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Workshop manual
510 16 77-26
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Contents Workshop manual Jonsered CS 2240 and CS 2240S Contents Index ....................................................................... 4 Introduction and safety instructions ................... 6 Technical data ...................................................... 10 Service tools ........................................................ 12 Service data ......................................................... 14 Safety equipment ................................................. 16 Repair
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Index Index Symbols in the Workshop Manual 9 B Symbols on the saw 9 Bar bolt 52 Structure 7 Replacing the bar bolt 52 Target group 7 Tools 7 C Carburettor 33 O Assemble on the saw 40 Oil pump and screen 31 Assembly 38 Assembling the oil pump and screen 32 Carburettor adjustment 41 Cleaning and inspection 31 Cleaning and inspection 37 Dismantling the oil pump and screen 31 Design 33 Dismantling 35 P Function 34 Piston and cylinder 45 Pressure testing the carburettor 39 Cleani
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Index Trouble shooting 54 Trouble-shooting methods 55 V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 English – 5
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Introduction and safety instructions 2 Introduction and safety instructions Contents 2.1 General ...........................................................................................................................7 2.2 Safety .............................................................................................................................7 2.3 Target group .........................................................................................................
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Introduction and safety instructions 2 Introduction and safety instructions 2.1 General 2.6 Structure This Workshop Manual describes in detail how the This Workshop Manual can be used in two diffe- chain saw is to be fault traced, repaired and tested. rent ways: A description of different safety measures that should be taken during repair work is also given. • For the repair of a particular system on the chain saw. 2.2 Safety • Dismantling and assembly of the entire chain saw. Note! The secti
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Introduction and safety instructions 2.8 General instructions 2.9 Special instructions The workshop where chain saw repairs are to be The fuel that is used in a chainsaw poses the fol- done must be equipped with safety equipment as lowing hazards: set out in local provisions. • The fuel and its fumes are toxic. No one may repair the chain saw unless they have • May cause irritation to skin or eyes. read and understood the content of this Workshop • May cause breathing difficulties. Manual. • H
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Introduction and safety instructions 2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual The symbols below are embedded on the chain saw. This symbol warns of personal injury Choke Lever when the instructions are not followed Refuelling Stop button Filling with chain oil Air purge Chain brake, activated (right) Chain brake, not activated (left) English – 9
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Technical data 3 Technical data Displacement Cylinder bore Stroke Max power/speed 3 cm /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 /
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Technical data rpm Idling speed Engagement speed Spark plug rpm rpm CS 2240/S: 2 900 3 800 NGK BPMR 7A Champion RCJ 7Y GAS OIL 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
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Special tools 4 Special tools 1 2 3 4 7 5 6 M5 M5 M6 8 9 10 11 12 – English
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Special tools 12 13a 14 13b 15 16b 16c 17 16a 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 filter hook Withdrawing the fuel filter 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
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Service data 5 Service data 14 – English
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Service data English – 15
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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 - refitting .......................
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Safety equipment 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 figure 1). Fig 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 tigh- ten anti-clockwise until the brake is activated. (see figure 2) WARNING! Exercise care to ensure the spring does not fly out and cau
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Safety equipment 6.2 Chain brake – reassembly 1 Bolt the elbow joint to the brake band (see figure 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 figure 6). Secure the circlip (A) (see figure 6). Fig 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 figure 7). WARNING! Make sure the sp
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Safety equipment Operating test: The engine must not be running during the test. Guide bar length Height 38cm/15" 50 cm/20" • Hold the chainsaw over a firm surface. The height of the guide bar above the surface is given in the table above. • Let go of the front handle and let the chainsaw fall towards the surface. Fig 10 • When the guide bar hits the surface the chain brake must engage (see figure 10). 6.3 Silencer – removal WARNING! Do not touch the silencer until it has cooled down, oth
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Safety equipment 6.5 Chain catcher – replacement If the chain catcher is worn it must be replaced with a new one. 1 Release the brake by pushing the kickback guard backwards. Undo the guide bar bolts and remove the clutch cover, chain and guide bar. 2 Remove the chain catcher and replace it with a new one. Check that the vibration damping spring Fig 12 locates correctly against the crankcase when you bolt the new chain catcher in position. (see figure 12) 6.6 Dismantling the start/stop co
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Safety equipment 6.7 Stop switch – resistance measurement Clean the mating surfaces and check the resis- tance as follows: Measure the resistance by connecting a multime- ter to the ignition coil. NOTE! The switch must be in the “on” (A) position to give the correct reading (see figure 14). The resistance must not be higher than 0.5 Ohm when the switch is in the on position. The stop switch is in the on position when the Fig 14 button is held down (A) (see figure 14) and in the off-positio
