Stihl MS 192 T Manual
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Stihl MS 192 T Manual

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STIH)
STIHL MS 192 T
20 05-0 2

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  • Page 1 STIH) STIHL MS 192 T 20 05-0 2...
  • Page 2 Rope Rotor Removing and 10.5 Starter Rope / Grip Installing 10.6 Tensioning the Rewind Chain Tensioner Spring Bar Mounting Stud 10.7 Replacing the Rewind Spring 10.8 Starter Rope Guide Bushing © ANDREAS STIHL AG & Co. KG, 2005 MS 192 T...

  • Page 3: Table Of Contents

    14.6 Tank Vent 14.6.1 Testing 14.6.2 Removing and Installing 14.7 Fuel Intake 14.7.1 Pick-up Body 14.8 Fuel Hoses 14.8.1 Fuel Pump 14.8.2 Fuel Tank Filler Cap 14.8.3 Tank Housing, Removing and Installing Special Servicing Tools Servicing Aids MS 192 T...
  • Page 4 Always use original STIHL replacement parts. supplement the parts list and b 4.2 = Reference to another service manual until an updated They can be identified by the STIHL edition is issued. chapter, i.e. to chapter 4.2 in part number STIH) logo this case.
  • Page 5 Improper handling may result in burns and other serious injuries. Do not bring any fire, flame, spark or other source of heat near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. MS 192 T...
  • Page 6 Specifications Engine MS 192 T Displacement: 30.1 cm Bore: 37 mm Stroke: 28 mm Engine power to ISO 7293 1.3 kW (1.8 HP) at 9500 rpm Max. permissible engine speed (with bar and chain): 13500 rpm Idle speed: 3000 rpm...
  • Page 7 Screw P 4x12 Annular buffer, support/ engine housing Screw P 5x29.6 Annular buffer/ handle housing Screw DG 5x20 Muffler / cylinder M 8X1 Flywheel/ crankshaft 18,0 M 14x1.25 Spark plug 25,0 Screw DG 4x20 Ignition module/ cylinder MS 192 T...
  • Page 8 Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread and weaken the assembly. Screwdriver speed when used in plastic material: DG screws max. 500 rpm. MS 192 T...
  • Page 9 Clutch spring hooks broken Replace clutch springs Loud noises Clutch springs stretched or fatigued Replace all clutch springs Needle cage damaged Fit new needle cage Clutch shoe retainer broken Fit new retainer Clutch shoes and carrier worn Install new clutch MS 192 T...
  • Page 10 Replace clutch springs Saw chain does not stop Brake spring stretched or broken Fit new brake spring immediately when brake is activated Brake band stretched, worn or Fit new brake band broken Clutch drum worn Install new clutch drum MS 192 T...
  • Page 11 Oil pump damaged or worn Replace oil pump Machine losing chain oil Oil pump housing defective Replace oil pump Oil pump damaged or worn Replace oil pump Oil pump delivers insufficient oil Oil pump worn Replace oil pump MS 192 T...
  • Page 12 (crankshaft does not turn) Spring clip fatigued Fit new spring clip Starter rope is difficult to pull and Starter mechanism is very dirty Thoroughly clean complete starter rewinds very slowly mechanism MS 192 T...
  • Page 13 Faulty insulation on ignition lead or short circuit wire, check ignition lead / ignition module and replace if necessary. Check operation of spark plug Clean the spark plug or replace if necessary Crankcase damaged (cracks) Replace crankcase MS 192 T...
  • Page 14 Inlet needle sticking to valve seat Remove inlet needle, clean and refit Diaphragm gasket leaking Replace diaphragm gasket Metering diaphragm damaged or Fit new metering diaphragm shrunk Impulse hose damaged or kinked Fit new impulse hose MS 192 T...
  • Page 15 Turn the high speed screw H rich clockwise (leaner) – max. up to the stop. Main jet bores or ports blocked Clean the carburetor Pump diaphragm damaged or Fit new pump diaphragm fatigued Impulse hose damaged or kinked Fit new impulse hose MS 192 T...
  • Page 16 Fit new hoses and route them or damaged without kinks 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 MS 192 T...
  • Page 17 : Unscrew the hex nut (arrow). : Turn the screw anticlockwise to relax the chain. : Unscrew the nut (arrow) and : Fit the sprocket cover, ensuring remove the sprocket cover (1). that the peg (arrow) engages in the hole. MS 192 T...
