers (2). -
Page 37: System
7.4.1 Decompression System Muffler / Spark Arresting Screen : To remove the muffler, take out the screws (arrows). – Remove cam gear cover, b 7.2 – Remove the rewind starter, b 5.2 : Check free movement and – Remove the shroud, b 5.7 function of decompression system lever (arrow). -
Page 38: Clutch
Clutch 7.6.1 Removing and Disassembling Troubleshooting, b 4.1 – Remove the shroud, b 5.2. – Remove the throttle cable and wiring of ignition module, b 8.2.2 100% : Inspect the clutch drum (1). : Take out the clutch shoe screws There should be no scores or (1 and 2). -
Page 39: Assembling And Installing
7.6.2 Assembling and Installing : Attach spring to clutch shoes. : Fit corrugated washers (1 and 2). : Fit screws (1 and 2) and tighten them down firmly, b 3.4 : Place cover plate (1), with "1" : Fit clutch shoes with lettering –... -
Page 40: Clutch Drum And Bearing
7.6.3 Clutch Drum and Bearing – Turn the removal tool and fan housing over – so that the fan housing rests on the removal tool. All models – Remove the engine, b 7.6.1 Polymer fan housing. : Remove the retaining ring (1). : Take out the screw (1). -
Page 41: Flywheel
Flywheel Installing the flywheel – Clean the stub of the crankshaft and the flywheel hub bore with a standard commercial, solvent- based degreasant containing no chlorinated or halogenated hydrocarbons, b 12 – Check Woodruff key or integrally cast key for damage and replace key or flywheel if necessary. -
Page 42: Crankshaft
Crankshaft 7.8.1 Replacing the Oil Seals It is not necessary to disassemble Installing oil seal at starter side the engine to replace the oil seals. – Inspect crankshaft running face Starter side for scores. – Remove the rewind starter, – Clean sealing face in crankcase. b 5.2 –... - Page 43 : Press home the oil seal (1) with : Apply puller (1) 5910 890 4400 : Slip installing sleeve press sleeve (2) 1115 893 4600 with No. 3.1 jaws (2) and clamp 4112 893 2400 (1) over the end so that it is flush with the the arms.
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Page 44: Crankcase, Lower Half
7.8.2 Crankcase, Lower Half – Remove the tank, b 6.6.3 Do not take the crankshaft out of the bearings because this will alter cam – Remove the muffler, b 7.5 gear timing, b 7.4. – Remove the flywheel, b 7.7 Reassemble in the reverse sequence. -
Page 45: Crankshaft
7.8.3 Crankshaft Always check and, if necessary, repair the fuel system, carburetor, air filter and ignition system before looking for faults on the engine, b 4.1 – Remove the lower half of the crankcase, b 7.8.2 : Examine ball bearings (1), –... -
Page 46: Piston
7.8.4 Piston – Remove the crankshaft, b 7.8.3 Important: Wear safety glasses when working with spring washers and snap rings. : Rotate flywheel until mark (1) is in : Use the assembly drift (2) line with screw head (2). 1110 893 4700 to push the piston pin (1) out of the piston. - Page 47 : Indentation (arrow) in piston Piston pin with diameter of 8 mm : Push the large slotted diameter of crown faces the spark plug hole. Use installing tool 5910 890 2208 to the sleeve over the magnet and fit the snap ring, b 11 snap ring.
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Page 48: Piston Rings
7.8.5 Piston Rings – Remove the piston rings from the piston. : Remove the sleeve and slip it : Fit the snap ring (1) so that its gap onto the other end of the shank. (arrow) points either up or down. –... -
Page 49: Valves/Valve Springs
Valves/Valve Springs Valve spring retainer must engage properly in groove of valve stem. Reassemble in the reverse sequence. – When installing, check the valves again, b 3.1 : Valves are distinguished by the : Press valve spring retainer (1) mark (1) on the valve head and down and move it sideways so the head diameter "d"... -
Page 50: Cylinder
7.10 Upper Half of Crankcase 7.11 Leakage Test with Cylinder – Remove the valves, b 7.9 Damaged oil seals and gaskets or cracks in castings cause leaks. – Remove the cam gear, b 7.4 Such faults allow supplementary air to enter the engine and upset the –... - Page 51 – Tighten down the screws firmly. Vacuum test Oil seals tend to fail when subjected to a vacuum, i.e. the sealing lip lifts away from the crankshaft during the piston's induction stroke because there is no internal counterpressure. : Push the test flange (1) Pressure test 1119 850 4201 into position.
