Technical Information · issue 8 of 2011
New cordless chain saw STIHL MSA 160 C
IssueTI 8/2011
Full text
Page 1 of 21
STIH)
Technical Information 08.2011
New cordless chain saw STIHL MSA 160 C – Series 1250
Summary
1. Technical description
2. Safety instructions
3. Specifications
4. Special accessories
5. Service accessories
6. Spare parts
7. Servicing
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)m~ge 2 Technical Information 08.2011
The STIHL Lithium Ion battery platform is being 1. Technical description
expanded by the new, powerful STIHL cordless
chain saw MSA 160 C. 1.1 Functional principle
Sophisticated lithium ion technology, the new 1/4" The STIHL MSA 160 C cordless chain saw is
STIHL PICCO™ Micro™ saw chain and the high powered by a rechargeable battery.
performance of the electric motor reveal to the user
The cordless chain saw, battery (lithium ion) and
a new dimension in cutting power for handheld,
charger constitute a modular system.
cordless devices.
The cordless chain saw may only be used with
Simple handling, optimal balance and low levels of
approved STIHL batteries. Use only STIHL
vibration support ergonomic working.
chargers to charge the STIHL batteries.
The new STIHL cordless chain saw MSA 160 C is
suitable for professional gardening and
landscaping, cutting firewood, and carpentry.
The low noise level in comparison with gasoline-
powered chain saws is advantageous for
maintaining trees and shrubs in noise-sensitive
areas, e. g., in residential areas and parks, around
schools or in cemeteries.
In addition, the exhaust-free and cordless battery
technology permits mobile, convenient use even
indoors.
3999TI002 KN
The cordless chain saw, battery and charger
exchange information. The charger cannot charge
the battery and the battery cannot supply the
necessary current unless data exchange is working.
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Technical Information 08.2011 Page 3
1.2 Electric motor and electronics module 1.4 Hand guard
The saw chain of the cordless chain saw is powered
with the help of a brushless electric motor. Unlike
other DC motors with carbon brushes, control and
position detection of the electric motor is entirely 1
electronic. In this way, it is possible to attain high
torque and very low wear and space requirements
at the same time, as well as low noise levels, without
using a transmission.
An electronics module transforms the voltage of the
3999TI003 KN
battery into the voltage required on the electric
motor and controls the electric motor according to
the switch state of the trigger switch. The electronics
module constantly monitors the operating state of The machine can be locked or unlocked as needed
the electric motor and regulates it as needed. using the hand guard (1):
This ensures constant cutting performance over the
entire running time. – Mechanical: Blocking / release of the chain
brake
1.3 Cutting attachment – Electrical: Integral switch on hand guard for
A new 1/4" STIHL PICCO™Micro™ 3 (71 PM3) interrupting the power supply
saw chain with a 1/4" STIHL PICCO™ chain pitch
was developed especially for the MSA 160 C 1.5 Instructions for use
cordless chain saw. Combined with the cordless
1.5.1 Switching on the machine
chain saw and the also new 1/4" P ROLLOMATIC®
E Mini guide bar, outstanding cutting performance is
attained (21 % more than with the familiar
3/8" PMMC3). 1
Additional strengths of the new 1/4" PM3 saw chain
are, low vibration, reduced tendency to chatter and
smooth cutting with little feed effort required.
For details about the cutting attachment – see
TI 03.2011.
3999TI004 KN
. Unlock the machine by moving the hand
guard (1) to ‚
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)m~ge 4 Technical Information 08.2011
2 1
3999TI005 KN
3999TI007 KN
. Press trigger switch lockout (2) with thumb . Set hand guard (1) to ƒ – machine is locked so
that it cannot be switched on
. Then operate the trigger switch (3) with the
index finger During breaks and after work, remove the battery
from the machine.
1.5.2 Switching off the machine
1.6 Trigger switch
3
3999TI006 KN
3999TI008 KN
. Release trigger switch lockout (2) and trigger
switch (3) so that the trigger switch returns to its For fine and precise cutting, the speed can be
initial position – in the initial position, it is once controlled continously using the trigger
again blocked by the trigger switch lockout (2) switch (arrow).