  • Page 18 : Remove the chain catcher (3). released. If the chain is tensioned – Reassemble parts in reverse excessively, this may result in order. damage to the chain, guide bar and sprocket, as well as its needle bearing. MS 192 T...
  • Page 19 : Apply a suitable tool to the tab : Unscrew the clutch (1). the peg is aligned in the recess (arrow) to prise the boot off the (arrows). spark plug (1). The clutch has a left-hand thread. – Reassemble remaining parts in reverse order. MS 192 T...
  • Page 20 – Clean all parts. The tips of the retainers (arrows) (arrow). must match one another on the side – Replace any damaged parts. with the raised hexagon and the series numbers must be visible on the clutch shoes. MS 192 T...
  • Page 21 – Pull the locking strip out of the halogenated hydrocarbons. cylinder. – Reassemble remaining parts in reverse order. – Grease the needle cage and crankshaft stub, b 16 : Slip the needle cage (1) onto the crankshaft stub. MS 192 T...
  • Page 22 The braking time is in order if deceleration of the saw chain is imperceptible to the eye. If the chain brake does not operate properly, see troubleshooting chart, b 4.2. : Take out the screws (arrows). MS 192 T...
  • Page 23 : Disconnect the brake band (1) : Remove the hand guard (2) with from the lever (arrow) and lever (1) from the pivot pins. remove it. – Pull the lever out of the hand guard. MS 192 T...
  • Page 24 Turn the pin anchor pin is worn. Proceed as back and forth as necessary. follows: : Slide the lever (1) through the opening in the cover. MS 192 T...
  • Page 25 Coat all sliding and bearing points with STIHL multi-purpose grease, b 16 Do not grease the brake band. : The turns of the brake spring The forked opening (2) must face towards the brake band. must lie tightly against one another when relaxed.
  • Page 26 (1) makes contact on the right and the screw tensioner slide (4) and replace if (arrow) is revealed. necessary. : Remove the screw (arrow). : Pull the thrust pad (1) off the adjusting screw. MS 192 T...
  • Page 27 – Ensure that the parts are installed in the correct order. – Check correct functioning. – Coat the threads and gear wheels with STIHL multi-purpose grease, b 16 : Turn the adjusting screw (arrow) : Push the stud puller (1) –...
  • Page 28 A gasket is not fitted between muffler and cylinder. – Reassemble parts in reverse order. : Remove the cover plate (2) and spark arresting screen (1) if fitted. – Clean the spark arresting screen (1) or replace if necessary. MS 192 T...
  • Page 29 : Close the vent screw (1). – Fit the test flange 1128 850 4200 (1). : Operate lever (2) until the : Screw on the nuts (arrows) and pressure gauge (arrow) indicates tighten them down firmly. a vacuum of 0.5 bar. MS 192 T...
  • Page 30 1106 850 2905. : Connect pressure hose (1) of tester 1106 850 2905 to nipple – Continue with vacuum test b 8.2.2 (arrow). : Close vent screw (1) on the rubber bulb. MS 192 T...
  • Page 31 – Free off the oil seal in its seat by any chlorinated or halogenated tapping it with a suitable tube or a hydrocarbons. punch. – Reassemble remaining parts in reverse order. : Apply puller 5910 890 4400 with No. 3.1 jaws 0000 893 3706. MS 192 T...
  • Page 32 – Remove the flywheel, b 9.5 : Prise off the supporting plate (1) with a suitable tool. : Remove the cover (1). : Lift the handle housing (1) slightly and pull the manifold off the intake stub (arrow). MS 192 T...
  • Page 33 : Remove the screws (arrows) on : Pull the engine out of the engine : Fit the screws (arrows) and the carburetor side. housing. tighten them down only moderately. MS 192 T...
  • Page 34 : Push the manifold (1) onto the the hole (arrow) when fitting the intake stub. sprocket cover. – Coat the manifold with STIHL Press Fluid, b 16 : Unscrew the nut (arrow) and : Tighten down the nut (arrow) and...
  • Page 35 (arrows) of the engine pan, then tap lightly to release – Tightening torques, b 3.5 and lift off the engine pan. : Connect the impulse hose (1) to : Remove the crankshaft from the the stub (arrow). bearing seats (arrows). MS 192 T...
