Jonsered CS 2240 User Manual
Workshop manual
510 16 77-26
Workshop manual
Jonsered CS 2240 and CS 2240S
Contents
Contents
Index ....................................................................... 4
Introduction and safety instructions ................... 6
Technical data ...................................................... 10
Service tools ........................................................ 12
Service data .........................................................14
Safety equipment ................................................. 16
Repair instructions .............................................. 24
Carburettor ........................................................... 33
Troubleshooting................................................... 53
Jonsered has a policy of continuous product development and therefore reserves the right to modify the
design and appearance of products without prior notice.
English – 3
Index
Index
B
Bar bolt 52
Replacing the bar bolt 52
C
Carburettor 33
Assemble on the saw 40
Assembly 38
Carburettor adjustment 41
Cleaning and inspection 37
Design 33
Dismantling 35
Function 34
Pressure testing the carburettor 39
Centrifugal clutch 30
Centrifugal clutch - retting 31
Centrifugal clutch - removal 30
Inspection and cleaning 30
Chain brake 17
Chaine brake - reassembly 18
Cleaning and inspection 17
Dismantling the chaine brake 17
Chain catcher 20
Chain catcher - replacement 20
Crankcase and crankshaft 50
Crankshaft bearings - replacement 50
Crankshaft complete - dismantling 50
Crankshaft complete - reassembly 51
F
Fuel system 44
Replacing the fuel lter 44
Replacing the fuel hose/return hose 44
Replacing the air-purge 44
Venting the fuel tank 42
I
Ignition module and flywheel 28
Cleaning and inspection 28
Ignition module - testing 27
Ignition module and ywheel - retting 29
Ignition module and ywheel - removal 28
Intake system 32
Air intake system removal 32
Assembling the intake system 32, 48
Cleaning and inspection 32
Introduction and safety instructions 7
Changes 7
General 7
General Instructions 8
Numbering 7
Safety 7
Special Instructions 8
Symbols in the Workshop Manual 9
Symbols on the saw 9
Structure 7
Target group 7
Tools 7
O
Oil pump and screen 31
Assembling the oil pump and screen 32
Cleaning and inspection 31
Dismantling the oil pump and screen 31
P
Piston and cylinder 45
Cleaning and inspection 45
Cylinder - pressure testing 49
Faults and causes 47
Piston and cylinder - retting 47
Piston and cylinder - removal 45
S
Service data 14
Special tools 12
Silencer 19
Cleaning and inspection 19
Silencer - retting 19
Silencer - removal 19
Starter 25, 26
Changing a broken or worn starter cord 26
Cleaning and inspection 25, 26
Replacing a worn recoil spring 27
Starter assembly - retting 27
Starter assembly - removal 25
Tensioning the recoil spring 26
Start/Stop switch 20
Assembling the start/stop control 21
Cleaning and inspection 20
Dismantling the start/stop control 20
Stopping function 21
Stop switch - resistance measurement 21
T
Tank unit 42
Assembly 43
Dismantling 42
Technical Data 10
Threads 51
Repairing damaged threads 51
Throttle lock, throttle trigger
and return spring 22
Cleaning and inspection 23
Throttle lock, throttle trigger and
return spring - retting 23
Throttle lock, throttle trigger and
return spring - removal 22
4 – English
Trouble shooting 54
Trouble-shooting methods 55
V
Vibration damping system 43
Assembly 43
Cleaning and inspection 43
Dismantling 43
Index
English – 5
Introduction and safety instructions
2 Introduction and safety instructions
Contents
2.1 General ...........................................................................................................................7
2.2 Safety .............................................................................................................................7
2.3 Target group ...................................................................................................................7
2.4 Changes ..........................................................................................................................7
2.5 Tools ...............................................................................................................................7
2.6 Structure .........................................................................................................................7
2.7 Numbering ......................................................................................................................7
2.8 General instructions ........................................................................................................8
2.9 Special instructions .........................................................................................................8
2.10 Symbols on the saw .......................................................................................................9
2.11 Symbols in the Workshop Manual ..................................................................................9
6 – English
Introduction and safety instructions
2 Introduction and safety instructions
2.1 General
This Workshop Manual describes in detail how the
chain saw is to be fault traced, repaired and tested.
A description of different safety measures that
should be taken during repair work is also given.
2.2 Safety
Note! The section dealing with safety must be
read and understood by all those carrying out
repair work or service on the chain saw.
Warning symbols can be found in this Workshop
Manual and on the chain saw. See “Symbols on
the saw” and “Symbols in the Workshop Manual”. A
new decal must be applied as soon as possible if a
warning symbol on the chain saw has been damaged or is missing so that the greatest possible
safety can be obtained when using the chain saw.
2.3 Target group
This Workshop Manual is written for personnel with
general knowledge about the repair and service of
chain saws.
2.6 Structure
This Workshop Manual can be used in two different ways:
• For the repair of a particular system on the
chain saw.
•
Dismantling and assembly of the entire chain
saw.