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Technical Information 08.2011 Page 5
1.7 Removing / inserting the battery
3999TI009 KN
3999TI010 KN
1) Unlock 2) Pull out
3999TI012 KN
3999TI011 KN
3) Remove 4) Insert
3999TI013 KN
3999TI014 KN
5) Press in and lock 6) Done!
The battery can be removed and inserted very
simply and quickly.
It is optimally protected thanks to its position in the
machine.
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1.8 Battery 1.8.2 Structure
The battery is a lithium ion rechargeable battery.
2
4
1
3901TI013 KN
3 #
3901TI012 KN
The STIHL rechargeable battery consists of
individual cells that are connected electrically in
– Light-emitting diodes (LEDs) (1)
series and in parallel.
(charge status indicator)
– Pushbutton (2) A
(for activating the charge status indicator)
– Ventilation slots (3)
– Contacts (4)
– Rating plate (#)
B
1.8.1 Advantages of lithium ion technology
3901TI067 KN
in comparison with other rechargeable
battery technologies
– higher cell voltage of the individual cells
A: Series connection
– lower weight and smaller volume with
B: Parallel connection
comparable capacity
– very low self-discharge The electrical circuit influences the voltage and
– long service life when used as specified capacity of the rechargeable battery. Connecting the
individual cells in series increases the voltage of the
– no memory effect
rechargeable battery.
Self-discharge denotes the loss in capacity of the Connecting the individual cells in parallel, on the
battery that is equalized again during charging. other hand, increases the capacity of the
Self-discharge can occur during storage. rechargeable battery.
Voltage and capacity determine battery power:
Power (Wh)
=
Voltage (V)
x
Capacity (Ah)
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Technical Information 08.2011 Page 7
The individual cells are mechanically protected in
a rugged housing and secured against vibration in
a cage.
1.8.3 Light-emitting diodes (LEDs) on battery
Four light-emitting diodes indicate the charge status
of the battery as well as faults in the battery.
3901TI015 KN
3901TI014 KN
1
When the charging process is completed, the LEDs
. Press button (1) to activate the display. on the battery switch off automatically.
The display switches off automatically after
5 seconds During work (discharging)
The LEDs can be green, red or flashing. The green LEDs indicate the charge status by
flashing and lighting up continuously.
LED is continuously green
LED flashes green
LED is continuously red
LED flashes red
During charging
The LEDs indicate the progress of charging by
flashing and lighting up continuously.
3901TI016 KN
During charging, the current charging capacity is
indicated by a flashing green LED.
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)m~ge 8 Technical Information 08.2011
If the red LEDs are continuously red / flash 1.8.4 Battery storage
. Remove the battery from the machine or
charger
. Store in a closed, dry space and keep in
a secure location. Protect against unauthorized
use (e. g., by children) and dirt
. Do not store backup batteries unused – use
them in alternation
For optimum service life, store the battery:
. at temperatures of 50° F (10 °C) to 68° F (20 °C)
. with a charge state of approx. 30 %
1.8.5 Transportation
STIHL batteries fulfill the test requirements stated in
UN Manual ST/SG/AC.10/11/Rev.5 Part III,
3901TI017 KN
Subsection 38.3.
Transport by the user
The user can transport STIHL batteries by road
transport to the place where the machine is to be
1 LED is continuously red: Battery used without additional requirements.
too warm 1) 2), Observe national regulations for air or sea transport.
too cold 1)
Transport by the servicing dealer
3)
4 LEDs flash red: Fault in battery When transporting STIHL batteries, the national
dangerous goods regulations for road transport and
3 LEDs are continuously red: Machine is too hot the international dangerous goods regulations for
– allow it to cool sea and air transport must be observed.
off For more information, see the information sheet at
www.stihl.com/battery.
3 LEDs flash red: Fault in machine 4)
1.8.6 Disposal
Observe national, state and local regulations with
1) regard to disposal.
