Technical Information · issue 39 of 1994
Wiring harness; muffler mounting
Model 029, 039 Chain Saws - Series 1127
Full text
Page 1 of 5
Technical Information
39.94
Model 029, 039 Chain Saws - Series 1127
Contents
1. Wiring harness, grommet, additional ground wire
2. Muffler mounting (nuts, conical
spring washers, sheet metal gasket)
1. Wiring harness, ground wire
The following changes will be made to eliminate
isolated cases of trouble with the wiring harness/
ground wire:
- Modified wiring harness
- Grommet for wiring harness and
ignition lead
- Second ground wire between ignition module
and cylinder
- Optimized routing of wiring
An instruction label with a pictogram (tighten filler
cap properly) will be bonded to the tank housing of
machines that incorporate the above-mentioned
changes.
The interim solution described in 1.1 differs very
slightly from the line modification planned for the
future and outlined in 1.2. This has to be taken into
account in the event of any repairs that may be
necessary at a later date. Both of these modifica-
tions are equally good.
1.1 Interim solution
An additional ground wire was installed as an
interim solution in a large number of machines
before the modified wiring harness was introduced.
Apart from the instruction label on the tank hou-
sing, these machines can be identified by a 15 mm
1
(5/8") long tube (1) which is fitted over the additio-
nal ground wire. This tube is positioned so that it
rests on the ignition lead (see illustration). These
machines have no grommet for the wiring harness
and ignition lead.
139TI001 Page 2 of 5
Technical Information 39.94 - Page 2
Service note
Wiring harness:
The new wiring harness 1127 440 3001 must be
used as a replacement for a defective wiring
harness on these machines. Install the completely
preassembled ignition module (with grommet
1125 084 8900 for the wiring harness and ignition
lead) in the engine housing. Make sure the tube
(1) is removed before re-attaching the additional
ground wire.
The tube (1) and grommet 1125 084 8900 must
not be used together.
Ground wire:
Use a new ground wire 1123 440 2200 to replace
a faulty additional ground wire (damaged insulation
or broken). Pull the tube off the faulty ground wire,
slip it over the new ground wire and position it so
that it rests on the ignition lead.
1.2 New line modification
Machines from No. X 30 222 572 will come
standard with the new version of the wiring
harness 1127 440 3001 in place of the original
wiring harness 1127 440 3000. The new wiring
harness is passed through the grommet
1125 084 8900 (arrow) together with the ignition
lead. Ground wire 1123 440 2200 is installed
additionally between the ignition module and
cylinder. The additional ground wire is equipped
with strengthened cable lugs (0.8 mm/0.03" thick).
139TI002
A label (pictogram) bonded to the tank housing
reminds the user that the fuel filler cap has to be
properly tightened down with a suitable tool after
fueling.
Service note
Depending on the fault, use the new wiring
harness 1127 440 3001 or the ground wire
1123 440 2200 for repairs.
The grommet 1125 084 8900 and instruction label
are also available as replacement parts (see
Summary).
1.3 Conversion and repair of original
versions of machine
All model 029 and 039 saws brought into STIHL If it is found that only one ground wire is
servicing dealers for repairs or servicing must be installed between the ignition module and
checked to ensure that the additional ground wire cylinder, it is absolutely essential to fit the
is fitted. additional ground wire. Page 3 of 5
Technical Information 39.94 - Page 3
The scope and type of conversion necessary If wiring harness is damaged:
depend on the condition of the wiring harness. Initially, install the complete new wiring harness
(with grommet 1125 084 8900) and then use the
If wiring harness is in good condition: conversion kit 1127 007 1010 (or 1127 007 1009
Use the conversion kit 1127 007 1010 (or for USA) to upgrade to the latest line status (see
1127 007 1009 for USA) to fit the additional 1.2). Important: The additional ground wire must
ground wire with the tube. The conversion kit co- be fitted without the tube in this case!
mes with detailed fitting instructions. A warranty Each conversion kit comes with a supplement to
request may be submitted for reimbursement of the owner’s manual. It must be given to the chain
these repair costs. saw user.
