Jonsered CS 2240 User's Manual
Contents
1. Repair instructions Dismantling the carburettor 1 Dismantle the cylinder cover and the air filter 2 Disassemble the handle holder see figure 29 3 Push the throttle actuator rod out of the han dle part Unhook it from the carburettor see figure 30 4 Remove the return hose B and suction hose C Loosen the fuel pump D Let the fuel hose G remain in place see figure 31 NOTE Take care when lifting out the carburettor so that the fuel hose does not become loose 5 Loosen the screws E and unhook the rubber mountings F see figure 32 Fig 29 Fig 32 English 35 Repair instructions 6 Disassemble the pump cover G over the measuring chamber cover R and carefully remove the control diaphragm H with gasket J Unscrew the screw K and remove the needle valve L with lever M shaft N and spring P Unscrew the screw Q above the pump unit and carefully remove the gasket S and dia phragm T Use a needle or similar device and carefully pull up the fuel screen U Unscrew the high V and low jet screws W see figure 34 If necessary dismount the throttle valve X choke valve Z and air shutter Y and remove the shaf2. Fig 48 Fig 49 Fig 50 English 43 Repair instructions 7 19 Replacing the fuel filter NOTE Do not use knurled pliers to disconnect or reconnect the fuel hose This could dam age the hose and lead to leakage or frac ture 1 First remove the old fuel filter 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 filter 3 Fit the new fuel filter 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 outside of the fuel tank Use suitable pliers with a plain cutting face and loosen the hose B see figure 45 from the fuel tank Align the cut out against the plastic pin when assembling Replace the return hose when required 7 21 Replacing the air purge Dismantling 1 Dismantle the cylinder cover and the air filter 2 Loosen the suction hose C and return hose from the fuel pump see figure 31 3 Unsnap the fuel pump from the filter holder Assembling 1 Fitthe return hose on the fuel pump 2 Snapthe purge into the filter holder see figure 51 4 Assemble the air filter and cylinder cover 44 English Fig 51 Fig 52 Repair instructions 7 22 Piston and cylinder removal Oylinder cover carburettor see Car
3. English 47 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 50 87 01 see figure 62 A W f Fig 62 48 English Repair instructions 7 24 Cylinder pressure testing 1 Remove cylinder cover carburettor spark plug 2 Mount cover plate 502 54 48 02 see figure 63 3 Loosen the screws on the muffler and press the rubber sheet 502 54 11 02 between the muffler and cylinder Tighten the top two muffler screws see figure 64 4 Fit the pressure testing spark plug 503 84 40 02 and connect the pressure testing tool 531 03 06 23 see figure 64 5 Pump the pressure up to 80 kPa 0 8 bar Wait 30 seconds The pressure should not be less than 60 kPa 0 6 bar Remove the cover plates from the silencer and carburettor tighten the bolts to the specified torque Remove the pressure test nipple 503 84 40 02 and refit the spark plug WARNING After pressure testing the cylinder check that the inlet manifold is seated correctly otherwise the saw may be damaged DI DI 2 N S NX AM IS S X
4. 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 8 33 46 13 18 17 3 9 000 8 25 0 325 1 3 0 050 1 5 0 058 10 English Technical data Idling speed Engagement speed Spark plug rpm rpm CS 2240 8 2 900 3 800 NGK BPMR 7A Champion RCJ 7Y FA n O OO O v 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 8 0 37 0 78 9 0 25 0 53 Yes G7 SE q B Weight without Weight with bar and chain bar and chain kg Ibs kg Ibs CS 2240 S 4 4 9 7 5 7 12 6 English 11 Special tools 4 Special tools Special tools 13a 14 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 34 02 8 Assembly fixture Assembling chain saw 502 51 02 01 9 Pressure gauge Pressurisation during testing 531 03 06 23 10 Test spark plug Checking the ignition mo
5. 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 da maged 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 The Workshop Manual must be read and under stood 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 Modifications will be successively introduced on the chain saw during production When these modifications affect the service and or spare parts separate service information will be sent out on each occasion This means that in time this Work shop 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 2 6 Structure This Workshop Manual can be used in two diffe rent ways Forthe repair of a particular system on the chai