  • Page 36 – Slide the piston into the cylinder, before inserting them in the the clamping strap moves cylinder. backwards at the same time. : Remove the clamping strap. The cylindrical crankshaft stub (arrow) must point towards the cylinder exhaust port. MS 192 T...
  • Page 37 16 : Apply sealing compound to the Before closing the crankcase, ensure that the cylindrical outside diameter (arrows) of the oil seals, b 16 crankshaft stub (1) is on the side of the cylinder exhaust port (arrow). MS 192 T...
  • Page 38 – Clean the crankshaft stub with standard solvent-based degreasant not containing any chlorinated or halogenated hydrocarbons. – Install the engine, b 8.4.2 : Remove the ball bearing (1) and : Fit the washer (1). – Reassemble remaining parts in washer. reverse order. MS 192 T...
  • Page 39 : If the ball bearing cannot be heated, it must be pressed in with a suitable sleeve (1) until the ball bearing rests against the washer. MS 192 T...
  • Page 40 1114 893 4700, small diameter side of the snap ring. first, through the piston hole and – Inspect the piston rings and small end (needle cage) and line replace if necessary, b 8.7 up the piston. MS 192 T...
  • Page 41 (arrow) does not coincide with the (arrow). tool's shank. recess (2). The inner pin must point towards the flat face. MS 192 T...
  • Page 42 : Use a piece of old piston ring to scrape the grooves clean. : Install the new piston rings in the grooves so that the radii at the ends of the rings (arrows) face towards the piston head. MS 192 T...
  • Page 43 Since there is no mechanical wear cover (1). in these systems, ignition timing cannot get out of adjustment during operation. : Apply a suitable tool to the tab (arrow) to prise the boot off the spark plug (1). MS 192 T...
  • Page 44 – Moderately tighten the screws on the ignition module. : Remove the screw (arrow). : Remove the cable guide (arrow). : Turn the flywheel until the magnet pole is lined up with the ignition module (arrow). MS 192 T...
  • Page 45 : Use adjusting knob (4) to set the : Crank the engine quickly with the spark gap to approx. 2 mm, rewind starter and check see window (3). sparkover in the window (2) of the ignition system tester. MS 192 T...
  • Page 46 : Remove the cover (1) from spark – Examine the ignition lead (2), plug boot. ignition module (3) and grommet (1) and replace if necessary. Ignition lead and ignition module can only be replaced as a complete unit. MS 192 T...
  • Page 47 – Reassemble remaining parts in reverse order. – Coat the inside of the spark plug Screw on the puller (1) boot with STIHL Press Fluid, 1116 893 0800, but do not screw it b 16 tight, and then tap the end of the puller lightly to release the flywheel.
  • Page 48 – If neither of these checks reveals a fault, install a new ignition module, b 9.1.1 – Reassemble parts in reverse Flywheel and magnet poles order. (arrows) must not show any signs of damage or blue discoloration, otherwise the flywheel must be replaced. MS 192 T...
  • Page 49 – Plug the contact spring (1) into remove the ground wire (2). (arrows) from the handle the terminal socket of the wiring housing. harness. : Disconnect the short circuit : Place the contact springs in the line (1). guides (arrows). MS 192 T...
  • Page 50 (1) is in position "0". – Reassemble parts in reverse order. – Set the air gap between ignition coil and flywheel b 9.1.1 – Reassemble remaining parts in reverse order. – Tightening torques, b 3.5 MS 192 T...
  • Page 51 – Spark plug boot damaged? – Replace spark plug boot and/or leg spring if necessary b 9.4 Check ignition: with ZAT 3 or ZAT 4 (use ZAT 3 as main spark gap see TI 32.94) b 9.2 and b 9.3 MS 192 T...
  • Page 52 – Resistance of spark plug boot to ground: required: 1.5...12 kW – Check resistance of ignition lead: value required < 10 W, – Replace spark plug boot and/or ignition lead with ignition module if necessary b 9.4 MS 192 T...
  • Page 53 Replace ignition module b 9.1.1 Engine runs Engine runs smoothly, – Look for fault in fuel or carburetor troubleshooting procedure completed system – Check power unit for leaks – Check position of flywheel on crankshaft b 8.2, b 9.5 MS 192 T...
