Jonsered CS 2159 C Manual
Jonsered CS 2159 C Chainsaw, size: 2.3 MB
Jonsered CS 2159 CWH
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User reviews and opinions
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Comments posted on www.ps2netdrivers.net are solely the views and opinions of the people posting them and do not necessarily reflect the views or opinions of us.
Chain saws - Jonsered CS 2159 C
A power pack for the professional lumberjack with strict requirements for power, control and design. With its 60 cc of raw power and a highly competitive power-to-weight ratio, this saw is just as good for felling really big trees as it is for limbing and cross-cutting. This is Jonsereds first saw that has a carburettor with built-in fuel compensation. This means that the fuel-air mixture is kept constant, so that the power remains unchanged over time. Together with turbo air cleaning, this keeps the power high while reducing filter wear, emissions and fuel consumption. The machine also has a magnesium crankcase, side-mounted chain tensioner and a catalytic converter which decreases emissions without affecting power.
Cylinder displacement Power Fuel tank volume Oil tank volume Oil pump type Power to weight ratio Chain pitch Recommended bar length Sound level Noise emissions, LWA Vibrations, front/rear handle Weight excl. cutting equipment
3.6 cu.inch / 59.0 cm 4,08 hp / 3,0 kW 1.43 US pint / 0.68l 0.80 US pint / 0.38l Adjustable flow 0.54 kW/kg / 0.24 kW/lbs.325 / 3/8" 13-20" / 33-50 cm 102 dB(A) 114 dB(A) 3.9 m/s / 4.4 m/s 12.3 lbs / 5.6 kg
Turbo air filtration Coil spring anti-vibration system Side-mounted chain tensioner Adjustable oil pump for chain lubrication Quick-release cylinder cover Combined choke/start control Automatic fuel compensation Compression-release valve Catalytic converter muffler
1 of 1
10/4/2008 1:39 PM
The fuel that is used in a chainsaw poses the following hazards: The fuel and its fumes are toxic. May cause irritation to skin or eyes. May cause breathing difculties. Highly ammable. 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 tted 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 y out and cause injury. Wear eye protection. If the spring is under compression when the pulley is removed it could y 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 y out and cause injury. After completing the repair the chain brake must be tested, see Chain brake reassembly \ Operating test. Always consider the re risk. A chainsaw can produce sparks that could start a re. Inspect the chain catcher and replace it if it is damaged.
WARNING! The warning text warns of the risk of personal injury if the instructions are not followed.
NOTE! The warning text warns of the risk of material damage if the instructions are not followed.
21 b 21 c Item Description Clutch tool Piston stop Stop plate Fuel lter hook Allen key Puller Removal tool Cover plate Pressure tester Feeler gauge Clamp stand Clutch tool Pressure gauge Piston tting kit Test plug Rev counter Removal tool Vacuum gauge Assembly pliers Used for Centrifugal clutch Locking crankshaft Locating intake gaiter Withdrawing the fuel lter For M5 bolts Frame bearing Remove seal from clutch side Order no. 16-54 15-54 17-50 83-a 18-90 90-50 55-54 21-84 40-51 34-51 02-52 22-50 38-50 70-71 13-71 14-51 61-50 37-50 06-50 30-50 30-50 30-54 18-50 30-16