6. 3 Lower the carburettor into a beaker of water see figure 37 4 Pump the pressure up to 50 kPa 5 No leakage is permitted If a leakage occurs refer to the table below Leakage at Fault with Diffuser jets Needle valve Leakage in impulse tube Pump diaphragm Ventilation hole on metering unit Control diaphragm Fig 38 English 39 Repair instructions Assemble on the saw 1 Press the carburettor down towards the parti tion wall Make sure that it gets into the correct position Fit the filter holder by hooking the choke con trol into the choke lever A Hook on the rubber mountings Insert and tighten the screws Insert the return hose B into its position in the filter holder Press on the fuel diaphragm D Fit the suc tion hose C and return hose B Hook in the throttle actuator rod into the carbu rettor Thread the handle holder into the throttle actuator rod A Push the rod forwards so that it can be inserted into the handle part Push down the handle holder into the filter holder see figure 42 8 Assemble the air filter and cylinder cover 9 Mount the handle holder 40 English Repair instructions Carburettor adjustment Conditions during adjustment The air filter should be clean and the cylinder cover fitted when adjustments are made Ad justing the carburet
7. Lubricate all pins and mating surfaces with a light oil 2 Fit the throttle control B and spring C see figure 22 3 Hold the spring and insert the throttle lock into the cut out in the handle see figure 23 4 Fit the throttle control pin E with the help of a punch see figure 23 5 Fit the throttle lock D by pressing it onto the shaft in the handle see figure 24 6 Assemble the handle insert using a screw when the throttle control lever throttle cable and throttle control lock with pin are fitted correctly see figure 25 Fig 23 English 23 Repair instructions 7 Repair instructions Contents 7 1 Starter assembly removal i 25 7 2 Changing a broken or worn starter cord nnne 26 7 3 Tensioning he recoil Spring 5 inerte tee sine 26 7 4 Replacing a worn recoil spring nennen ennemi 27 7 5 Starter assembly refitting i 27 7 6 Ignition module testing lia 27 7 7 Ignition module and flywheel removal namen 28 7 8 Ignition module and flywheel refitting ses namen 29 7 9 Centrifugal clutch removal ii 30 7 10 Centrifugal clutch refitting esses eene nennen nennen nene nnne nenas 31 7 11 Dismantling the oil pump and screen eene enne 31 7 12 Assembling the oil pump and screen
8. Fig 63 Fig 64 English 49 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 out of the crankcase see figure 66 7 26 Crankshaft bearings replacement Remove The crankshaft complete from the crankcase 1 Pull the crankshaft bearing off of the crankshaft using a bearing puller see figure 67 2 Place a new bearing on the shaft and push into position using tool 502 50 30 22 see figure 68 50 English Fig 66 Fig 68 Repair instructions 7 27 Crankshaft complete reassembly 1 Fit the crankshaft complete in the crankcase Refit the following parts piston and cylinder handle system hand guard silencer carburettor centrifugal clutch starter assembly cylinder cover clutch cover chain and bar See special instructions 7 28 Repairing damaged threads A repair kit 503 27 33 01 is available for repairing damaged threads First drill out the hole using Then screw in the thread insert using a suitable bolt and spanner 6 1 mm drill bit for plastic crankcase Fig 69 This type
9. fuel tank 42 Ignition module and flywheel 28 Cleaning and inspection 28 Ignition module testing 27 Ignition module and flywheel refitting 29 Ignition module and flywheel 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 4 English 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 Oylinder pressure testing 49 Faults and causes 47 Piston and oylinder refitting 47 Piston and cylinder removal 45 S Service data 14 Special tools 12 Silencer 19 Cleaning and inspection 19 Silencer refitting 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 refitting 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. intake system 1 Fit the intake manifold A and the partition walls B and C on the cylinder using tool 502 50 87 01 see figure 21 Cleaning and inspection Clean and check all parts carefully Parts must be replaced if cracked or show signs of other defects Always use original spare parts Fig 21 Ay W 32 English Repair instructions 7 15 Carburettor WARNING The fuel used in the chainsaw has the following hazardous properties 1 The fluid and its fumes are poisonous 2 Can cause skin irritation 3 Is highly inflammable Description The drawings accompanying this description do not correspond with the carburettor on the chainsaw They only show the principle for the design and function Design The carburettor is based on three sub systems The metering unit A The mixing venturi B The pump unit C The jets and the fuel s control functions are located in the metering unit A Here the correct quantity of fuel is adjusted for the actual speed and power output see figure 22 The mixing venturi B houses the choke throttle valve and diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark see figure 23 In the pump unit C fuel is pumped from the fuel tank to the metering unit One side of the pump di aphragm is connected to the crankcase and pulses in time with the pressure chan
11. 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 locates correctly against the crankcase when you bolt the new chain catcher in position see figure 12 6 6 Dismantling the start stop control 1 Remove the cylinder cover and air filter 2 Loosen the screw and dismantle the control see figure 13 3 Loosen the filter holder from the rubber mountings B see figure 13 4 Cut off the starlock washer and pull out the control from the shaft on the filter holder see figure 14 Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones Always use original parts 20 English Fig 12 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 button is held down A see figure 14 and in the off positi