1.4 Fitting instructions for additional
ground wire
- At connection point A on the cylinder, fit both
cable lugs with their flat sides against one
A
another (the lug of the additional ground wire
must be on top). Cable lugs must be exactly
aligned with one another and be about 2 to
6 mm (0.08"-0.24") away from the cylinder
base (see ill.). 2.
..6
- Tighten screw (A) to 4.0 Nm (3 lbf.ft). m
m
- Do not damage or weaken cable lugs by
bending them to shape.
139TI003
- At connection point B, fit both cable lugs
with their flat sides downward (the lug of
the additional ground wire must be at the
bottom).
- Tighten screw (B) to 4.8 Nm (3.5 lbf.ft).
- Use suitable blunt tool to push ground wire
into the slot (see arrow).
B
139TI004
Note:
The 0.8 mm (0.03") thick cable lugs used for the
wiring harness and the ground wire cannot be
fitted with a standard commercial crimping tool.
For this reason replacement wiring harnesses and
ground wires are only available as assemblies. Page 4 of 5
Technical Information 39.94 - Page 4
139TI006
139TI007
3 44
10
11 9
2 4 6
6
1 1
7 4 7
8 8
5 5
12, 13
1.5 Summary
Part Name Original New Key Rem. MOQ
version version H
Wiring harness;
including items 1 to 8:
1127 440 3000 fo
1127 440 3001 1) 1
Terminal socket 4.8-1 0751 030 8957 -*- 1 2) 3)
Cable lug A 5-2.5 0751 030 8961 --- 2 1)
Cable lug A 4-1 0751 030 8950 --- 3 2)
Cable lug A 5-1.5 --- -*- 4 3)
Terminal socket 4.8-1/0.4 0751 030 8955 -*- 5 2) 3)
Shrink-on tube 1123 442 0400 -*- 6 2) 3)
Grommet 0000 989 0814 0000 989 0814 7
Terminal socket 3.5 mm 0751 030 8490 -*- 8 2) 3)
Grommet --- 1125 084 8900 9 1
Ground wire --- 1123 440 2200 10 1
Tube 15 mm --- 1127 442 2000 11 10
Instruction label --- 0000 967 3675 12 5
Instruction label (USA) --- 0000 967 3674 13 5
Ground wire conversion kit; --- 1127 007 1010 1
including: items 10 to 12
Ground wire conversion kit (USA); --- 1127 007 1009 1
including: items 10,11 and 13
Modification to be introduced from machine number X 30 222 572
Remarks
1) Original version of part no longer available from factory
2) Original version of part remains available for other models
3) New version of part is not available as separate item Page 5 of 5
Technical Information 39.94 - Page 5
2. Muffler mounting
In the foreseeable future the original exhaust
gasket 1127 149 0600 (0.75 mm/0.03" thick) will
be replaced by a 1 mm (0.04") thick sheet metal
gasket. The new gasket has improved setting
properties. The muffler mounting will be further
improved by the use of higher strength flange
locknuts and conical spring washers. The new
gasket 1127 149 0650 is supplied as a replace-
ment together with three conical spring washers.
139TI005
Note:
Check that conical spring washers are properly
installed as shown in illustration.
Summary
Part Name Original New Key Rem. MOQ
version version H
Exhaust gasket; --- 1127 149 0650 10
including items 1 and 2:
Exhaust gasket 1127 149 0600 -*- 1 1) 2)
Conical spring washer --- 9331 630 0120 2 1
Flange locknut V M5-8 9216 261 0700 --- 3)
Flange locknut V M5-10 --- 9216 263 0700 3 10
Modification to be introduced: in progress
Remarks
1) Original version of part will be supplied from factory only as long as existing stocks last
2) New version of part is not available as separate item
3) Original version of part remains available for other models
Last Technical Information on models 029, 039: 33.92
Waiblingen, November 23, 1994 Andreas Stihl
D1/MTK-sc Technical Documentation Extracted from the manufacturer's 2012 service catalogue. Most of these PDFs embed fonts with a shifted character map, so the text above was recovered rather than copied — read it as a faithful but imperfect transcription, and treat the page image above each block as the authority where the two disagree — the figures exist only there, because they are vector drawings that text extraction cannot keep.