Mandrel, sealing ring Removing crankshaft Connection to cylinder Adjusting ignition module Clamping the saw Centrifugal clutch Pressurisation during testing Fitting piston Checking ignition module Adjusting carburettor Removing crankshaft Vacuum test Fitting spark plug guard Fitting crankshaft Flywheel side Clutch side Removing crankshaft Fitting crankshaft seal
Sealing during pressure testing 11-02
21a Sleeve 21b Shaft extension 21c Shaft extension 24 Stop plate Assembly tool Crankshaft tool
Assembling spring, chain brake 67-01
Displacement cm3/cubic inches CS 2149/W: 49,4 / 3,0 CS 2150: 49,4 / 3,0 CS 2141: 40,8 / 2,5 CS 2145: 45,0 / 2,75 CS 2147/C/W/H: 45,0 / 2,75 CS 2152/C/W/H: 51,7 / 3,2 CS 2156/C/W/H: 56,5 / 3,45 CS 2159/C/W/H: 59,0 / 3,6
Cylinder bore mm/ inches 44 / 1,73" 44 / 1,73" 40 / 1,57" 42 / 1,65" 42 / 1,65" 45 / 1,77" 46 / 1,81" 47 / 1,85"
Stroke mm/inches 32,5 / 1,28" 32,5 / 1,28" 32,5 / 1,28" 32,5 / 1,28" 32,5 / 1,28" 32,5 / 1,28" 34,0 / 1,34" 34,0 / 1,34"
Max power/speed kW/hp/rpm 2,3/ 3,1 /2,3/ 3,1 /2,0 / 2,7 / 2,2 / 3,0 / 2,5 / 3,4 / 2,4 / 3,3 / 3,2 / 4,35 / 3,0 / 4,1 / 9 000
Spark plug gap mm/inches 0,5 / 0,02"
Ignition system SEM CD
Air gap mm/inches 0,3 / 0,012"
Carburettor type ZAMA C3-EL17 (EPA) ZAMA C3-EL18 Walbro HDA 195 (EPA) ZAMA C3-EL18 ZAMA C3-EL 17 ZAMA C3-EL17 (EPA) ZAMA C3-EL18 Walbro HDA 198 (EPA) Walbro HDA 199 Walbro HDA 198/190 (H) (EPA) Walbro HDA 199/191 (H)
CS 2141/CS 2145/ CS 2150: 0,5 / 0,02" CS 2147/C/W/H: 0,5 / 0,02" CS 2152/C/W/H: 0,5 / 0,02" CS 2156/C/W/H: 0,5 / 0,02" CS 2159/C/W/H: 0,5 / 0,02"
SEM CD SEM CD SEM CD SEM CD SEM CD
0,3 / 0,012" 0,3 / 0,012" 0,3 / 0,012" 0,3 / 0,012" 0,3 / 0,012"
Effective cutting length Chain speed at cm/inches max power revs m/s rpm CS 2149/W: 30-48 / 12"-19" 17,3 / CS 2141/CS 2145/ CS 2150: 30-43 / 12"-17" 17,3 / CS 2147/C/W/H: 30-48 / 12"-19" 18,5 / CS 2152/C/W/H 30-48 / 12"-19" 17,3 / CS 2156/C/W/H: 30-48 / 12"-19" 21,4 / CS 2159/C/W/H: 31-48 / 12"-19" 8 English 20 / 9 000
Too much fuel at idling
Idling too rich
Troubleshooting High rpm Will not run at Adjust H screw full throttle Blocked air lter Blocked fuel tank vent Blocked fuel lter 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 Low power Adjust H screw Blocked fuel tank vent Blocked fuel lter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air lter 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 lter 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 and retardation Does not accelerate Adjust L screw Adjust H screw Blocked air lter Blocked fuel tank vent Blocked fuel lter Fuel line blocked Loose or damaged fuel hose Impulse channel blocked Loose cover on carburettor pump side Faulty 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 Adjust L screw Adjust H screw Blocked air lter Faulty pump diaphragm Faulty diffuser jets
Engine stalls when throttle released
Over rich acceleration
In addition to the faults described in the above table, trouble shooting can be carried out on specic 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
Will not fourstroke
Chain brake dismantling
WARNING! Make sure the spring does not y out and cause injury. Wear eye protection.