12. 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 figure 48 3 Fit the handle with the screws A Tighten the screws with the torque set out in the service data see figure 46 4 Fit the fuel hose B and fuel pump return hose D on the carburettor see figure 45 Mount the throttle actuator rod see figure 45 Assemble the cylinder cover bar and chain See the Operator s Manual 7 18 Vibration damping system Dismantling 1 Dismantle the following parts Bar and chain See the Operator s Manual Oylinder cover See the Operator s Manual Tank unit and handle 2 Dismantle the spring on the cylinder with the help of a 5 mm allen key see figure 49 3 Dismantle the springs on the tank unit with the help of a 5 mm allen key tool 502 50 18 01 see figure 50 Cleaning and inspection Clean and inspect all parts Assembly 1 Assemble the springs on the cylinder with the help of a 5 mm allen key tool 502 50 18 01 Note Springs with a greater resistance are av ailable but should only be used together with a longer bar See illustrated part list for spare part number 2 Assemble the following parts Tank unit and handle Cylinder cover See the Operator s Manual Bar and chain See the Operator s Manual
13. of thread insert is best suited for use in plastic and magnesium but not for repairing threads in aluminium In that case use a helicoil insert with metric screw see figure 69 English 51 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 bolt hole in the crankcase see figure 70 5 Pull the steel wire so the bolt comes out of its hole see figure 71 6 Check that the bolt s square head fits in the washer D which is positioned in the cut out in the crankcase 7 Pull out the bar bolt with its nut Place a spacer between the nut and crankcase see figure 71 8 Refill with chain oil Replacing the rear bar guide 1 Pull out the bar guide C with the help of slip joint pliers see figure 70 2 Fit the bar guide with the help of a hammer 52 English Fig 70 Troubleshooting 8 Troubleshooting Contents 8 1 MN TROUDIS SHOOTING ssa c eect ented ann ii 54 8 2 Troubleshooting methods aE AE nennen 55 English 53 Troubleshooting 8 1 Troubleshooting The various faults that can affect a chainsaw are divided into fo
14. so that the key lines up with the keyway in the shaft Fit the nut on the shaft and tighten to a torque of 25 30 Nm see figure 11 2 To refit the ignition module proceed as follows Turn the flywheel so that the magnets are in line with the ignition module Fit the ignition module with the plastic feeler gauge 502 51 34 02 held in position at the same time without tightening the bolts Fit the earth cable black A Set a distance of 0 3 0 1 mm between the ignition module and magnet The measurement applies to the two lowest lugs on the ignition module Tighten the screws tightening torque 4 5 6 Nm Fit the blue cable on the ignition module see figure 12 3 Then refit cable guide and press the leads into position HT lead starter assembly tighten to a torque of 2 5 3 5 Nm cylinder cover When replacing the cables they are fitted on the stop switch as shown in middle figure on the pre vious page Fig 11 Air gap tool Fig 12 English 29 Repair instructions 7 9 Centrifugal clutch removal 1 Remove the cylinder cover Disengage the chain brake by pushing the kickback guard backwards Undo the bar nut and remove the clutch cover bar and chain see figure 13 2 Disconnect the HT lead Remove the spark plug and fit piston stop 502 54 15 01 A in its place see figure 14 3 Unbolt the clutch using tool 502 54 16 03 B and a suita
15. sss ene 32 1 13 Air mtake system remoVval a tee Leda aa 32 7 14 Assembling the intake system nennen enne nnne 32 poem 33 FREMITU 42 7 17 Mentng tlie fuel tank uccidere tnde edat odia eat 42 7 18 Vibration damping system u ann edlen 43 7 19 Replacing the fuel filter i 44 7 20 Replacing the fuel hose return hose nn 44 7 21 Replacing the air purge e 44 7 22 Piston and cylinder removal sse eene eene nnn nnne 45 7 23 Piston and cylinder refitting nnnm mene 47 7 24 Cylinder pressure testing i 49 7 25 Crankshaft complete dismantling e 50 7 26 Crankshaft bearings replacement i 50 7 27 Crankshaft complete reassembly nnne nens 51 7 28 Repairing damaged threads eese ennt 51 4 29 Replacing the barbolt aiii ipa den sina a 52 24 English Repair instructions 7 Repair instructions 7 1 Starter assembly removal 1 Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assembly see figure 1 2 Pull out about 30 cm of the cord and fasten it in the 2 notch in the pulley rim Release the tension in the return spring by letting the pulley wind backwards slowly see figure 2 WARNING If the recoil spring is still under 9 tension when the pulley is re mov