  • Page 54 Before installing, lubricate the rewind spring and starter post with STIHL special lubricant, b 16 If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed : Press the locking lug (arrow) and disassembled.
  • Page 55 The system will not be under – Install a new starter rope, b 10.5 tension if the starter rope or rewind spring is broken. Lubricate the hole in the rope rotor with STIHL special lubricant oil, b 16 MS 192 T...
  • Page 56 – Tension the rewind spring, b 10.6 – Grease the pegs of the pawls, b 16 : Tie one of the two special knots shown above at the end of the rope in the starter grip. MS 192 T...
  • Page 57 : Thread the rope (1) into the rope the knot at the end of the rope is sleeve into the starter grip. rotor (arrows). in the recess (arrow). – Tie a special knot in the end of the rope. MS 192 T...
  • Page 58 – Hold the rope rotor (2) steady. – Install the fan housing, : Pull out the rope (1) with the b 10.2 starter grip and straighten it out. – Tightening torques, b 3.5 MS 192 T...
  • Page 59 – Remove any fragments of the old fixture (arrow). spring. – Lubricate the spring with a few drops of STIHL special lubricant before installation, b 16 : Fit the rewind spring (1) in a Ensure that the new rewind spring...
  • Page 60 (3), until the in the hole in the fan housing. bushing is firmly seated. The installing tool flares the lower end of the rope bushing. – Remove the installing tool. – Reassemble remaining parts in reverse order. MS 192 T...
  • Page 61 : Examine the rubber buffer and replace it if necessary. – Reassemble parts in reverse order. – Tightening torques, b 3.5 : Remove the screw (arrow). : Take out the screws (arrows). – Remove the rubber buffer. MS 192 T...
  • Page 62 : Examine the front handle (1), : Insert and tighten down the screw underneath the engine housing. spring (2) and bearing plug (3) (arrow). and replace if necessary. – Tightening torques, b 3.5 – Reassemble remaining parts in reverse order. MS 192 T...
  • Page 63 Remove the engine, b 8.4 – Remove the sprocket cover and bar and chain, b 5.1 – The following work is made easier by using STIHL Press Fluid, b 16 – Open the handle housing, b 12.1 : Remove the screw (arrow).
  • Page 64 – Insert and tighten down the screw. – Tightening torques, b 3.5 : Remove the throttle rod (1). : Place the torsion spring in the fixture (arrows). MS 192 T...
  • Page 65 (1) can be fitted in the trigger and double lever. upper hole (arrow) and the throttle rod from the carburetor – Install the handle moulding, fit the (2) in the lower hole (arrow). screws and tighten them down securely. MS 192 T...
  • Page 66 : Check the switch shaft – the metal pin (1) must be firmly seated in the hole and the cam (arrow) must be present. : Fit the switch shaft (1), pushing the rear contact spring (3) slightly to the side. MS 192 T...
  • Page 67 : Remove the screw (arrow). : Take out the screw (arrow) and – Disconnect the spring of the front remove the ground wire (2). handle from the engine housing. : Remove the short circuit wire (1). : Remove the screw (arrow). MS 192 T...
  • Page 68 – Tightening torques, b 3.5 – Installation of rubber parts is made easier by using STIHL Press Fluid, b 16 : Push the fuel return line (1) out. : Disconnect the impulse hose (1) from the stub (arrow).
  • Page 69 : Use hook 5910 893 8800 to pull : Remove the cover (1), pulling the the pick-up body (1) out of the oil worm (2) off the crankshaft stub tank. at the same time. Take care not to overextend the suction hose. MS 192 T...
  • Page 70 (1) into the hole suction hose and place it in the oil worm (2) off the crankshaft stub in the engine housing. tank. at the same time. – Reassemble remaining parts in reverse order. MS 192 T...
  • Page 71 : Remove the oil pump (1), pulling – Drain the oil tank. the connector (2) out of the recess in the engine housing. Collect chain oil in a clean container or dispose of it properly at an approved disposal site. MS 192 T...
  • Page 72 Ensure that the parts are installed correctly. and sealing ring (2) and replace if necessary. : Carefully fit the valve in the hole in the engine housing. The filler cap is supplied complete with cord and sealing ring. MS 192 T...