Disengage the brake by pushing the kickback guard backwards. Unscrew the guide bar bolts and remove the clutch cover, chain and guide bar. 2
Hand grip heater on model CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W removal
No heating or heating only in front hand grip Front hand grip troubleshooting 1
2 Reconnect the lead and ret the hand grip cover and cylinder cover. Switch troubleshooting 1 Carefully free the switch and frame from the front hand grip using a screwdriver. 2 Disconnect the leads from the switch and connect a multimeter to it. The meter should read over 1000 ohm when the switch is in the 0 position. The meter should read no higher than 0.1 ohm with the switch in the 1 position. Replace the meter if the readings are outside these limits. Rear hand grip heater not working Rear hand grip heater troubleshooting 1 Remove the cylinder cover, air lter and cover from the rear hand grip.
Remove the three bolts that secure the cover over the front hand grip. Disconnect the leads from the switch and generator and measure the resistance of the hand grip heater, which should be 34 ohm. Replace the front hand grip if the resistance is higher. 2
2 Disconnect the red lead from the heater and connect a multimeter between it and the black earth lead that is bolted to the bottom of the carburettor on the clutch side of the saw. The meter should read 0.71.2 ohm. If the reading is higher replace the heater element. 3 Remove the air lter, throttle pushrod, rubber diaphragm and carburettor, see Carburettor removal. 4 Remove the bolt from the plate at the base of the carburettor to release the lead for the heater element. 5
Reconnect the leads and ret the cover. 3 Push the switch back into place and reconnect the leads. 4 Bolt the cover back onto the hand grip. Generator troubleshooting 1 Remove the cylinder cover and cover from the front hand grip. Disconnect the black lead from the generator and connect a multimeter between it and a clean area on the cylinder. The multimeter should show a resistance of 0.91.3 ohm. If the reading is higher or lower, replace the generator, see Replacing the generator. 20 English
Unscrew the three bolts from the front hand grip and remove the cover to reveal the leads. Disconnect the red lead.
Repair instructions 6 Rear handle heater Measure the resistance between F and Z. It should be 1 0.5 ohm. If not, replace the rear handle heater. Generator Measure the resistance between G and H. It should be between 0.31.3 ohm. If not, replace the generator. Carburettor heater Disconnect the lead at X and clean the connectors. Measure the resistance between X and G. The reading should be between 310 ohms. If not, disconnect the lead at Y and clean the connectors. Measure the resistance between X and Y, if the reading is not between 37 ohms replace the carburettor heater.
Unscrew the two bolts from the right side of the rear hand grip. Remove the throttle lock and throttle handle, see Throttle trigger. Pull out the heater element with the leads still connected.
Troubleshooting carburettor heater (CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W)
Operation The carburettor temperature is controlled by an electronic thermostat to eliminate the risk of ice formation in the carburettor. The thermostat switches on/off at 12C/54F. This means that the saw operator does not need to remember to switch the carburettor heater on or off. Troubleshooting Front handle heater Remove the side cover from the handle. Disconnect the leads at F and G (see diagram). Clean the connectors. Turn the switch on. Measure the resistance between F and G. The reading should be 41 ohms. If not, disconnect the lead at O and remove the switch. Measure the resistance between O and F. The reading should be 41 ohms. If the resistance is incorrect, replace the front handle. Disconnect the lead at N and G and measure the resistance between these points. The reading should be no higher than 0.1 ohm. If it is too high, replace the lead. Switch Measure the resistance between N and O with the switch turned off. The reading should be ohms or higher. Repeat the measurement with the switch turned on. The reading should be no higher than 0.1 ohm. If it is too high, replace the switch.
Heater element and rear hand grip removal
1 Remove the cylinder cover, hand grip cover, hand grip and right-hand stop. Then remove: throttle lock, throttle trigger and recoil spring, see Throttle trigger. fuel hose and throttle pushrod from the carburettor Unbolt the rear tank mounting from the crankcase, i.e. the rear vibration damping spring, and both stops. Lower the tank as far as it will go to allow access to the heater lead where it is connected to the tank. Ret: fuel tank with both stops and the rear vibration damping spring throttle lock, throttle trigger and recoil spring, see Throttle trigger. fuel hose and throttle pushrod to the carburettor (check that the hose is not trapped between the tank and crankcase, measurement 43 mm/1.69 inches) hand grip cover, air lter and cylinder cover
Hand grip heater on model CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W retting
1 Feed the leads into the rear hand grip and insert the heater element in the hand grip. Screw in the two bolts through the right side of the hand grip to secure the heater. 2
Press the black lead into the base of the carburettor and connect it with the bolt. Tighten to a torque of 34 Nm. 3 Run the red lead to the front hand grip and connect it. 4 Press the throttle trigger and throttle lock into position and check that they work correctly, see Throttle trigger. 5
Repair instructions Model CS 2156, CS 2159
Replacing a worn recoil spring
WARNING! Make sure the recoil spring does not y out and cause injury. Wear eye protection.