16. 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 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 spring does not fly out and cause injury Wear eye protection Fit the cover over the chain brake spring tighten ing the screws to a torque of 1 1 5 Nm see figure 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 figure 9 5 Turn the chain tensioner anticlockwise as far as it will go Refit guide bar chain clutch cover NOTE After completing the repair the chain brake must be tested as described below 18 English Fig 9 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 When the guide bar hits the surface the chain bra
17. 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 refitting 23 Throttle lock throttle trigger and return spring removal 22 Index Trouble shooting 54 Trouble shooting methods 55 V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 English 5 Introduction and safety instructions 2 Introduction and safety instructions Contents 2 1 General RC Rp 2 2 Safety uuu Uu NIHILNE INCIP LEN ie 23 Target OUN c 24 Changes scsi H 25 TOOD HM 26 gt SUCUS q c O RR DR M 2 7 use mm 28 Generalinstr cti ns ie scooter rt te ree e ala 2 9 Special instrictlOlS aco ero er ea nie 2 10 Symbols On tlie SAW atlanta 2 11 Symbols in the Workshop Manual errar aaa renan nennen 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
18. Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Needle valve assembly sticking Leak in metering system air or fuel Metering system incorrectly assembled Loose diaphragm rivet Hole in diaphragm Leaking control diaphragm cover plate Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor mounting bolts Needle valve set too low Leak in metering system air or fuel Metering unit incorrectly assembled Loose diaphragm rivet Hole in diaphragm Leaking control diaphragm cover plate Acceleration och retardation Does not accelerate Adjust L screw Adjust H screw Blocked air filter Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor mounting bolts Needle valve set too low Metering system incorrectly assembled Needle valve assembly sticking Faulty diffuser jets Blocked silencer Adjust L screw Adjust H screw Faulty pump diaphragm Needle valve set too high Needle valve assembly sticking Faulty diffuser jets Engine stalls when throttle
19. JONSERED SERVICE Contents Workshop manual Jonsered CS 2240 and CS 2240S Contents MINOX em aaa 4 Introduction and safety instructions 6 Technical da ta 5 c ee 10 Service tools ii 12 Service data ri 14 Safety equipment eeren 16 Repair instructions nenn 24 Carburettor i 33 Troubleshooting i 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 refitting 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 filter 44 Replacing the fuel hose return hose 44 Replacing the air purge 44 Venting the
20. ble socket or wrench Turn the clutch clock wise to remove it see figure 15 4 Secure the clutch in a vice as shown in figure Care fully release the clutch springs C see figure 16 NOTE Handle the clutch springs carefully If they are opened up too much they could dam age the saw Inspection and cleaning Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones Always use original parts Check the thickness of the clutch shoes by using vernier callipers to measure the diameter of the clutch If the diameter is less than 60 mm the clutch assembly must be replaced see figure 16 30 English Fig 16 Repair instructions 7 10 Centrifugal clutch 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 Tightening torque min 20 Nm 3 Remove the piston stop Fit the spark plug tightening it to a torque of 20 Nm then connect the HT lead Then refit cylinder cover guide bar chain clutch cover 7 11 Dismantling the oil pump and screen 1 Empty and clean the oil tank Remove the cylinder cover Release the brake by moving the front hand guard backward Undo the bar nut and remove the clutch cover bar a
21. burettor removal silencer spark plug fuel unit 2 Undo the four cylinder bolts from the underside and lift the cylinder off carefully see figure 52 3 Cover the opening in the crankcase see figure 54 4 KENNEN Remove the circlips from the ends of the gudgeon pin and press it out Then lift off the piston see DN S figure 53 and 54 De 5 gt Remove the little end bearing see figure 54 um Fig 54 If replacing the cylinder Remove the intake manifold see Air intake sys tem removal Fig 55 Cleaning and inspection Clean all the components scraping off all traces of old gasket and carbon from the following places Piston crown i p oS Top of the cylinder bore Yy Za O Cylinder exhaust port SS To Decompression valve channel SHAE J SSO Cylinder base and or crankcase AS see figure 56 A Fig 56 T English 45 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 fine emery paper The piston ring is freely moving in its groove see figure 57 g Fig 57 Measure piston ring wear This should not exceed 1 mm see figure 58 Us