During charging: The charging process starts
automatically after the battery has cooled down
/ warmed up.
2) During work: Machine switches off
automatically – let the battery cool off for
a while, it may help to remove the battery from
the machine for this.
3)
Remove battery from the machine and reinsert
it. Turn on the machine – if the LEDs still flash,
the battery is faulty and must be replaced.
4)
Remove battery from the machine and reinsert
it. Turn on the machine – if the LEDs still flash,
check the machine, b 7.3.
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1.8.7 Battery Recycling 1.9 Charger
Battery recycling information:
3901TI081 KN
#
– Light-emitting diode (LED) (1)
STIHL is committed to the development of products – Power cord with power plug (not shown in
that are environmentally responsible. This illustration)
commitment does not stop when the product leaves – Rating plate (#)
the STIHL dealer. STIHL has partnered with the
RBRC (Rechargeable Battery Recycling
Corporation) to promote the collection and recycling STIHL offers two chargers.
of spent STIHL lithium ion batteries in the United
States and Canada. The RBRC seal can be found – AL 300 charger
on every STIHL rechargeable battery and indicates with high charging current and air cooling
that STIHL has prepaid for recycling the battery. The (with fan) for short charging times
seal has a toll free phone number (1-800-822-8837) – AL 100 charger
under which information on battery recycling with low charging current and without air cooling
locations and information on battery disposal bans (without fan)
or restrictions is offered.
Charging principle
The charger charges the battery in two stages. First
the battery is charged with a constant current up to
a preset voltage limit. Then the charger switches to
charging with a constant voltage. The charging
current is then reduced until the minimum charging
current is exceeded or the preset total charging time
is exceeded. Then the charger switches off
automatically.
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)m~ge 10 Technical Information 08.2011
1.9.1 Charging a battery The battery warms up in the machine during use.
When delivered, the battery is charged to a charge If a battery that is too warm is inserted in the
state of approx. 30 %. charger, it may be necessary for the battery to cool
The battery must be charged before being used for off before charging. The charging process does not
the first time. start until the battery has cooled off. The charging
time can be extended by the cooling off period.
The battery and the charger warm up during the
charging process.
The AL 300 charger is equipped with a fan for
cooling the battery. The fan can be heard during
charging.
2 The AL 100 charger waits with the charging
procedure until the battery has cooled off on its own.
The battery is cooled by the natural flow of air.
Once the battery is completely charged, the charger
3901TI019 KN
switches off automatically, then:
– the LEDs on the battery go out
. Slide the battery (1) into the charger (2) until you – the LED on the charger goes out
start to feel resistance – then push it in until it
engages – the fan on the charger switches off
(if present)
Make certain that the battery is completely inserted
in the charger as far as it will go. The battery is Remove the charged battery from the charger after
already in contact with the charger when you begin charging.
to feel resistance. If the battery is pushed in as far
as it will go within 3 seconds, the battery and the
charger can exchange data with one another.
The charger can only charge the battery if data
exchange is working.
If the battery is not inserted completely in the
charger, the contact between battery and charger is
not sufficient. In this case, the LED on the charger
flashes red. Then remove the battery from the
charger and reinsert it.
3901TI020 KN
3 4
After insertion of the battery, the LED (3) on the
charger is on.
The charging process begins as soon as the
LEDs (4) on the battery are green.
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Technical Information 08.2011 Page 11
1.9.2 Light-emitting diode (LED) on charger 2. Safety instructions
For transport and before all repair and
maintenance work, always switch off
the machine, set the hand guard to ƒ
and remove the battery from the
machine. This prevents inadvertent
starting of the motor.
2.1 Battery
3901TI021 KN
1 Warning!
Risk of fire, explosion and/or burns,
including chemical burns. Do not
The LED (1) on the charger can be green or flash
disassemble, crush, heat above 212 °F
red.
(100 °C), expose to fire or incinerate.
A constant green light ... Never expose the battery to
... may have the following meanings: microwaves or high pressures.
The battery
– is being charged Warning!