1 Remove the bolt from the centre of the pulley and lift off the pulley and spring. 2 Remove the broken recoil spring. For model 2159: remove the recoil spring cassette. Cleaning and inspection: 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 light oil. 3 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152
Tensioning the recoil spring
1 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152 Fasten the starter cord in the notch in the pulley rim and wind the pulley about 2 turns clockwise. Check that the pulley is free to rotate at least another half turn when the starter cord is fully extended. Model CS 2156, CS 2159
Fit a new recoil spring, with the retaining wire still in place. Do not remove the wire until the spring is in position. If the spring comes loose when you put it in place wind it up from the outside working inwards. Lubricate the recoil spring with light oil. Model CS 2156, CS 2159
Lubricate the recoil spring with light oil. Fit the new recoil spring and cassette. Screw the cassette onto the cover using the two screws. 4 Fit the bolt through the centre of the pulley and tighten to a torque of 23 Nm. Tension the recoil spring, see Tensioning the recoil spring. 24 English
Starter assembly retting
Ignition module/ywheel removal
Position the starter assembly on the crankcase and tighten the bolts to a torque of 2.53.5 Nm.
Remove the cylinder cover. Disconnect the HT lead, remove the spark plug and t piston stop 15-01 in its place. Take off the starter assembly, release the leads from the cable guide and remove it. Model CS 2149, CS 2152: Remove the cover from the hand grip. 2
Ignition module testing
If there is a fault in the ignition system the ignition module must be tested before the ignition system is removed.
If replacing the ignition module, disconnect its leads and unscrew it. The ignition module can be left in place if you are simply removing the ywheel. 3 Test the ignition module as follows: Connect a test spark plug 13-01 to the ignition lead 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.
Loosen the ywheel nut using a suitable socket and unscrew it until it is ush with the end of the shaft.
Repair instructions 4
Clean all the carburettor components in petrol. Use an airline to dry off the petrol from all components. Blow through all the channels in the carburettor body and check that they are not blocked. Check that: The gasket, pump diaphragm and metering diaphragm are undamaged. There is no play in the throttle and choke valves.
The needle valve and its lever arm are not worn. The fuel lter is undamaged. The tips of the high and low speed jet screws are not damaged. The air intake duct is not cracked.
The item numbers in the diagram refer to the steps below (17). 1 Remove the cover from the metering unit and carefully remove the metering diaphragm and gasket. 2 Undo the screw and take out the needle valve, together with the lever arm, spindle and spring. 3 Remove the cover from the pump unit and carefully remove the gasket and pump diaphragm. 4 Remove the fuel lter. 5 Remove the high, low and idling jet screws. (HDA 159A high and low jet screws are protected by plastic caps which can be prised off with a screwdriver. Only on EPA, see appendix A.) 6 Remove the plug by rst drilling a hole in it and then prising it out with a screwdriver or the like. 7 If necessary remove the throttle and choke valves, and remove the spindles together with the lever arms and springs. 36 English NOTE! Cleanliness is very important when reassembling the carburettor. Tiny particles of dirt can cause operating problems.
The item numbers in the diagram refer to the steps below (18).