22. ctuator rod G from the carburettor see figure 45 4 Dismantle the fuel hose B and the fuel pump return hose D see figure 45 5 Remove the screws A Loosen the handle see figure 46 6 Dismantle the fuel tank NOTE Exercise care so that the fuel hose and throttle cable are not damaged 7 17 Venting the fuel tank The two way valve C has the following properties see figure 47 Controlled opening pressure in both directions which prevents a positive pressure or a vacuum developing in the fuel tank and impairing engine performance This also prevents fuel leakage Opening pressure outward 100 450 mbar Opening pressure inward vacuum max 70 mbar 2 positions Test Opening pressure outward 1 Open the filler cap and let the cap remain open during the entire test Drain the fuel from the tank 2 Connect the pump ref no 531 03 06 23 to the tank valve C 3 Switch the pump to vacuum mode 4 After pumping the indicator should be between 10 45 kPa Opening pressure inward 1 Open the filler cap and let the cap remain open during the entire test Drain the fuel from the tank 2 Connect the pump ref no 531 03 06 23 to the tank valve C Switch the pump to pressure mode After pumping the indicator should stop at max 7 kPa 42 English Fig 45 B Fig 47 Repair instructions Assembly 1 If the throttle
23. d cause serious or fatal injury Take care to ensure that the spring inside the starter assembly does not fly out and cause injury Wear eye protection If the spring is under compression when the pulley is removed it could fly 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 fly out and cause injury After completing the repair the chain brake must be tested see Chain brake reassembly Operating test Always consider the fire risk A chainsaw can produce sparks that could start a fire Inspect the chain catcher and replace it if it is damaged Introduction and safety instructions 2 10 Symbols on the saw The symbols below are embedded on the chain saw y Choke Lever alin Refuelling Stop button 9 Filling with chain oil Air purge Chain brake activated right O O Chain brake not activated left 2 11 Symbols in the Workshop Manual This symbol warns of personal injury when the instructions are not followed English 9 Technical data 3 Technical data Y 1 lt A lo EEE Displacement Cylinder bore Stroke Max power speed cm cubic inches mm O inches mm inches kW hp rpm CS 2240 8 40 9 2 49 41 1 51 31 1 22 1 8 2 4 9 000 o Dal Spark plug gap Ignition system Air gap Carburettor type mm inches mm inches CS 2240 8 0 5 0 02 Walbro MBU 16 0 3 0 012 Zama EL41AC1T
24. dule 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 flywheel 502 51 94 01 18 Adjustment screwdriver Adjustment of the carburettor 530 03 55 60 English 13 Service data 5 Service data 15Nm 5mm 14 English DA Ags D Q Q QY l M 15 English Safety equipment 6 Safety equipment Contents 6 1 Dismantling the chain brake ii 17 6 2 Chain brake reassembly nennen nennen nennen rennes nnn senes 18 6 3 Silencer removal ii 19 6 4 Silencer refitting i 19 6 5 Chain catcher replacement eene nennen entree nnns nnne nens 20 6 6 Dismantling the start stop control i 20 6 7 Stop switch resistance measurement eene 21 6 8 Assembling the start stop control eene nennen 21 6 9 Throttle lock throttle trigger and return spring removal nn 22 6 10 Throttle lock throt
25. e the piston to push the piston ring for correct alignment The needle roller bearing is undamaged The intake manifold is undamaged That the air hoses and impulse hose are unda maged Pressure test the decompression valve Fig 58 46 English Repair instructions Faults and causes Score marks on the piston A 1 Incorrect carburettor setting Too high over speed Too low octane fuel Too low or incorrect oil in the fuel Carbon build up B 1 Incorrect carburettor setting Too low over speed 2 Too much or incorrect oil in the fuel Piston ring breakage 1 Excessive engine speed 2 Piston ring worn out 3 Oversized piston ring groove See figure 59 7 23 Piston and cylinder refitting 1 Lubricate the little end bearing with two stroke oil and insert it in the connecting rod see figure 60 2 Fit the piston with the arrow pointing towards the exhaust port Push the gudgeon pin in and fit the circlips NOTE Use new wire fuses see figure 60 3 Fit the intake manifold on the cylinder with insula ting plate 4 screws 4 Lubricate the piston ring and piston with two stroke oil 5 Fit new cylinder base gaskets Lower the cylinder over the piston carefully 6 Fit the cylinder bolts tightening them in diagonal pairs to a torque of 13 15 Nm NOTE It is very important that there are no leaks in the inlet system otherwise the engine may seize B
26. ead and clip the test spark plug onto the cylinder Turn the engine over using the starter cord If the test spark plug produces a spark the ignition module is OK see figure 7 English 27 Repair instructions 7 7 Ignition module and flywheel removal 1 Remove the cylinder cover Disconnect the HT lead remove the spark plug and fit piston stop 502 54 15 01 in its place Take off the starter assembly release the leads from the cable guide and remove it see figure 8 2 If replacing the ignition module B loosen the cable lug C and screw A and unscrew it The ignition module can be left in place if you are simply removing the flywheel see figure 9 3 Loosen the flywheel nut E using a suitable socket and remove it see figure 10 When replacing the cables they are fitted on the stop switch as shown in figure see figure 9 4 Knock on the punch using a metal mallet until the flywheel releases from the shaft Remove the punch and the flywheel see figure 10 Cleaning and inspection Clean all parts especially the tapers on the flywheel and shaft Check that the flywheel is not cracked or da maged in any other way 28 English Fig 8 Fig 9 Fig 10 Repair instructions 7 8 Ignition module and flywheel refitting 1 Fit the flywheel on the crankshaft journal Turn the flywheel
