Jonsered CS 2240 Workshop Manual
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Jonsered CS 2240 Workshop Manual

Jonsered chainsaw user manual
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Workshop manual
510 16 77-26

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Summary of Contents for Jonsered CS 2240

  • Page 1 Workshop manual 510 16 77-26...

  • Page 2: Table Of Contents

    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. Workshop manual Contents...

  • Page 3: Index

    Index Bar bolt 52 Replacing the bar bolt 52 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...

  • Page 4: English

    Trouble shooting 54 Trouble-shooting methods 55 Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 English –...

  • Page 5: Introduction And Safety Instructions

    Introduction and safety instructions 2 Introduction and safety instructions Contents General ...7 Safety ...7 Target group ...7 Changes ...7 Tools ...7 Structure ...7 Numbering ...7 General instructions ...8 Special instructions ...8 2.10 Symbols on the saw ...9 2.11 Symbols in the Workshop Manual ...9 –...

  • Page 6: General

    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...

  • Page 7: General Instructions

    The warning text warns of the risk of ma- terial damage if the instructions are not followed. – 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. •...

  • Page 8: Symbols In The Workshop Manual

    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) Introduction and safety instructions 2.11 Symbols in the Workshop Manual This symbol warns of personal injury when the instructions are not followed English –...

  • Page 9: Technical Data

    CS 2240/S: 40,9 / 2,49 Spark plug gap mm/inches CS 2240/S: 0,5 / 0,02 Effective cutting length cm/inches CS 2240/S: 33-46 / 13-18 – English 3 Technical data Cylinder bore Stroke Ø mm/Ø inches mm/inches 41 / 1,51 31 / 1,22...
  • Page 10 Technical data Idling speed Engagement speed Spark plug 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...

  • Page 11: Service Tools

    Special tools – English 4 Special tools...
  • Page 12 Item Description Used for Clutch tool Centrifugal clutch Piston stop Locking the crankshaft Fuel filter hook Withdrawing the fuel filter Allen key, 4mm For M5 bolts Allen key, 4mm For M5 bolts Allen key, 5mm For M6 bolts Pressure tester Pressure testing cylinder Feeler gauge Adjusting ignition module...

  • Page 13: Service Data

    Service data 5 Service data – English...
  • Page 14 Service data English –...

  • Page 15: Safety Equipment

    Safety equipment 6 Safety equipment Contents Dismantling the chain brake ...17 Chain brake - reassembly ...18 Silencer - removal ...19 Silencer - refitting ...19 Chain catcher - replacement ...20 Dismantling the start/stop control ...20 Stop switch - resistance measurement ...21 Assembling the start/stop control ...21 Throttle lock, throttle trigger and return spring - removal ...22 6.10...

  • Page 16: 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). Carefully tighten the clutch housing in a vice. Release the brake by using the saw's front hand guard (A) as a tool.

  • Page 17: Chain Brake - Reassembly

    Safety equipment 6.2 Chain brake – reassembly 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).

  • Page 18: Silencer - Removal

    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 brake must engage (see figure 10).

  • Page 19: Chain Catcher - Replacement

    Safety equipment 6.5 Chain catcher – replacement If the chain catcher is worn it must be replaced with a new one. Release the brake by pushing the kickback guard backwards. Undo the guide bar bolts and remove the clutch cover, chain and guide bar. Remove the chain catcher and replace it with a new one.

  • Page 20: Stop Switch - Resistance Measurement

    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).

  • Page 21: Throttle Lock, Throttle Trigger And Return Spring - Removal

    Safety equipment 6.9 Throttle lock, throttle trigger and return spring – removal Loosen the throttle actuator rod on the carburettor, the fuel hose and the suction hose to the fuel pump. Dismantle the tank unit from the engine unit by loosening the screws A (see figure 17) Dismantle the handle insert (B) by loosening the screw C on the handle (see figure 18).

  • Page 22: Throttle Lock, Throttle Trigger And Return Spring - Refitting

    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. Check that the spring is not broken and has not •...

  • Page 23: Repair Instructions

    Repair instructions 7 Repair instructions Contents Starter assembly - removal ...25 Changing a broken or worn starter cord ...26 Tensioning the recoil spring ...26 Replacing a worn recoil spring ...27 Starter assembly - refitting ...27 Ignition module - testing ...27 Ignition module and flywheel - removal ...28 Ignition module and flywheel - refitting ...29 Centrifugal clutch - removal ...30...

  • Page 24: Repair Instructions

    7 Repair instructions 7.1 Starter assembly – removal Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assembly. (see figure 1) Pull out about 30 cm of the cord and fasten it in the notch in the pulley rim.

