Workshop manual
510 16 77-26
Index
Index
Symbols in the Workshop Manual 9
Symbols on the saw 9
Structure 7
Target group 7
Tools 7
B
Bar bolt 52
Replacing the bar bolt 52
C
Carburettor 33
Assemble on the saw 40
Assembly 38
O
Oil pump and screen 31
Assembling the oil pump and screen 32
Carburettor adjustment 41
Cleaning and inspection 37
Design 33
Cleaning and inspection 31
Dismantling the oil pump and screen 31
Dismantling 35
Function 34
Pressure testing the carburettor 39
P
Piston and cylinder 45
Cleaning and inspection 45
Cylinder - pressure testing 49
Faults and causes 47
Piston and cylinder - refitting 47
Piston and cylinder - removal 45
Centrifugal clutch 30
Centrifugal clutch - refitting 31
Centrifugal clutch - removal 30
Inspection and cleaning 30
Chain brake 17
S
Chaine brake - reassembly 18
Cleaning and inspection 17
Dismantling the chaine brake 17
Service data 14
Special tools 12
Chain catcher 20
Chain catcher - replacement 20
Silencer 19
Cleaning and inspection 19
Silencer - refitting 19
Silencer - removal 19
Crankcase and crankshaft 50
Crankshaft bearings - replacement 50
Crankshaft complete - dismantling 50
Crankshaft complete - reassembly 51
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
F
Fuel system 44
Replacing the fuel filter 44
Replacing the fuel hose/return hose 44
Replacing the air-purge 44
Venting the fuel tank 42
Start/Stop switch 20
Assembling the start/stop control 21
Cleaning and inspection 20
Dismantling the start/stop control 20
I
Ignition module and flywheel 28
Cleaning and inspection 28
Ignition module - testing 27
Stopping function 21
Stop switch - resistance measurement 21
Ignition module and flywheel - refitting 29
Ignition module and flywheel - removal 28
T
Tank unit 42
Assembly 43
Dismantling 42
Intake system 32
Air intake system removal 32
Assembling the intake system 32, 48
Cleaning and inspection 32
Technical Data 10
Threads 51
Introduction and safety instructions 7
Changes 7
General 7
Repairing damaged threads 51
Throttle lock, throttle trigger
and return spring 22
General Instructions 8
Numbering 7
Safety 7
Cleaning and inspection 23
Throttle lock, throttle trigger and
return spring - refitting 23
Throttle lock, throttle trigger and
return spring - removal 22
Special Instructions 8
4 – English
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
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
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
6 – English
Introduction and safety instructions
2 Introduction and safety instructions
2.1 General
2.6 Structure
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.
This Workshop Manual can be used in two diffe-
rent ways:
•
•
For the repair of a particular system on the
chain saw.
2.2 Safety
Dismantling and assembly of the entire chain
saw.
Note! The section dealing with safety must be
read and understood by all those carrying out
repair work or service on the chain saw.
Repair of a specific system
When a particular system on the chain saw is to be
repaired, proceed as follows:
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.
1. Look up the page for the system in question.
2. Carry out the sections: Dismantling
Cleaning and inspection
Assembling
2.3 Target group
Dismantling and assembling the entire chain saw
Proceed as follows when the entire chain saw is to
be dismantled and assembled:
This Workshop Manual is written for personnel with
general knowledge about the repair and service of
chain saws.
1. Look up the chapter “Repair instructions”,
which deals with the Starter and carry out the
instructions set out under Dismantling.
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. Work forward in the Manual and carry out Dis-
mantling in the order set out in the sections.
2.4 Changes
3. Go back to the Starter and carry out the in-
structions under Cleaning and Inspection.
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.
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.
2.5 Tools
7. Work back in the Manual and carry out As-
sembling in the order set out in the sections.
Special tools are required for some stages. All
service tools are listed in the Workshop Manual.
Usage is evident from respective sections.
Some sections include a Description of the actual
unit in order to increase the basic understanding.