– is too warm and must cool off before charging Use STIHL batteries only with STIHL power tools
The green LED goes out as soon as the battery is and charge them only with STIHL chargers.
fully charged. Replace battery with STIHL AP battery only. Use
only original STIHL rechargeable batteries.
A red flashing light ...
Charge the battery before use.
... may have the following meanings:
– no electrical contact between battery and
Protect from rain – do not immerse in
charger – remove the battery and reinsert it
fluids.
– Battery faulty
(4 LEDs on the battery flash red for approx. Use and store the battery only within
5 seconds) a temperature range from 14 °F
– Charger faulty (-10 °C) and no more than 122 °F
(+ 50 °C). Protect the battery from
1.9.3 Storing the charger direct sunlight.
. Remove battery
. Disconnect the power plug
Warning!
Store charger in a closed, dry space and keep in Do not open, drop or damage battery. Never insert
a secure location. Protect against unauthorized use objects into the battery's cooling slots, since they
(e. g., by children) and dirt. may damage the battery. Never use or charge a
defective, damaged, cracked or deformed battery.
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)m~ge 12 Technical Information 08.2011
Use and store charger only indoors in
Warning! dry rooms.
Fluid may leak from the battery if it is damaged or
is not used properly – avoid contact with the skin!
Leaking battery fluid may cause skin irritation and . Operate charger at temperatures between 41 °F
chemical burns. In the event of accidental contact, (5 °C) and 104 °F (40 °C).
immediately rinse thoroughly with mild soap and . Allow the charger to cool down normally – do not
water. If fluid gets into your eye(s), do not rub your cover it.
eye(s) and rinse water over the open eye(s) for
15 minutes at least. Also seek medical attention . Never bridge the contacts of the charger with
immediately. metallic objects (e.g. nails, coins, jewelry) –
short circuit. The charger may be damaged by
a short circuit.
Warning! . In the event of smoke or fire in the charger,
Never bridge (short circuit) the battery terminals disconnect it from outlet immediately.
with metallic objects, since this may damage the
battery and possibly cause a fire. Keep a battery
that is not in use away from metal objects (e.g. Warning!
nails, coins, jewelry). Do not use metal containers To reduce the risk of electric shock or short circuit,
for transporting batteries. do not insert any objects in the charger's cooling
slots.
Store the battery out of reach of children in a cool
and dry area away from direct sunlight and excess
heat or cold (14 °F – 122 °F (-10 °C – +50 °C)). Warning!
The charger heats up during the charging process.
2.2 Charger Do not operate on an easily combustible surface
. Use only original STIHL chargers. (e.g. paper, textiles) or in an easily combustible
environment – risk of fire.
. Use only for charging matching STIHL type AP
batteries with a maximum capacity of 10 Ah and
a maximum voltage of 42 V.
Warning!
. Never charge defective, leaking or deformed Do not operate in a hazardous location, i.e. in
batteries. a location where there are combustible liquids
. Connect the charger only to a power supply with (fumes), vapors or dusts. Chargers can produce
the voltage and frequency specified on the sparks, which may ignite the dust or vapors – risk
rating plate. Always connect the charger to of explosion.
a properly installed wall outlet.
. Never use a charger with damaged housing, Check the charger's power supply
damaged power supply cord or damaged plug. cord and plug regularly for damage.
Do not operate the charger if it has received If the power supply cord or plug is
a sharp blow, been dropped or otherwise damaged, immediately disconnect the
damaged in any way. plug from the wall outlet to avoid the
risk of electric shock.
. Do not open or disassemble charger – no user
serviceable parts inside.
. Never jerk the power supply cord to disconnect
. Store charger out of the reach of children. it from the wall outlet. To unplug, grasp the plug,
not the cord. Have a damaged power supply
Protect charger from rain and cord repaired by an experienced electrician.
dampness. Keep charger dry. . Do not use the power supply cord for any other
purpose, e.g. for carrying or hanging up the
charger.
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Technical Information 08.2011 Page 13
. Never use power supply cords that do not
comply with regulations.