Repair instructions 1 If the throttle and choke butteries and their spindles were removed, these must be retted. Lubricate the spindle bearings with light oil. 2 Insert the plug in the hole with the convex side upwards and expand it by pressing downwards with a drift. 3 Ret the high and low speed jet screws and springs, plus the idling screw. Fit the plastic caps over the high and low speed screws. 4 Fit the fuel lter, using the handle of a small screwdriver. 5 Fit the pump diaphragm, gasket and cover to the pump unit. 6
Carburettor pressure testing
Pressure testing should be carried out with the carburettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but can also be performed for troubleshooting before dismantling. Carry out the test as follows: Screw in the high and low speed jet screws and back them off one turn. Connect pressure tester 38-01 to the carburettor fuel inlet.
Lower the carburettor into a beaker of water. Pump up the pressure to 50 kPa (0.5 bar) and clamp the pump tube. There should be no leakage. If leakage occurs, refer to the table below.
Push down the rear carburettor mounting into the rubber bushings using a small screwdriver. Remove tool 17-01. 5 Ret: cylinder, see special instructions silencer support (does not apply to CS 2141, CS 2145, CS 2150) air lter HT lead cylinder cover after the test run retighten the silencer bolts to a torque of 810 Nm
Repair instructions If it is not possible to check the maximum speed with a tachometer then the H jet should not be set to a weaker mixture than the basic factory setting. The recommended maximum speed must not be exceeded. NOTE! If the chain turns at idling speed, the T screw should be turned anti-clockwise until the chain stops. Fine adjustment Once the chainsaw is run in the carburettor should be readjusted. First adjust the L jet screw, then the idling screw T and nally the H jet screw. The recommended engine speeds are as follows: Model CS 2141 CS 2145 CS 2147 CS 2149 CS 2150 CS 2152 CS 2156 CS 2159 Max revs 12,500 rpm 12,500 rpm 14,200 rpm 13,000 rpm 13,000 rpm 13,000 rpm 14,000 rpm 13,500 rpm Idle revs 2,700 rpm 2,700 rpm 2,700 rpm 2,700 rpm 2,700 rpm 2,700 rpm 2,700 rpm 2,700 rpm Fine adjustment of idling speed T The idling speed is adjusted using the screw marked T. If adjustment is necessary, screw in the idling screw T until the chain starts to turn. Then screw it out until the chain stops moving. The idling speed is correctly set when the engine runs smoothly in all positions and there is a clear margin to the speed at which the chain starts to move. High speed jet H The high speed jet H inuences the saw power output and engine speed. If the H jet is set too weak the saw will over-rev, which could cause engine damage. Run the saw at full throttle for about 10 seconds. H=1. Then screw out the H screw 1/4 turn. H=1 1/4. Run the saw again at full throttle for about 10 seconds and listen to the difference in the engine note. Repeat this procedure again with the H screw screwed out another 1/4 turn. H=1 1/2. You have now run the saw at settings H 0, H = +1/4 and H = +1/2 from the factory setting. At full throttle the engine will sound different at each setting. The H screw is correctly adjusted when the saw burbles a little at full throttle without any load. If there is a lot of smoke from the silencer and the saw does not run smoothly then the setting is too rich. Screw in the H screw to the setting that sounds right. NOTE! For optimum adjustment, a tachometer should be used. The recommended maximum speed should not be exceeded. Carburettor correct adjustment When the carburettor is correctly adjusted the saw should accelerate without hesitation and the engine will burble a little at full throttle without any load. The chain must not turn when idling. If the L screw is set too weak this can make the saw difcult to start and cause poor acceleration. If the H screw is set too weak the saw will produce less power, poor acceleration and there is a risk of engine damage. If either the L or H screws are set too rich it will cause acceleration problems or too low working speed.
Basic requirements Before making any adjustments the air lter should be clean and the cylinder cover should be in place. If the carburettor is adjusted with a dirty air lter, the mixture will be too weak next time the air lter is cleaned. This can cause serious engine damage. Carefully screw in the L and H jets fully, then back them off 1 turn. The carburettor now has the settings H = 1 and L = 1. Start the chainsaw and allow it to warm up for 10 minutes. Place the saw on a at surface so that the guide bar is pointing away from you and the guide bar and chain are not touching the surface. Low speed jet L Find the highest idling speed by slowly screwing the L screw in and then out again. When the highest speed has been found, screw out the L screw 1/8 - 1/4 turn.
