Jonsered CS 2240 manual

W orkshop manual 510 16 77-26[...]

English – 3 W orkshop manual Jonsered CS 2240 and CS 2240S Contents Index ....................................................................... 4 Introduction and saf ety instructions ................... 6 T echnical data ...................................................... 10 Service tools ....................................................[...]

4 – English Index Inde x 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 clutc h 30 Centrifugal clutch - retting 31 Centrifugal clutch - removal 30 Inspection and [...]

English – 5 Index T roub le shooting 54 T rouble-shooting methods 55 V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43[...]

6 – English Introduction and safety instructions 2 Intr oduction and saf ety instructions Contents 2.1 General ........................................................................................................................... 7 2.2 Safety ....................................................................................................[...]

English – 7 2 Intr oduction and saf ety instructions 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 saf[...]

8 – English 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 indi- cate where caution should be tak[...]

English – 9 Introduction and safety instructions 2.10 Symbols on the saw The symbols below are embedded on the chain saw . Choke Lever Refuelling Stop button Filling with chain oil Air purge Chain brake, activated (right) Chain brake, not activated (left) 2.11 Symbols in the W orkshop Man ual This symbol warns of personal injury when the instruct[...]

10 – English Displacement Cylinder bore Stroke Max power/speed cm 3 /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 W albro MBU-16 0,3 / 0,012 Zama EL41AC1T Effective cutting length Chain[...]

English – 1 1 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 Y es Weight without W eight with bar and chain bar and chain kg / lbs [...]

12 – English 4 Special tools Special tools 11 4 6 9 1 2 3 7 8 10 M5 M6 5 M5[...]

English – 13 Special tools 12 13a 14 15 13b 16a 16c 16b 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 Al[...]

14 – English 5 Service data Service data[...]

English – 15 Service data[...]

16 – English 6 Safety equipment Safety equipment Contents 6.1 Dismantling the chain brake ........................................................................................... 17 6.2 Chain brake - reassembly ............................................................................................... 18 6.3 Silencer - removal ............[...]

English – 17 3 Loosen the screws and carefully remove the cover over the brake spring. (see gure 3) W ARNING! Exer cise care to ensure the spring does not fly out and cause perso- nal injury . W ear pr otective glasses. 6.1 Dismantling the chain brake 2 Carefully tighten the clutch housing in a vice. Release the brake by using the saw's [...]

18 – English NO TE! After completing the repair the chain brake must be tested as described belo w . 6.2 Chain brake – reassembl y 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 sp[...]

English – 19 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 rm 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. • When the guide ba[...]

20 – English 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 [...]

English – 21 Safety equipment 6.7 Stop switc h – 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 gure 14). The resistance must not be higher t[...]

22 – English Safety equipment 3 Dismantle the handle insert (B) by loosening the screw C on the handle (see gure 18). 4 Press out the throttle control pin (D) with the help of a punch (see gure 19). 5 Loosen the throttle lock as illustrated with the help of a screwdriver or the like. Then dismantle from the shaft in the handle (see gure [...]

English – 23 6.10 Throttle loc k, throttle trigger and return spring – refitting 1 Lubricate all pins and mating surfaces with a light oil. 2 Fit the throttle control (B) and spring (C) (see gure 22). 3 Hold the spring and insert the throttle lock into the cut-out in the handle (see gure 23). 4 Fit the throttle control pin (E) with the h[...]

24 – English 7 Repair instructions Repair instructions Contents 7.1 Starter assembly - removal ............................................................................................. 25 7.2 Changing a broken or worn starter cord ......................................................................... 26 7.3 T ensioning the recoil spring ..[...]

English – 25 Repair instructions W ARNING! If the recoil spring is still under tension when the pulley is re- moved it can fly out and cause injury . W ear ey e protection. 7.1 Starter assembly – remo val 1 Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assembly . (see gure 1) 3 Remove the bol[...]

26 – English Repair instructions 7.2 Changing a broken or w orn starter cord Whe n the s tar te r c or d i s wor n and m ust b e r ep lac ed , the t ens io n o n the r etu rn sp ri ng mu st be re le ase d. 1 Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley . Release the tension on the return spring by [...]

English – 27 Repair instructions W ARNING! Make sure the recoil spring does not fly out and cause injury . W ear eye pr otection.. 7.4 Replacing a worn recoil spring 1 Remove the bolt from the centre of the pulley and lift off the pulley and spring cassette. 2 Replace the defective spring cassette with a new one. 3 Fit the bolt through the centr[...]

28 – English Repair instructions 7.7 Ignition module and flywheel – remov al 1 R e m o v e t h e c y l i n d e r c o v e r . D i s c o n n e c t t h e H T l e a d , r e m o v e t h e s p a r k p l u g a n d  t p i s t o n s t o p 502 54 15- 01. i n i t s p l a c e . T a k e o f f t h e s t a r t e r a s s e m b l y , r e l e a s e t h e l e[...]

