Jonsered CS 2240 - Manual

6 – English Introduction and safety instructions 2 Introduction and safety instructions Contents 2.1 General ...........................................................................................................................7 2.2 Safety ..........................................................

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 follow...

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 Workshop Manual This symb...

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 Walbro MBU-16 0,3 / 0,012...

English – 11 Idling speed Engagement speed Spark plug rpm rpm CS 2240/S: 2 900 3 800 NGK BPMR 7A Champion RCJ 7Y Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump Litres/US pints 8,500 rpm, Litres/US pints ml/min CS 2240/S: 0,37 / 0,78 9 0,25 / 0,53 Yes Weight without Weig...

English – 17 3 Loosen the screws and carefully remove the cover over the brake spring. (see figure 3) WARNING!Exercise care to ensure the spring does not fly out and cause perso-nal injury. Wear protective glasses. 6.1 Dismantling the chain brake 2 Carefully tighten the clutch housing in a vice. Rel...

18 – English NOTE! After completing the repair the chain brake must be tested as described below. 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 ...

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 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 t...

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 o...

English – 25 Repair instructions WARNING!If the recoil spring is still under tension when the pulley is re-moved it can fly out and cause injury. Wear eye protection. 7.1 Starter assembly – removal 1 Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assem...

26 – English 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 t...

English – 27 Repair instructions WARNING!Make sure the recoil spring does not fly out and cause injury. Wear eye protection.. 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...

30 – English Repair instructions 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 c...

English – 31 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 spar...

32 – English 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...

English – 33 Repair instructions 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. 7.15 Carburettor Description The drawings accompanying this description do not correspond wit...

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 figure) the choke valve (H) is fully closed. This increases the vacuum in the carburettor so that ...

English – 35 Repair instructions Dismantling the carburettor 1. Dismantle the cylinder cover and the air filter.2. Disassemble the handle holder (see figure 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 figure 30). 4....

38 – English 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 tens...

English – 39 Leakage at Fault with Diffuser jets Needle valve Leakage in impulse tube Pump diaphragm Ventilation hole on metering unit. Control diaphragm Pressure testing the carburettor Pressure testing should be carried out with the car- burettor fully assembled. Testing should always be carried o...

40 – English 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. Hook on the rubber mountings. Insert and tighten the screws. Repair inst...

English – 41 Repair instructions Carburettor adjustmentConditions during adjustment • The air filter should be clean and the cylinder cover fitted when adjustments are made. Ad- justing the carburettor with a dirty air filter will give a too lean fuel mixture the next time the air filter is cleaned....

42 – English 7.16 Tank 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 figure 45). 4. Dismantle the fuel hose (B) and the fuel pump return hose (D) (see figur...

English – 43 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). 3. ...

44 – English 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 ...

English – 45 Repair instructions 7.22 Piston and cylinder – removal 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...

English – 47 A B Faults and causesScore 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. 2. Too much or incorrect oil in the fuel....

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 wa...

English – 49 Repair instructions WARNING!After pressure testing the cylinder, check that the inlet manifold is seated correctly, otherwise the saw may be damaged. 7.24 Cylinder – pressure testing 1 Remove: • cylinder cover• carburettor• spark plug 2 Mount cover plate 502 54 48-02 (see figure 63). 3 ...

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 th...

English – 51 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• c...

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 stee...

English – 53 Troubleshooting 8 Troubleshooting Contents 8.1 Troubleshooting ..............................................................................................................54 8.2 Troubleshooting methods ......................................................................................

54 – English Troubleshooting Starting Idling (low rpm) Idling (low rpm) (cont.) Adjust L screw 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...

English – 55 Troubleshooting Acceleration och retardation Does not accelerate Engine stalls when throttle released Over rich acceleration 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 L...