Fuel tank removal
WARNING! The fuel used in chainsaws is harmful if inhaled, may cause skin irritation and is highly ammable. 1 Empty the fuel tank. 2 Remove the following: cylinder cover air lter clutch cover chain and guide bar starter assembly cable guide 3 Disconnect the fuel hose from the carburettor. 4
Unscrew both stops and the three vibration damping springs from the ywheel side and clutch side of the engine. 6
Disconnect the pushrod from the carburettor by rst carefully prising up the spring over the end of the rod, where it connects to the throttle lever (A). Then press the throttle lever forwards (B) while pressing the throttle pushrod backwards (C) and lifting it off the lever. Withdraw the throttle pushrod from the tank and lift it upwards without pulling it through the rubber inlet manifold.
Disconnect and remove the fuel hose from the crankcase.
Carefully check that: there are no leaks from the fuel tank there are no leaks from the tank ller cap the fuel hose is undamaged and free from wear the fuel lter is not clogged the tank vent is not blocked or leaking the vibration damping springs and stops are not damaged
Tank vent testing
Replacing the fuel lter
NOTE! Do not use knurled pliers to disconnect or reconnect the fuel hose. This could damage the hose and lead to leakage or fracture. 1 First remove the old fuel lter from the tank unit using special tool 83-01. 2 Pull the fuel hose out of the tank and pull off the lter. 3 Fit the new fuel lter and feed the fuel hose back into position.
Connect pressure gauge 38-01 to the fuel hose. Pump the pressure up to 50 kPa (0.5 bar). The pressure should drop to 20 kPa (0.2 bar) within 60 seconds. 2
Replacing the fuel hose
NOTE! Do not use knurled pliers to disconnect or reconnect the fuel hose. This could damage the hose. 1 Before replacing the fuel hose, measure the length of hose between the crankcase and carburettor and between the tank and crankcase. The correct hose length between the tank and crankcase is 43 mm (1.69 inches). The correct hose length between the crankcase and carburettor is 53 mm (2.09 inches). 2 Remove the fuel hose from the fuel tank using tool 83-01. Trim off 5 mm (0.20 inches) from the mitred end of the hose. Fit the fuel lter and reinsert the hose in the tank.
Use gauge 37-01 to measure vacuum. Readings should be as follows: the vacuum should increase from 30 to 15 within 30 seconds. If readings are outside this range the vyon plugs must be replaced.
Fuel tank retting
1 Insert the fuel hose into the carburettor chamber. Ret the fuel tank. 2
Bolt the front vibration damping spring into position, followed by both stops and the remaining two vibration damping springs. Tighten to a torque of 23 Nm. Check that both vibration damping springs and the stops are correctly seated on the crankcase. Incorrect tting may result in higher vibration levels.
Piston and cylinder removal
1 Remove: cylinder cover carburettor (see Carburettor removal) silencer spark plug fuel tank (applies to CS 2141, CS 2145)
Fit the throttle pushrod in the tank and connect it to the carburettor. Ret the spring. 4
Connect the fuel hose to the carburettor. Check that the hose is not kinked or too long to be clamped between the crankcase and tank. The correct hose length between the tank and crankcase is 43 mm (1.69 inches). The correct hose length between the crankcase and carburettor is 53 mm (2.09 inches) excluding the mitred section. 5
Unbolt the vibration damping spring from the hand grip. 3
Undo the four cylinder bolts and lift the cylinder off carefully. Models CS 2141, CS 2145
Connect the fuel hose to the carburettor. 6 Then ret: cable guide starter assembly (2.53 Nm) chain and guide bar clutch cover air lter cylinder cover 46 English
Undo the four cylinder bolts from the underside and lift the cylinder off carefully.