English – 29 Repair instructions 7.8 Ignition module and flywheel – refitting 1 Fit the ywheel on the crankshaft journal. T urn th e yw hee l s o t hat th e k ey lin es up wit h t he key way in the sh aft . Fit the nut on the shaft and tighten to a torque of 25-30 Nm (see gure 1 1). 2 T o ret the ignition module proceed as follows[...]

30 – English Repair instructions 4 Sec ure th e c lut ch in a v ice as sh own in g ure . C are - ful ly rel eas e t he clu tch sp rin gs (C) (s ee gu re 16) . NO TE! Handle the clutc h springs carefully . If they are opened up too muc h they could dam- age the saw . Inspection and cleaning  • Clean and inspect all parts carefully . If [...]

English – 31 7.10 Centrifugal clutc h – refitting 1 Insert the clutch springs in the shoes. 2 Screw the clutch (anti-clockwise) until it stops. Now tighten using tool 502 54 16-03 and a suitable socket wrench or combination spanner . T ightening torque min. 20 Nm. 3 Re m ov e t h e p is t on st o p. Fi t t h e s pa r k p lu g , t ig h te n in [...]

32 – English Repair instructions 7.12 A s s e m b l i n g th e o i l p u mp an d sc r ee n 1 Fit the chain guide plate with tightening torque 1–1.5 Nm. Fit the drive gear , needle bearing, clutch drum and the clutch (min. 20 Nm). Fit the chain, bar and clutch cover . W ARNING! Poo r c hai n l ubr ica tio n c an res ult in fai lur e o f t he cha[...]

English – 33 Repair instructions W ARNING! T h e f u e l u s e d i n t h e c h a i n s a w h a s t h e f o l l o wi n g h a z a r do u s p r op e rt i e s : 1. The flui d a nd its fu mes ar e poi son ous . 2. Can cause skin irritation. 3. Is highly inflammab le. 7.15 Carburettor Description The drawings accompanying this description do not corr[...]

34 – English Repair instructions Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In the cold start mode (see gure) the choke valve (H) is fully closed. This increases the vacuum in the carburettor so that fuel is sucked more easily from all [...]

English – 35 Repair instructions Dismantling the carburettor 1. Dismantle the cylinder cover and the air lter . 2. Disassemble the handle holder (see gure 29). Fig 29 Fig 30 Fig 31 Fig 32 3. Push the throttle actuator rod out of the han- dle part. Unhook it from the carburettor (see gure 30). 4. Remove the return hose (B) and suction hos[...]

36 – English Repair instructions 6. Disassemble the pump cover (G) over the measuring chamber cover (R) and carefully remove the control diaphragm (H) with gasket (J). 7. Unscrew the screw (K) and remove the needle valve (L) with lever (M), shaft (N) and spring (P). 8. Unscrew the screw (Q) above the pump unit and carefully remove the gasket (S) [...]

English – 37 Repair instructions Cleaning and inspection Clean all units in clean petrol. Use compressed air to dry the petrol on the com- ponents. Direct the air through all channels in the carburettor housing and ensure that they are not blocked. Check the following: 1. That gaskets, pump and control diaphragms are undamaged. 2. That there is n[...]

38 – English Repair instructions Assembl y Maintain a high level of cleanliness when assem- bling the carburettor . The slightest contamination can result in running problems. 1. If the throttle and choke valves, together with levers and springs were removed, they should be retted. The spring is tensioned 1-2 turns. Lubricate the shaft bearing[...]

English – 39 Leakage at Fault with Dif fuser jets Needle valve Leakage in impulse tube Pump diaphragm V entilation hole on metering unit. Control diaphragm Pressure testing the carburettor Pressure testing should be carried out with the car- burettor fully assembled. T esting should always be carried out after the carburettor has been repaired, b[...]

40 – English Assemble on the sa w 1. Press the carburettor down towards the parti- tion wall. Make sure that it gets into the correct position. 2. Fit the lter holder by hooking the choke con- trol into the choke lever (A). 3. Hook on the rubber mountings. Insert and tighten the screws. Repair instructions Fig 39 Fig 40 Fig 41 Fig 42 4. Insert[...]

English – 41 Repair instructions Carburettor adjustment Conditions during adjustment • The air lter should be clean and the cylinder cover tted when adjustments are made. Ad- justing the carburettor with a dirty air lter will give a too lean fuel mixture the next time the air lter is cleaned. This can result in serious damage to the[...]