27. ection 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 indi cate where caution should be taken WARNING The warning text warns of the risk of personal injury if the instruc tions are not followed NOTE The warning text warns of the risk of ma terial damage if the instructions are not followed 8 English 2 9 Special instructions The fuel that is used in a chainsaw poses the fol lowing hazards The fuel and its fumes are toxic May cause irritation to skin or eyes May cause breathing difficulties Highly flammable 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 fitted 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 coul
28. ed it can fly out and cause injury Wear eye protection C S 3 Remove the bolt from the centre of the pulley and lift off the pulley see figure 3 Cleaning and inspection Clean the parts and check the following The starter cord That the pawls on the flywheel are undama ged i e that they spring back towards the centre and move freely Lubricate the return spring with light oil Fig 3 er English 25 Repair instructions 7 2 Changing a broken or worn starter cord When the starter cord is worn and must be replaced the tension on the return spring must be released 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 allowing the starter pulley to rotate slowly backwards see figure 2 WARNING If the spring tension is activated on the starter pulley the spring can fly out and cause personal injury Wear protective glasses 2 Undo the bolt in the centre of the pulley and re move the pulley see figure 3 3 Fit a new cord through the hole in the pulley and tie a knot to secure it Feed the other end of the cord through the hole in the starter housing and through the starter handle then tie a double knot in the end Wind about 3 turns of the starter cord onto the pulley Fit the bolt through the centre of the pulley and tighten to a torque of 2 3 Nm Cleaning and inspec
29. ges in the crankcase The other side of the diaphragm pumps the fuel see figure 24 Fig 22 Fig 23 Fig 24 English 33 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 figure the choke valve H is fully closed This increases the vacuum in the carburettor so that fuel is sucked more easily from all the diffuser jets D E and F The throttle valve 1 is partly open Extra air inlet J is closed see figure 25 In the idling mode see figure the throttle valve I and J is closed and the choke valve H is open Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied th rough the diffuser jet D see figure 26 In the part throttle mode see figure below the th rottle valve I is partially open and the choke valve H is open Fuel is supplied through the diffuser jets D and E The throttle valve J starts to open see figure 27 In full throttle mode se figure below all valves are open and fuel is supplied through all diffuser jets D E F and G Extra air inlet J is also fully opened see figure 28 34 English Fig 25 Fig 26 Fig 27 Fig 28
30. ke must engage see figure 10 6 3 Silencer removal WARNING Do not touch the silencer until it e has cooled down otherwise you may burn yourself 1 Remove the cylinder cover silencer gasket and cooling plate 2 If the saw is fitted with a spark arrestor mesh A this must also be removed If necessary use the com bination spanner to push down the plate edge and remove the spark arrestor mesh see figure 11 Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones The spark arrestor mesh is best cleaned with a wire brush If the mesh is damaged it must be replaced If the mesh is blocked the saw will overheat and this will cause damage to cylinder and piston Never use the saw with a silencer that is in poor condition Always use original parts 6 4 Silencer refitting 1 If the saw is equipped with a spark arrestor mesh this should be fitted first When fitting the mesh make sure that the mesh is inserted in the right position If necessary use the combination spanner to insert the mesh 2 Refit cooling plate gasket silencer tighten bolts to a torque of 8 10 Nm Oylinder cover 3 Run the saw for at least 1 minute then retighten the silencer bolts to 12 14 Nm Fig 10 English 19 Safety equipment 6 5 Chain catcher replacement If the chain catcher
31. n 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 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 in structions 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 figu res are designated A B etc The figures are numbered 1 2 etc The position references and figure numbers restart in each new s