Repair instructions 4 Cover the opening in the crankcase. 5 8
When replacing the cylinder CS 2141, CS 2145: Unscrew the decompression valve. (CS 2145) Remove the intake system, see Air intake system removal. Remove the circlips from the ends of the gudgeon pin and press it out. Then lift off the piston. 6 Model CS 2150 is tted with a spacer, which is secured using four bolts from the underside. The spacer does not however need to be removed when removing the cylinder.
Fit the cylinder bolts, tightening them in diagonal pairs to a torque of 810 Nm.
Piston and cylinder retting CS 2141, CS 2145, CS 2152, CS 2159
1-5 See Piston and cylinder CS 2147, CS 2149, CS 2150, CS 2152, CS 2156, CS 2159 Retting points 1-5. 6 Apply silicone adhesive/sealing compound (037062) to the crankcases contact surfaces with the cylinder. Carefully slide the cylinder down over the piston towards the big end bearing. Note! Work is facilitated if the crankshaft complete with bearing and piston is released from the crankcase and the piston is pushed into the cylinder. The unit is then retted in the crankcase. 7
Cylinder pressure testing
Loosen the carburettor bolts so that the carburettor can be moved back about 4 mm. Insert cover plate 11-02 between the carburettor and the carburettor ange. Tighten the carburettor bolts to a torque of 11.5 Nm. Loosen the silencer bolts so that the silencer can be moved back about 4 mm. Insert cover plate 11-02 between the silencer and the exhaust ange on the cylinder ange. Tighten the silencer bolts to a torque of 810 Nm. Unscrew and remove the spark plug. Screw in pressure test nipple 40-02. Connect tool 38-01 to the nipple. The decompression valve must be closed. The decompression valve must be closed. To check the decompression valve itself, see Decompression valve pressure testing. Pump up the pressure 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 specied torque. Remove the pressure test nipple 40-02 and ret the spark plug. WARNING! After pressure testing the cylinder, check that the inlet manifold is seated correctly, otherwise the saw may be damaged.
Fit the cylinder bolts, tightening crosswise to a torque of 1315 Nm. 8 Pressure test the cylinder. 9 Ret: spark plug, tighten to a torque of 15 Nm carburettor, see Carburettor retting, silencer, tighten to a torque of 810 Nm cylinder cover
NOTE! If a new piston or cylinder has been tted the saw must be run for the rst 34 hours with carburettor adjusted to the factory settings.
Crankcase and crankshaft dismantling CS 2147, CS 2149, CS 2152, CS 2156, CS 2159
1 Remove the following: guide bar and chain clutch cover cylinder cover starter assembly* ignition system* generator* centrifugal clutch* oil pump* bark rest chain tensioner throttle pushrod carburettor* carburettor base silencer* piston and cylinder* fuel tank* * See special instructions. NOTE! Take care to prevent dirt or foreign particles getting into the bearings. 2
Split the crankcase with the aid of tool 6101 (A) and stop plate 18-01 (B), working from the ywheel side of the saw. 4
Press the crankshaft out of the ywheel side of the crankcase using tool 61-01. 5 Do the same on the clutch side without using stop plate 18-01.
Unscrew the 6 bolts that hold the crankcase together.
Crankshaft complete - dismantling CS 2141, CS 2145, CS 2150
1 Remove the following: chain and bar clutch cover cylinder cover starter assembly* ignition system* generator centrifugal clutch* throttle pushrod carburettor* silencer* piston and cylinder* fuel tank* * See special instructions. 2
Crankshaft bearings replacement CS 2147, CS 2149, CS 2152
If the crankshaft bearings are to be replaced, tap them out gently using drift 30-18.
The new bearings must be shrunk-t into the crankcase using a hot air gun.
Clean and inspect all parts carefully.
Sealing ring replacement
Remove the sealing ring from the magnet side using tool 55-01.