Repair of a specific system
When a particular system on the chain saw is to be
repaired, proceed as follows:
1. Look up the page for the system in question.
2. Carry out the sections: Dismantling
Cleaning and inspection
Assembling
Dismantling and assembling the entire chain saw
Proceed as follows when the entire chain saw is to
be dismantled and assembled:
The Workshop Manual must be read and understood by personnel who will carry out repair work
and service on the chain saw. The Manual is also
suitable for use when training new employees.
2.4 Changes
Modications will be successively introduced on
the chain saw during production. When these
modications affect the service and/or spare parts,
separate service information will be sent out on
each occasion. This means that in time this Workshop Manual will become out of date. In order to
prevent this, the Manual should be read together
with all service information concerning the chain
saw in question.
2.5 Tools
Special tools are required for some stages. All
service tools are listed in the Workshop Manual.
Usage is evident from respective sections.
Always use Husqvarna’s original:
• Spare parts
• Service tools
• Accessories
1. Look up the chapter “Repair instructions”,
which deals with the Starter and carry out the
instructions set out under Dismantling.
2. Work forward in the Manual and carry out Dis-
mantling in the order set out in the sections.
3. Go back to the Starter and carry out the instructions under Cleaning and Inspection.
4. Work forward in the Manual and carry out
Cleaning and Inspection in the order set out
in the sections.
5. Order or take out all requisite spare parts from
the stores.
6. Look up the chapter “Repair instructions” which
deals with the Crankcase and carry out the
instructions set out under Assembling.
7. Work back in the Manual and carry out As-
sembling in the order set out in the sections.
Some sections include a Description of the actual
unit in order to increase the basic understanding.
2.7 Numbering
Position references to components inside the gures are designated A, B, etc.
The gures are numbered 1, 2 etc.
The position references and gure numbers restart
in each new section.
English – 7
Introduction and safety instructions
2.8 General instructions
The workshop where chain saw repairs are to be
done must be equipped with safety equipment as
set out in local provisions.
No one may repair the chain saw unless they have
read and understood the content of this Workshop
Manual.
In this workshop manual the following boxes indicate where caution should be taken.
WARNING!
The warning text warns of the risk
of personal injury if the instructions are not followed.
NOTE!
The warning text warns of the risk of ma-
terial damage if the instructions are not
followed.
2.9 Special instructions
The fuel that is used in a chainsaw poses the following hazards:
• The fuel and its fumes are toxic.
• May cause irritation to skin or eyes.
• May cause breathing difculties.
• Highly ammable.
When using compressed air the air jet should
never be pointed at the body. Air can be forced into
the bloodstream and cause fatal injury.
Wear ear protection when testing saws.
After testing a saw do not touch the silencer until
it has cooled down. The silencer gets very hot and
you may burn yourself. Wear protective gloves
when working on the silencer.
The guide bar, chain and clutch cover (chain brake)
must be tted before the saw is started. If not, the
clutch may come loose and cause injury.
Poor chain lubrication can result in failure of the
chain, which could cause serious or fatal injury.
Take care to ensure that the spring inside the
starter assembly does not y out and cause injury.
Wear eye protection. If the spring is under
compression when the pulley is removed it could
y out and cause injury.
Before removing the tensioning spring from the
chain brake, ensure that the brake is in the on
position, otherwise the spring may y out and
cause injury.
After completing the repair the chain brake must be
tested, see “Chain brake – reassembly \ Operating
test”.
Always consider the re risk. A chainsaw can
produce sparks that could start a re.
Inspect the chain catcher and replace it if it is
damaged.
8 – English
Introduction and safety instructions
2.10 Symbols on the saw
The symbols below are embedded on the chain
saw.
Choke Lever
Refuelling
Stop button
2.11 Symbols in the Workshop Manual
This symbol warns of personal injury
when the instructions are not followed
Filling with chain oil
Air purge
Chain brake, activated (right)
Chain brake, not activated (left)
English – 9
Technical data
3 Technical data
Displacement Cylinder bore Stroke Max power/speed
cm3/cubic inches Ø mm/Ø inches mm/inches kW/hp/rpm
CS 2240/S: 40,9 / 2,49 41 / 1,51 31 / 1,22 1,8 / 2,4 / 9 000
Spark plug gap Ignition system Air gap Carburettor type
mm/inches mm/inches
CS 2240/S: 0,5 / 0,02 Walbro MBU-16 0,3 / 0,012 Zama EL41AC1T
Effective cutting length Chain speed at Chain pitch Drive link
cm/inches max power – revs mm/inches mm/inches
m/s - r/min
CS 2240/S: 33-46 / 13-18 17,3 / 9 000 8,25 / 0,325 1,3 / 0,050 - 1,5 / 0,058
10 – English
GAS
OIL
Technical data
rpm
Idling speed Engagement speed Spark plug
rpm rpm
CS 2240/S: 2 900 3 800 NGK BPMR 7A
Champion RCJ 7Y
Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump
Litres/US pints 8,500 rpm, Litres/US pints
ml/min
CS 2240/S: 0,37 / 0,78 9 0,25 / 0,53 Yes
Weight without Weight with
bar and chain bar and chain
kg / lbs kg / lbs
CS 2240/S: 4,4 / 9,7 5,7 / 12,6
English – 11
Special tools
4 Special tools
M5
1
4
5
M5
M6
2
6
3
7
8
10
9
11
12 – English
Special tools
12 13a
15
16b
16a
13b
16c
14
17
18
Item Description Used for Order no.