. Make sure the power supply cord is located
and/or marked so that it will not be stepped on,
tripped over, come in contact with sharp edges
or moving parts or otherwise be subjected to
damage or stress.
. An extension cord should not be used unless
absolutely necessary. If an extension cord must
be used, plug the charger into a properly wired
16 gauge (AWG 16) or heavier gauge extension
cord with blades that are the same number, size
and shapes as the blades on the charger.
To reduce the risk of electric shock:
. Always connect the unit to a properly installed
wall outlet.
. Make sure the insulation of the power supply
cord and plug is in good condition.
Unplug the power supply cord from the outlet when
charger is not in use.
Never store the battery in the charger.
More safety precautions – see instruction manual.
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)m~ge 14 Technical Information 08.2011
3. Specifications 3.3 Chain lubrication
Fully automatic, speed-controlled oil pump with
3.1 Battery reciprocating piston
The STIHL MSA 160 C cordless chain saw can be
used with Type AP STIHL batteries. Oil tank capacity: 7.1 fl.oz. (0.21 l)
The running time of the machine depends on the
energy of the battery (e. g., 80 Wh with AP 80 or 3.4 Weight
160 Wh with AP 160). With cutting attachment,
without battery: 7.1 lbs. (3.2 kg)
3.2 Charger
AL 100 3.5 Cutting attachment
Power supply: 120 V
3.5.1 ROLLOMATIC® E Mini guide bar
Rated current: 1.3 A
Frequency: 60 Hz
Power consumption: 75 W Length: 12 in. (30 cm)
Charging current: 1.6 A Pitch: 1/4" P (6.35 mm)
Charging time (for AP 80): Groove width: 0.043 in. (1.1 mm)
– up to 80 % capacity: 70 min Sprocket nose: 10-tooth
– up to 100 % capacity: 100 min
Charging time (for 3.5.2 Oilomatic saw chain
AP 160): STIHL PICCO™ Micro™(71 PM3)
– up to 80 % capacity: 150 min Pitch: 1/4" P (6.35 mm)
– up to 100 % capacity: 165 min Drive link gauge: 0.043 in. (1.1 mm)
Protection class: II, E (double insulated)
3.5.3 Chain sprocket
7-tooth for 1/4" P
AL 300
Power supply: 120 V
Rated current: 4.7 A
Frequency: 60 Hz
Power consumption: 330 W
Charging current: 6.5 A
Charging time (for AP 80):
– up to 80 % capacity: 25 min
– up to 100 % capacity: 50 min
Charging time (for
AP 160):
– up to 80 % capacity: 35 min
– up to 100 % capacity: 60 min
Protection class: II, E (double insulated)
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Technical Information 08.2011 Page 15
4. Special accessories
Designation Part number Use
STIHL battery:
– AP 80: 4850 400 6503
– AP 160: 4850 400 6505
STIHL charger: Charging a battery
– AL 100: 4850 430 2502
– AL 300: 4850 430 5502
STIHL battery belt 4850 490 0100 Reducing the weight of the machine
5. Service accessories
5.1 New special tools
Item Designation Part number Use
1 Analyzer 4850 840 0202 Testing the cordless machine
ADG 2
2 Installing tool 1250 890 2200 Removing and installing oil pump
5.2 Existing special tools
Item Designation Part number Use
1 Battery analyzer 4850 840 0102 Testing a battery
ADG 1
2 Installing tool 1123 890 2202 Removing and installing oil pump
3 Stud puller, M8 5910 893 0501 Unscrewing collar screw
All other existing special tools are listed in the
Service Manual for the STIHL MSA 160 C.
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)m~ge 16 Technical Information 08.2011
6. Spare parts 7.2.1 Receipt
Separate spare parts documentation is available for First always conduct a visual inspection.
the new STIHL MSA 160 C cordless chain saw.
7. Servicing
The specific national safety regulations and the
safety instructions in the instruction manual must be
observed if the machine has to be started up during
servicing.
Before all repair and maintenance
3901TI027 KN
work, always switch off the machine,
set the hand guard to ƒ and remove
the battery from the machine. This
prevents inadvertent starting of the . Check contacts (arrows)
motor.