Sealing ring replacement - drive side
Lift the crankshaft completely out of the crankcase. CS 2150: Unbolt the four bolts from underneath and lift off the spacer. Lift the crankshaft completely out of the crankcase. Remove the oil pump. 1
Pry up the sealing ring from the bearing by using a small screwdriver or the like. Note. The sealing ring can be replaced without the need of removing the bearing. 2 Press the new sealing ring into the bearing.
Crankshaft bearings replacement CS 2156, CS 2159
If the crankshaft bearings are to be replaced they must be pulled off the crankshaft using puller 90-02. The new bearings must be shrunk-t into the crankcase using a hot air gun. Heat the crankcase half to around 130C and t the new bearing.
Crankshaft bearings CS 2141, CS 2145, CS 2150 replacement
Remove: The crankshaft complete from the crankcase, see page 47.
1 Pull off the crankshaft bearing from crankshaft. 2 Fit a new bearing on the crankshaft.
Remove the sealing ring from the crankcase using a small screwdriver. NOTE! Take care to avoid damaging the crankcase.
Crankcase and crankshaft reassembly CS 2147, CS 2149, CS 2152
To t the sealing ring use the sleeve that is supplied with 30-16. The end with the half moon is used for the sealing ring on the clutch side, which must be tted ush with the surface of the crankcase. The other end of the sleeve is used to t the sealing ring on the ywheel side and ensures that the sleeve is tted at the correct depth, 1.8 mm. Lubricate the sealing rings with oil.
Hold the clutch side of the crankcase in a vice. Pull the crankshaft into its bearing using assembly tools 30-18.
Repair instructions 2 fuel tank* piston and cylinder* generator* carburettor base carburettor* throttle pushrod silencer* Check that the guide pins are in place. Fit a new gasket to the mating surface of the clutch side of the crankcase. 3 ignition system* starter assembly* cylinder cover clutch cover guide bar and chain * See special instructions. NOTE! If a new crankshaft has been tted the saw must be run in for 3-4 hours with the carburettor adjusted to the factory settings.
Crankcase and crankshaft reassembly CS 2156, CS 2159
Place the ywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 30-18. 4
Hold the clutch side of the crankcase in a vice. Pull the crankshaft into its bearing using assembly tools 30-16. 2 Fit and tighten the six crankcase bolts to a torque of 810 Nm. Check that the crankshaft rotates freely. 5 Ret the following parts: bark rest oil pump* chain tensioner centrifugal clutch* 54 English Check that the guide pins are in place. Fit a new gasket to the mating surface of the clutch side of the crankcase.
Repair instructions 3 ignition system, 8-10 Nm, see Ignition module and ywheel - retting starter assembly, 2,5-3,5 Nm, see Starter assembly - retting cylinder cover clutch cover guide bar and chain NOTE! If a new crankshaft has been tted the saw must be run in for 3-4 hours with the carburettor adjusted to the factory settings.
Crankshaft complete CS 2141, CS 2145, CS 2150 reassembly
Place the ywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 30-16. 4
1 Fit the crankshaft complete in the crankcase. Fit and tighten the six crankcase bolts to a torque of 810 Nm. Check that the crankshaft rotates freely. 5 Ret the following parts: bark rest, 8-10 Nm oil pump, 3-4 Nm, see Oil pump - retting chain tensioner centrifugal clutch, min 20 Nm, see Centrifugal clutch - retting fuel tank, see Fuel tank - retting piston and cylinder, see Piston and cylinder - retting generator, see Replacing the generator carburettor base, 3-4 Nm carburettor, 1-1,5 Nm, see Carburettor - retting throttle pushrod silencer, 12-14 Nm, see Silencer - retting CS 2150: Fit and tighten the four bolts holding the spacer from underneath and t the crankshaft complete in the crankcase. Ret the following parts: piston and cylinder* fuel tank* silencer* carburettor* throttle pushrod centrifugal clutch* generator* ignition system* starter assembly* cylinder cover clutch cover chain and bar * See special instructions.
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