1 Clutch tool Centrifugal clutch 502 54 16-03
2 Piston stop Locking the crankshaft 504 91 06-05
3 Fuel lter hook Withdrawing the fuel lter 502 50 83-01
4 Allen key, 4mm For M5 bolts 502 50 87-01
5 Allen key, 4mm For M5 bolts 502 50 18-01
5 Allen key, 5mm For M6 bolts 502 50 64-01
6 Pressure tester Pressure testing cylinder 503 84 40-02
7 Feeler gauge Adjusting ignition module 502 51 34-02
8 Assembly xture Assembling chain saw 502 51 02-01
9 Pressure gauge Pressurisation during testing 531 03 06-23
10 Test spark plug Checking the ignition module 501 97 64-01
11 Rev counter Adjusting carburettor 502 71 14-01
12 Assembly pliers Fitting spark plug guard 502 50 06-01
13a Cover plate, exhaust Sealing the exhaust port 502 54 11-02
13b Cover plates, inlet Sealing the intake manifold 504 63 93-01
14 Assembly tool Assembling spring, chain brake 502 50 67-01
15 Puller Pulling bearing of crankshaft 504 90 90-01
16a Sleeve Fitting crankshaft 502 50 30-22
16b Shaft extension Flywheel side 502 50 30-22
16c Shaft extension Cluch side 502 50 30-22
17 Punch Dismantling the ywheel 502 51 94-01
18 Adjustment screwdriver Adjustment of the carburettor 530 03 55-60
English – 13
Service data
5 Service data
14 – English
Service data
English – 15
Safety equipment
6 Safety equipment
Contents
6.1 Dismantling the chain brake ...........................................................................................17
6.2 Chain brake - reassembly ...............................................................................................18
6.3 Silencer - removal ...........................................................................................................19
6.4 Silencer - retting ............................................................................................................19
6.5 Chain catcher - replacement ..........................................................................................20
6.6 Dismantling the start/stop control ...................................................................................20
6.7 Stop switch - resistance measurement ...........................................................................21
6.8 Assembling the start/stop control ....................................................................................21
6.9 Throttle lock, throttle trigger and return spring - removal ................................................22
6.10 Throttle lock, throttle trigger and return spring - retting .................................................23
16 – English
6 Safety equipment
6.1 Dismantling the chain brake
1
Release the brake by moving the front hand guard
backward. Loosen the bar nut and remove the
clutch cover, chain and bar (see gure 1).
2
Carefully tighten the clutch housing in a vice.
Release the brake by using the saw's front hand
guard (A) as a tool. Mesh with the brake and tighten anti-clockwise until the brake is activated. (see
gure 2)
Safety equipment
Fig 1
WARNING!
Exercise care to ensure the spring
does not fly out and cause personal injury. Wear protective glasses.
3
Loosen the screws and carefully remove the cover
over the brake spring. (see gure 3)
4
Hold one hand over the brake spring; press a narrow screwdriver in between the rear section of the
spring and the clutch cover. Carefully pry upward
until the spring releases and runs onto the screwdriver shaft. (see gure 4)
Fig 2
Fig 3
Cleaning and inspection
• Carefully clean and check all parts. Parts must
be replaced if cracked or show signs of other
defects. Always use original spare parts.
• Measure the thickness of the chain brake band.
It must not be less than 0.6 mm at any point.
(see gure 5)
• Lubricate the knee joint with grease.
Fig 4
min 0,6 mm
Fig 5
English – 17
Safety equipment
6.2 Chain brake – reassembly
1
Bolt the elbow joint to the brake band (see gure 5)
and tighten to a torque of 1–1.5 Nm.
Locate the elbow joint and connected brake band
in their recesses in the clutch cover. Lubricate the
recess for the spring with grease (see gure 6).
Secure the circlip (A) (see gure 6).
2
Grip the clutch cover in a vice. Compress the
spring with special tool 502 50 67-01 and push it
down with your thumb (see gure 7).
WARNING!
Make sure the spring does not fly
out and cause injury. Wear eye
protection.
Fig 6
3
Fit the cover over the chain brake spring, tightening the screws to a torque of 1–1.5 Nm (see gure
8).
4
Tension the brake spring by using the kickback
guard from the saw as a tool. Engage it with the
brake mechanism and turn clockwise to release
the brake (see gure 9).
5
Turn the chain tensioner anticlockwise as far as it
will go.
Fig 7
Fig 8
Ret:
• guide bar
• chain
• clutch cover
NOTE!
After completing the repair the chain
brake must be tested as described below.
18 – English
Fig 9
Loading...