  • Page 73: Fuel System

    Check the filter and foam inlay and replace them if damaged or dirty. – If soiled, wash all parts of the filter in STIHL universal cleaner or a fresh, non-flammable cleaning solution (e.g. warm soapy water) and allow to dry.

  • Page 74: Air Filter Base

    – Reassemble parts in reverse – Before installing the filter base, order. lubricate the sealing ring on the carburetor connector with STIHL Press Fluid, b 16 – Reassemble parts in reverse order. Ensure that the air filter rests uniformly on the filter base all round.

  • Page 75: Leakage Test

    – Push the fuel hose onto the elbow connector. – Install the carburetor, b 14.2 – Tightening torques, b 3.5 – Reassemble remaining parts in reverse order. : Push the fuel line with double connector onto the fuel port (arrow). MS 192 T...

  • Page 76: Carburetor Repair

    : Gasket and metering diaphragm be removed very carefully. must be aligned so that the tab (arrow) points towards the adjusting nozzles. : Carefully separate the metering diaphragm (1) and gasket (2). MS 192 T...

  • Page 77: Inlet Needle

    (1) with spindle (2) – Remove and examine the spring over the spring, then slide the (1), replace it if necessary. fork of the inlet control lever into the groove in the inlet needle (1). MS 192 T...

  • Page 78: Fixed Jet

    : Carefully remove the gasket with : Pull the fuel strainer (1) out of the pump diaphragm from the carburetor body with a needle carburetor body. and clean or replace it. – Reassemble parts in reverse order. MS 192 T...

  • Page 79: Choke Shaft / Choke Shutter

    : Remove the screw (arrow) from carburetor body from below so the choke shaft. that the gasket and pump diaphragm remain secured to the The screw thread may be damaged end cover. when it is removed. – Use a new screw – MS 192 T...
  • Page 80 – Close the choke shutter (3) and centre it in the bore of the carburetor body. – Tighten down the screw. – Check correct functioning and easy movement. MS 192 T...

  • Page 81: Throttle Shaft / Throttle Shutter

    – Examine the throttle shaft for signs of damage and replace it if necessary. – Examine the torsion spring and – Turn the throttle shaft slightly. replace it if necessary. : Pull out the throttle shutter (1). MS 192 T...

  • Page 82: Accelerator Pump

    : Fit the throttle shutter (1) with the Press the pump piston with spring dent (3) on the left and the into the hole (arrow) before number (2) visible on the right. installing the throttle shaft (1). – Reassemble remaining parts in reverse order. MS 192 T...