In the event of external damage (e. g., bent or
7.1 Service Manual damaged contacts, deformations, cracks in the
housing), the battery must always be replaced.
A separate service manual is available for the new
STIHL MSA 160 C cordless chain saw. 7.2.2 Testing
7.2 Battery Never open or repair batteries; always replace
defective batteries.
3901TI026 KN
3901TI082 KN
. The battery is delivered sealed (arrow). Never
open or repair the battery. – Test batteries with the STIHL ADG 1 battery
analyzer, see ADG 1 battery analyzer
Instruction Manual
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Technical Information 08.2011 Page 17
7.3 Troubleshooting chart
Machine does not run or only hums
Check battery for state of charge, proper installation
and damage (housing, seal, contacts)
Battery
Charge / properly install /
- charged, properly installed, replace battery
undamaged?
yes
no Does yes
Check light-emitting diodes (LEDs) on battery machine run?
no LED light up or flash
red?
yes
3 LEDs flash 4 LEDs flash 3 LEDs light up 1 LED lights up
Fault in machine, Fault in battery, Machine is too hot Battery too hot /
check machine check with ADG 1 – allow it to cool cold, allow it to
and replace if off cool off / warm up
necessary
Does no
machine run?
1 2 yes 3
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)m~ge 18 Technical Information 08.2011
1 2 3
Check machine for external damage:
- Cutting attachment
- Operating elements
- Housing
Is machine Replace damaged parts
yes
damaged?
Test electronic components with ADG 2
for damage and function no Does yes
and replace if necessary machine run?
no Does yes
machine run?
Repair procedure
completed
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Technical Information 08.2011 Page 19
7.4 Oil pump 7.4.2 Removal
. Remove sprocket cover, cutting attachment and
7.4.1 Reworking installing tool 1123 890 2202 chain brake cover
The installing tool 1123 890 2202 was modified for . Position the installing tool 1250 890 2200 on the
use with the MSA 160 C. collar screws
3999TI017 KN
3999TI018 KN
Top: previous version . Fasten (1) with guide bar, tensioning gear and
Bottom: new version with additional hole for an M8 nut
MSA 160 C
The previous version of the installing tool can be
reworked:
2
3999TI019 KN
3999TI024 KN
. Remove oil hose at the oil pump and seal it
. Screw puller (2) of the installing tool
1250 890 2200 into the oil pump
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)m~ge 20 Technical Information 08.2011
7.5 Serial number
3
2
1
3999TI020 KN
3999TI023 KN
. Position installing tool 1123 890 2202 at
lever (1) and puller (2) and secure with bolt (3) The serial number is on the rear hand guard of the
. Remove oil pump machine.
7.4.3 Installation
3999TI021 KN
Make certain that the oil pump is inserted in
accordance with the marking on the
housing (arrow).
1
3999TI022 KN
Use the installer (1) of the installing tool
1250 890 2200 to press in the oil pump.
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)qechnic~l=fnform~tion=MUKOMNN===================================================================m~ge=ON
7.6 Repair times
The specified repair times apply for trained and
Code Type of Repair MSA
qualified personnel as well as for properly equipped
160 C
repair shops.
1 Replace shroud 5
The repair times are specified in minutes.
3 Replace handlebar 15
The following table of repair times can be added to 4 Replace on/off trigger switch(s).
the STIHL table of repair times. Includes electrical test. 25
5 Replace wiring harness.
Includes electrical test. 30
6 Replace electronic module.
Includes electrical test. 30
10 Replace hand guard
switch/chain brake.
Includes electrical test 30
15 Replace motor. Includes
electrical test. 35
17 Replace motor housings.
Includes electrical test. 35
21 Replace oil hose. 15
22 Replace oil pump 15
40 Miscellaneous repairs and
other repairs not listed. 15
45 Handling allowance only-no
labor 5
50 No labor 0
© ANDREAS STIHL AG & Co. KG, 2011 Technical Documentation
D1/MTK-ro
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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.