Always use Husqvarna’s original:
• Spare parts
2.7 Numbering
• Service tools
• Accessories
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 section.
English – 7
Introduction and safety instructions
2.8 General instructions
2.9 Special instructions
The workshop where chain saw repairs are to be
done must be equipped with safety equipment as
set out in local provisions.
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.
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.
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.
WARNING!
The warning text warns of the risk
of personal injury if the instruc-
tions are not followed.
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.
NOTE!
The warning text warns of the risk of ma-
terial damage if the instructions are not
followed.
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 could 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.
8 – English
Introduction and safety instructions
2.10 Symbols on the saw
2.11 Symbols in the Workshop Manual
The symbols below are embedded on the chain
saw.
This symbol warns of personal injury
when the instructions are not followed
Choke Lever
Refuelling
Stop button
Filling with chain oil
Air purge
Chain brake, activated (right)
Chain brake, not activated (left)
English – 9
Technical data
3 Technical data
Displacement
cm3/cubic inches
Cylinder bore
Ø mm/Ø inches
Stroke
mm/inches
Max power/speed
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
mm/inches
Ignition system
Walbro MBU-16
Air gap
mm/inches
Carburettor type
Zama EL41AC1T
CS 2240/S:
0,5 / 0,02
0,3 / 0,012
Effective cutting length
cm/inches
Chain speed at
max power – revs
m/s - r/min
Chain pitch
mm/inches
Drive link
mm/inches
CS 2240/S: 33-46 / 13-18
17,3 / 9 000
8,25 / 0,325
1,3 / 0,050 - 1,5 / 0,058
10 – English
Technical data
rpm
Idling speed
rpm
Engagement speed
rpm
Spark plug
CS 2240/S:
2 900
3 800
NGK BPMR 7A
Champion RCJ 7Y
GAS
OIL
Fuel tank capacity
Litres/US pints
Oil pump capacity at
8,500 rpm,
ml/min
Oil tank capacity
Litres/US pints
Automatic oil pump
CS 2240/S:
0,37 / 0,78
9
0,25 / 0,53
Yes
Weight without
bar and chain
kg / lbs
Weight with
bar and chain
kg / lbs
CS 2240/S:
4,4 / 9,7
5,7 / 12,6
English – 11
Special tools
4 Special tools
2
1
3
4
7
5
6
M5
M5
M6
8
9
11
10
12 – English
Special tools
12
13a
13b
15
16b
16c
17
16a
18
Item Description
Used for
Order no.
1
2
3
Clutch tool
Centrifugal clutch
Locking the crankshaft
502 54 16-03
504 91 06-05
502 50 83-01
Piston stop
Fuel filter hook
Withdrawing the fuel filter
4
5
5
Allen key, 4mm
Allen key, 4mm
Allen key, 5mm
For M5 bolts
For M5 bolts
For M6 bolts
502 50 87-01
502 50 18-01
502 50 64-01
6
7
8
Pressure tester
Feeler gauge
Pressure testing cylinder
Adjusting ignition module
Assembling chain saw
503 84 40-02
502 51 34-02
502 51 02-01
Assembly fixture
9
Pressure gauge
Pressurisation during testing
Checking the ignition module
Adjusting carburettor
531 03 06-23
501 97 64-01
502 71 14-01
10 Test spark plug
11 Rev counter
12 Assembly pliers
Fitting spark plug guard
Sealing the exhaust port
Sealing the intake manifold
502 50 06-01
502 54 11-02
504 63 93-01
13a Cover plate, exhaust
13b Cover plates, inlet
14 Assembly tool
15 Puller
Assembling spring, chain brake 502 50 67-01
Pulling bearing of crankshaft
Fitting crankshaft
504 90 90-01
502 50 30-22
16a Sleeve
16b Shaft extension
16c Shaft extension
17 Punch
Flywheel side
502 50 30-22
502 50 30-22
502 51 94-01
530 03 55-60
Cluch side
Dismantling the flywheel
18 Adjustment screwdriver Adjustment of the carburettor
English – 13
Service data
5 Service data
14 – English
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