32. nd chain Loosen spark plug cap and remove the spark plug fit the piston stop 502 54 15 01 Loosen the clutch clockwise using tool 502 54 16 03 and a suitable socket wrench or combination spanner 2 Remove the centrifugal clutch A Remove the clutch drum B needle bearing C and pump drive wheel D see figure 17 3 Unscrew the chain guide plate see figure 18 4 Unbolt the oil pump from the crankcase and remove it together with the oil pressure hose see figure 19 5 The oil pump E is not adjustable see figure 20 Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the dama ged parts with new ones Always use original parts Lubricate all moving parts with chain oil Fig 20 English 31 Repair instructions 7 12 Assembling the oil pump and screen 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 WARNING Poor chain lubrication can result in failure of the chain which could cause serious or fatal injury 7 13 Air intake system removal The air intake system comprises intake manifold A plastic partition wall B rubber partition wall C see figure 21 1 Now loosen the screws using tool 502 50 87 01 7 14 Assembling the
33. on the button is neutral B see figure 15 6 8 Assembling the start stop control 1 Fit a new control and tighten the screw 2 Fit air filter and cylinder cover Fig 15 Fig 16 English 21 Safety equipment 6 9 Throttle lock throttle trigger and return spring removal 1 Loosen the throttle actuator rod on the carburettor the fuel hose and the suction hose to the fuel pump 2 Dismantle the tank unit from the engine unit by loosening the screws A see figure 17 3 Dismantle the handle insert B by loosening the screw C on the handle see figure 18 4 Press out the throttle control pin D with the help of a punch see figure 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 figure 20 6 Dismantle the throttle control see figure 20 7 Now loosen the spring 22 English Fig 18 Fig 19 bo Y NY A x i y M NS Fig 20 L D C Fig 21 Safety equipment Gisa and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the dama ged parts with new ones Always use original parts e Check that the spring is not broken and has not lost its tension 6 10 Throttle lock throttle trigger and return spring refitting 1
34. r U by using the handle of a small screwdriver See figure 33 4 Fit pump cover G gasket S and measuring chamber cover R over the pump unit see figure 33 5 Fit the needle valve L with lever M shaft N and spring P and tighten the screw K Fit the expansion washer F see figure 35 6 Check using a ruler or the like that the lever is level with the assembly plane on the cover The lever arm can be bent if necessary see figure 36 7 Fit the control diaphragm T with gasket S and measuring chamber cover R over the metering unit see figure 37 8 Press in the screen U Fit the measuring chamber cover R and tighten the screw Q see figure 37 9 Puttogether the gasket J and control dia phragm H and press up see figure 37 10 Assemble all the parts and tighten the four Screws see figure 37 11 Carry out a pressure test 38 English Fig 35 Fig 36 Fig 37 Repair instructions Pressure testing the carburettor Pressure testing should be carried out with the car burettor fully assembled Testing should always be carried out after the carburettor has been repaired but it can also be carried out as trouble shooting before dismantling the carburettor See figure and carry out the test as follows 1 Set the high and low jet screws two turns from the bottom 2 Connect pressure tester to the carburettor s fuel intake
35. released Adjust L screw Adjust H screw Blocked air filter Faulty pump diaphragm Faulty diffuser jets Over rich acceleration 8 2 Troubleshooting methods In addition to the faults described in the above table trouble shooting can be carried out on specific components or sub systems of the chainsaw The various procedures are described in the relevant chapters see the contents page as follows Checking the operation of the chain brake Measuring the resistance of the stop plate Pressure testing the carburettor Pressure testing the decompression valve Pressure testing the cylinder English 55 510 16 77 26 2009W39
36. tion Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones Lubricate the return spring with a little grease 7 3 Tensioning the recoil spring 1 Fasten the starter cord in the notch in the pulley rim and wind the pulley about 3 turns clockwise Check that the pulley is free to rotate at least an other half turn when the starter cord is fully exten ded see figure 4 2 Tension the cord with the handle Remove the thumb and released back the cord see figure 5 26 English Fig 4 Repair instructions 7 4 Replacing a worn recoil spring WARNING Make sure the recoil spring does not fly out and cause injury Wear eye protection 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 centre of the pulley and tighten to a torque of 2 3 Nm Tension the recoil spring see Tensioning the recoil spring 7 5 Starter assembly refitting 1 Position the starter assembly on the crankcase and tighten the bolts to a torque of 2 5 3 5 Nm 7 6 Ignition module testing If there is a fault in the ignition system the ignition module must be tested before the ignition system is removed Test the ignition module as follows Connect a test spark plug 502 71 13 01 to the ignition l