  • Page 83: Adjusting Screws

    – Adjust the high speed screw, b 14.4.1 : Take out the low speed screw (1). : Prise the limiter cap (1) off the high speed screw with tool 5910 890 4501. Always fit a new limiter cap. MS 192 T...

  • Page 84: Carburetor Adjustment

    6. Fit the limiter cap. : Turn the low speed screw L (2) clockwise until it is firmly in its seat. : Turn the low speed screw L (2) anticlockwise until it is one turn open. MS 192 T...

  • Page 85: User Setting

    – Carefully turn the high speed screw H anticlockwise as far as possible (max. 3/4 turn). – Carefully turn the low speed screw L clockwise until it is firmly in its seat. Then open it one turn. MS 192 T...

  • Page 86: Intake Elbow, Removing And Installing

    – Press the flange of the intake elbow out through the hole in the handle housing towards the cylinder. – Examine the intake elbow and replace it if necessary. : Lift the handle housing and pull the elbow (1) off the cylinder. MS 192 T...
  • Page 87 (arrow) and tab (1) face the carburetor. – Coat with STIHL Press Fluid, b 16 In this way, the elbow flange is fitted through the intake port of the tank housing without damaging it.

  • Page 88: Impulse Hose

    – Push the intake elbow out of the – Lubricate the ends of the impulse handle housing, b 14.5 hose with STIHL Press Fluid, b 16 – Troubleshooting, b 4.6 or b 4.7 The impulse hose is shown on the...

  • Page 89: Tank Vent

    – Clean the area around the tank vent. – Replace the tank vent or tank if necessary, b 14.6.2 or b 14.8.3 : Remove the cover (1). MS 192 T...

  • Page 90: Removing And Installing

    – Reassemble parts in reverse If cleaning the tank does not remedy order. the problem, clean the pick-up body or replace it if necessary. – Troubleshooting, b 4.6 or b 4.7 MS 192 T...

  • Page 91: Fuel Hoses

    – Check the pick-up body and clean or replace it if necessary. : Slide the connectors of the : Push the fuel return line (1) out. cleaned or replaced pick-up body (1) into the fuel hose (2). MS 192 T...
  • Page 92 : Align the flange (1) and press it – Remove the pick-up body, b 14.7.1 guides and flange (arrow). into the fixture on the housing until it rests against the housing. : Prise off the flange (1) with a suitable tool. MS 192 T...

  • Page 93: Fuel Pump

    : Remove the tank vent (1). : Disconnect fuel hose (1) and : Examine the fuel pump and examine fuel hose (2), replace if replace it if necessary, necessary. – Reassemble parts in reverse – Reassemble parts in reverse order. order. MS 192 T...

  • Page 94: Fuel Tank Filler Cap

    : Prise the nipple out from inside the tank (arrow). : Examine the filler cap (1), cord and sealing ring (2) and replace if necessary. The filler cap is supplied with cord and sealing ring; the sealing ring is available separately. MS 192 T...

  • Page 95: Special Servicing Tools

    5910 890 2000 Clamp machine to assembly stand stand Puller 1116 893 0800 Remove flywheel Ignition system tester ZAT 4 5910 850 4503 Test ignition system Ignition system tester ZAT 3 5910 850 4520 Test ignition system MS 192 T...
  • Page 96 Carburetor nuts Stud puller 5910 893 0501 Remove rail mounting studs Crimping pliers 5910 890 8210 Cable ties, cable lugs, etc. Assembly pin 1114 893 4700 Remove and install the piston pin Remarks: 1) Use only for releasing. MS 192 T...

  • Page 97: Servicing Aids

    Engine pan, oil seals (outside) High-strength thread-locking 0786 111 2109 adhesive (Loctite 270) Standard commercial solvent- Cleaning sealing faces and the carburetor, based degreasant containing no cleaning the crankshaft stub and tapers in chlorinated or hydrogenated flywheel hydrocarbons MS 192 T...
  • Page 98 englisch / english 0455 217 0123. M5. B5. T. Printed in Germany...

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