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Page 52: Ignition System
Ignition System Spark Plug Boot – Remove the shroud, b 5.7 Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The ignition lead is molded to the The high voltages which occur can ignition module. cause serious or fatal accidents. -
Page 53: Ignition Module
Ignition Module 8.2.1 Ignition Timing 8.2.2 Removing and Installing Ignition timing is not adjustable. Since there is no mechanical wear in these systems, ignition timing cannot get out of adjustment during operation. However, an internal fault in the circuit can alter the switching point in such a way that a spark test will still show the system to be in order although timing is outside the... - Page 54 Depending on the type of cylinder, the ignition module is mounted to the cylinder with or without washers. The height of the cylinder bosses for mounting the ignition module are different: : Take the screw (1) out of the fan Both models housing and remove the engine.
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Page 55: Testing The Ignition System
Testing the Ignition System ZAT 3 5910 850 4520 Using ZAT 4 ignition system Using ZAT 3 ignition system : When using the ZAT 3, hold it tester 5910 850 4503 tester 5910 850 4520 only by the handle (4) or position it in a safe place. -
Page 56: Ignition System Troubleshooting
Ignition System Troubleshooting Machine does not run Slide control in position # or stop switch in position "I"? Check the spark plug: – Smeared with oil, black? – Sooted? – Electrode gap correct? – Contacts shorted? Clean, readjust or replace the spark plug Check the spark plug boot: –... - Page 57 Ignition spark? Check air gap and reset if necessary Check the flywheel: Have pole shoes turned blue? Install new flywheel Disconnect short circuit wire from ignition module Check the ignition lead: – Severe chafing? – Spark plug boot: Holes/cracks? – Resistance: spark plug boot to ground: spec. 1.5 –...
- Page 58 Check operation of slide control or separate stop switch Short circuit wire chafed? Contact gap (contact springs) If necessary, install new ignition lead and/or contact springs, microswitch Re-connect short circuit wire Ignition spark? Install new ignition module Engine runs Check # / STOP-O function Look for fault in fuel system on slide control or separate stop or carburetor,...
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Page 59: Throttle Control
Throttle Control Throttle Trigger, Lockout Lever : Use a screwdriver to push the : Remove the torsion spring. : Take the tensioner (1) out of the slide (if fitted) to the bottom end guide and remove the throttle of the slot (arrow). cable. -
Page 60: Tensioner
Tensioner Adjusting Throttle Cable 9.3.1 Control Handle with Slide – Remove the shroud, b 5.7 – Adjust idle speed screw correctly. : Remove the torsion spring. – Remove the carburetor, b 6.2.2 : Swing tensioner (1) vertically Reassemble in the reverse sequence. -
Page 61: Control Handle Without Slide
9.3.2 Control Handle without Slide – Remove the shroud, b 5.7 If the lever does not butt against the stop: – Adjust idle speed screw correctly. – Readjust tensioner until the lever butts against the respective stops. – Adjust the throttle cable and check the adjustment again. -
Page 62: Checking Adjustment
9.3.3 Checking Adjustment Slide Control Throttle lever must butt against the stop on the carburetor cover when the throttle trigger is squeezed as far as stop (full throttle), and butt against the idle speed screw (LA) when the throttle trigger is in the idle position. -
Page 63: Av System
AV System – Turn the removal tool and fan housing over – so that the fan housing rests on the removal tool. All models – Remove the engine, b 7.6.1 : Jaws must engage the cutouts in the clamp (1). : Take screw (1) out of fan housing. -
Page 64: Special Servicing Tools
Special Servicing Tools Part Name Part No. Application Assembly stand 5910 890 3101 Holding powerhead Clamp 5910 890 8800 Holder for No. 1 Compression tester 5910 850 2000 Testing valves and piston rings for leaks Remove the locking screw 4282 890 2700 Blocking the crankshaft Extension 4180 893 4400... -
Page 65: Special Accessories
Rubber elements of AV system (50 ml and 100 ml bottle) Fuel line connector Grommet on molded hose (one-part system) STIHL special lubricant 0781 417 1315 Bearing bore in rope rotor, bearing bore in rope rotor Dirko HT red sealant... - Page 66 englisch / english 0455 933 0123. M0,2. L11. FST. Printed in Germany...