  • Page 25: Changing A Broken Or Worn Starter Cord

    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. Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley.

  • Page 26: Replacing A Worn Recoil Spring

    7.4 Replacing a worn recoil spring WARNING! Make sure the recoil spring does not fly out and cause injury. Wear eye protection.. Remove the bolt from the centre of the pulley and lift off the pulley and spring cassette. Replace the defective spring cassette with a new one.

  • Page 27: Ignition Module And Flywheel - Removal

    Repair instructions 7.7 Ignition module and flywheel – removal 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).

  • Page 28: Ignition Module And Flywheel - Refitting

    7.8 Ignition module and flywheel – refitting Fit the flywheel on the crankshaft journal. Turn the flywheel 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).

  • Page 29: Centrifugal Clutch - Removal

    Repair instructions 7.9 Centrifugal clutch – removal 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). Disconnect the HT lead. Remove the spark plug and fit piston stop 502 54 15-01 (A) in its place (see figure 14).

  • Page 30: Centrifugal Clutch - Refitting

    7.10 Centrifugal clutch – refitting Insert the clutch springs in the shoes. 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. Remove the piston stop. Fit the spark plug, tightening it to a torque of 20 Nm, then connect the HT lead.

  • Page 31: Assembling The Oil Pump And Screen

    Repair instructions 7.12 Assembling the oil pump and screen 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...

  • Page 32: Carburettor

    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.

  • Page 33: Function

    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).

  • Page 34: Dismantling

    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.
  • Page 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). 7. Unscrew the screw (K) and remove the needle valve (L) with lever (M), shaft (N) and spring (P).

  • Page 36: Cleaning And Inspection

    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.

  • Page 37: Assembly

    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.

  • Page 38: Pressure Testing The Carburettor

    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: Set the high and low jet screws two turns from the bottom.
  • Page 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. 2. Fit the filter holder by hooking the choke con- trol into the choke lever (A). 3.

  • Page 40: Carburettor Adjustment

    3. Adjust the H-needle to give a top speed of ”B” rpm. Use a tachometer. CS 2240/S B = 12500-13 000, speed limitation Use screwdriver 530 03 55-60. 4. Let the engine run at ”B” rpm ~ 1 minute, until warm.

  • Page 41: Tank Unit

    Repair instructions 7.16 Tank unit WARNING! The fuel used in the chain saw has 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.

  • Page 42: Vibration Damping System

    Assembly 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 figure 48).

  • Page 43: Replacing The Fuel Filter

    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. First remove the old fuel filter from the tank unit using special tool 502 50 83-01.

  • Page 44: Piston And Cylinder - Removal

    7.22 Piston and cylinder – removal Remove: • cylinder cover • carburettor (see “Carburettor – removal”) • silencer • spark plug • fuel unit Undo the four cylinder bolts from the underside and lift the cylinder off carefully (see figure 52). Cover the opening in the crankcase (see figure 54).
  • Page 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.

  • Page 46: Faults And Causes

    Faults and causes Score marks on the piston (A) 1. Incorrect carburettor setting. Too high over- speed. 2. Too low octane fuel. 3. Too low or incorrect oil in the fuel. Carbon build-up (B) 1. Incorrect carburettor setting. Too low over- speed.

  • Page 47: Assembling The Intake System

    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 Mount the intake manifold (A) and the partition walls (B and C) on the cylinder using tools 502 50 87-01 (see figure 62).

  • Page 48: Cylinder - Pressure Testing

    7.24 Cylinder – pressure testing Remove: • cylinder cover • carburettor • spark plug Mount cover plate 502 54 48-02 (see figure 63). Loosen the screws on the muffler and press the rubber sheet 502 54 11-02 between the muffler and cylinder.

  • Page 49: Crankshaft Complete - Dismantling

    Repair instructions 7.25 Crankshaft complete - dismantling 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.

  • Page 50: Crankshaft Complete - Reassembly

    7.27 Crankshaft complete – reassembly 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 •...

  • Page 51: Replacing The Bar Bolt

    Repair instructions 7.29 Replacing the bar bolt Replacing the front bar guide. Drain the oil tank. Knock through the old guide bar bolt so that it falls into the oil tank. Remove the bolt from the oil tank. 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).

  • Page 52: Troubleshooting

    Contents Troubleshooting ...54 Troubleshooting methods ...55 8 Troubleshooting Troubleshooting English –...

  • Page 53: Troubleshooting

    8.1 Troubleshooting The various faults that can affect a chainsaw are divided into four 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.

  • Page 54: 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: •...
  • Page 55 510 16 77-26 2009W39...

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Cs 2240s

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