37. tle trigger and return spring refitting ee eeeteeeeeeeetteeeeeeeee 23 16 English Safety equipment 6 Safety equipment 6 1 Dismantling the chain brake 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 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 cause perso nal injury Wear protective glasses Loosen the screws and carefully remove the cover over the brake spring see figure 3 4 Hold one hand over the brake spring press a nar row screwdriver in between the rear section of the spring and the clutch cover Carefully pry upward until the spring releases and runs onto the screw driver shaft see figure 4 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 e Measure the thickness of the chain brake band It must not be less than 0 6 mm at any point see figure 5 Lubricate the knee joint with grease English 17 Safety equipment 6 2 Chain brake reassembly 1 Bolt the elbow joint
38. tor with a dirty air filter will give a too lean fuel mixture the next time the air filter is cleaned This can result in serious damage to the engine Mount for this model approved bar and chain combination see Technical data in the Operator s Manual CS 2240 8 16 The chain should not be tensioned more than that it remains 0 2 inches to the bar See figure 43 Replacement of the H needle or complete car burettor 1 Carefully screw the new H needle to the bot tom and turn it anticlockwise A turns CS 2240 8 Az2 2 Start the engine If necessary adjust the idling speed with the T screw until the chain stops 3 Adjust the H needle to give a top speed of B rpm Use a tachometer CS 2240 8 B 12500 13 000 speed limitation Use screwdriver 530 03 55 60 4 Letthe engine run at B rpm 1 minute until warm Replacement of the L needle 1 Screw the new L needle to the bottom and then turn it counterclockwise D turns CS 2240 8 D 2 5 See figure 44 Fig 43 Fig 44 English 41 Repair instructions 7 16 Tank unit WARNING The fuel used in the chain saw has e the following hazardous properties The fluid and its vapour are poisonous Can cause skin irritation Is highly inflammable 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 a
39. ts with levers and springs see figure 34 36 English Fig 38 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 That there is no play on the throttle and choke valve shafts That the needle valve L and its lever M are not worn see figure 33 That the fuel screen U is whole and clean see figure 33 That the tips of the high V and low jet screws W are not damaged see figure 34 That the intake manifold R2 is undamaged see figure 33 The carburettor has an extra air shutter con nected in parallel with the ordinary throttle valve English 37 Repair instructions Assembly 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 refitted The spring is tensioned 1 2 turns Lubricate the shaft bearings with light oil 2 Fit the high V and low W speed needles and springs Note Do not fully tighten the screws This will damage the seats and needle tips 3 Fit the fuel filte
40. ur groups In each group the likely symptoms are given on the left and possible causes are listed on the right The most likely faults are given first and so on Starting Difficulty starting Carburettor leaking fuel Flooding when engine not running Idling low rpm Will not idle Idling too rich 54 English Idling low rpm cont Idles when L screw closed Adjust L screw Air filter blocked Choke not working Worn choke pivot Worn choke valve Fuel filter blocked Fuel line blocked Piston ring seized Blocked impulse channel Idling uneven Loose or faulty fuel pipe Hole in diaphragm Worn needle valve Needle valve assembly sticking Needle valve set too high Leak in metering system air or fuel Loose cover on carburettor pump side Worn needle valve Needle valve set too high Needle valve assembly sticking L screw requires constant adjust Adjust L screw ment Leaking air intake hose rubber Loose carburettor mounting bolts Loose or faulty fuel hose Fuel filter blocked Fuel line blocked Fuel tank vent blocked Throttle valve pivot stiff Throttle pushrod sticking Defective throttle return spring Bent throttle stop Faulty diffuser jet Too much fuel at idling Adjust L screw Worn needle valve Needle valve set too high Worn needle valve lever Leaking control diaphragm cove plate Needle valve assembly sticking Worn needle valve Leaking control diaphragm cove plate Needle val
41. ve assembly sticking Worn needle valve lever Faulty diffuser jet Fuel filter blocked Fuel line blocked Leaking air intake hose rubber Loose carburettor mounting bolts Worn throttle valve pivot Loose throttle valve screw Worn throttle valve Needle valve assembly sticking Leak in metering system air or fuel Metering system centre knob is worn Hole in diaphragm Leaking control diaphragm cove plate Crankcase leaking Fuel line blocked Needle valve set too high Needle valve assembly sticking Leak in metering system air or fuel Leaking control diaphragm cove plate Faulty diffuser jets Crankcase leaking Needle valve set too high Needle valve assembly sticking Metering system damaged Worn needle valve Leaking control diaphragm cove plate Metering system incorrectly assembled Troubleshooting High rpm Will not run at Adjust H screw full throttle Low power Will not four stroke Blocked air filter Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor mounting bolts Needle valve set too low Metering system damaged Metering system incorrectly assembled Leaking control diaphragm cover plate Needle valve assembly sticking Blocked silencer Adjust H screw Blocked fuel tank vent
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