42 – English 7.16 T ank unit Dismantling 1. Drain the fuel from the tank. 2. Dismantle the cylinder cover , bar and chain. See the Operator's Manual. 3. Unhook the throttle actuator rod (G) from the carburettor (see gure 45). 4. Dismantle the fuel hose (B) and the fuel pump return hose (D) (see gure 45). 5. Remove the screws. (A). Loos[...]

English – 43 Assembl y 1. If the throttle lock has been removed, this must be assembled before the tank unit and engine unit are assembled. 2. Lift the engine unit above the tank unit and insert the fuel hose (in J), return hose (in H) in the bottom of the carburettor compartment (see gure 48). 3. Fit the handle with the screws (A). T ighten t[...]

44 – English 1 First remove the old fuel lter from the tank unit using special tool 502 50 83-01. 2 Pull the fuel hose (B) out of the tank unit and pull off the lter . 3 Fit the new fuel lter (A) and feed the fuel hose back into position. 7.20 Replacing the fuel hose/ return hose The fuel hose is moulded and can only be removed from outs[...]

English – 45 Repair instructions 7.22 Piston and cylinder – remo v al 1 Remove: • cylinder cover • carburettor (see “Carburettor – removal”) • silencer • spark plug • fuel unit If replacing the cylinder: Remove the intake manifold, see “Air intake sys- tem – removal”. Cleaning and inspection Clean all the components, scrap[...]

46 – English Repair instructions Check the following: • The surface coating of the cylinder is not worn through, especially in the upper part of the cylinder . • The cylinder is free from score marks and areas of wear . • The piston is free from score marks. Small scratches can be polished out with ne emery paper . • The piston ring is[...]

English – 47 A B Faults and causes Score marks on the piston (A) 1. Incorrect carburettor setting. T oo high over- speed. 2. T oo low octane fuel. 3. T oo low or incorrect oil in the fuel. Carbon build-up (B) 1. Incorrect carburettor setting. T oo low over- speed. 2. T oo much or incorrect oil in the fuel. Piston ring breakage 1. Excessive engine[...]

48 – English Repair instructions Inlet manifold The intake system has two intakes. 1. The lower intake leads the fuel and air mixture from the carburettor to the cylinder . 2. The upper intake leads air to the cylinder . Assembling the intake system 1 Mount the intake manifold (A) and the partition walls (B and C) on the cylinder using tools 502 [...]

English – 49 Repair instructions W ARNING! Af t er pr e ss u re te s ti n g t he c yl i nd e r , c he c k th a t t he in l et ma n if old is se a te d c o rr e ct l y , o th e rw i se th e s a w ma y b e d a ma g ed . 7.24 Cylinder – pressure testing 1 Remove: • cylinder cover • carburettor • spark plug 2 Mount cover plate 502 54 48-02 (s[...]

50 – English Repair instructions 7.25 Crankshaft complete - dismantling 1 Remove the following: • chain and bar • clutch cover • cylinder cover • starter assembly* • centrifugal clutch* • carburettor* • silencer* • handle system • hand guard • piston and cylinder* * See special instructions. 2 Lift the crankshaft completely ou[...]

English – 51 Repair instructions 7.27 Crankshaft complete – reassembl y 1 Fit the crankshaft complete in the crankcase. Ret the following parts: • piston and cylinder* • handle system • hand guard • silencer* • carburettor* • centrifugal clutch* • starter assembly* • cylinder cover • clutch cover • chain and bar * See spe[...]

52 – English Repair instructions 7.29 Replacing the bar bolt Replacing the front bar guide. 1 Drain the oil tank. 2 Knock through the old guide bar bolt so that it falls into the oil tank. 3 Remove the bolt from the oil tank. 4 Secure steel wire to the outer part of the bar bolt (A), thread the steel wire through the oil tank and out through the [...]

English – 53 T roubleshooting 8 T r oubleshooting Contents 8.1 T roubleshooting .............................................................................................................. 54 8.2 T roubleshooting methods ............................................................................................... 55[...]

54 – English T roubleshooting Starting Idling (low rpm) Idling (low rpm) (cont.) Adjust L screw Le a ki n g a ir in t ak e h o se (r u bb e r) Loose carburettor mounting bolts Loose or faulty fuel hose Fuel lter blocked Fuel line blocked Fuel tank vent blocked Throttle valve pivot stiff Throttle pushrod sticking Defective throttle return sprin[...]

English – 55 T roubleshooting Acceleration och retar dation Does not accelerate Engine stalls when throttle released Over rich acceleration Adjust L screw Adjust H screw Blocked air lter Blocked fuel tank vent Blocked fuel lter Fuel line blocked Loose or damaged fuel hose Impulse channel blocked Loose cover on carburettor pump side Faulty p[...]

510 16 77-26 2009W39[...]