Dolmar PS-350 User Manual

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Repair Manual

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PS-350

PS-420

Caution:

Before doing any maintenance or service work, the combination switch must be engaged in the service position, in order to prevent unintended starting by the easy start system!

www.dolmar.de

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

1

CONTENTS

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Page

 

Technical data ...........................................................................................................................................................................

3

 

Troubleshooting ........................................................................................................................................................................

4

00

Special tools..........................................................................................................................................................................

5 - 7

01

Sprocket guard / Chain tensioning system ................................................................................................................................

8

02

Clutch drum with chain sprocket ...............................................................................................................................................

9

03

Chain brake / Guide bar bolt ............................................................................................................................................

10 - 11

04

Clutch................................................................................................................................................................................

12 - 13

05

Oil pump...................................................................................................................................................................................

14

06

Starter ......................................................................................................................................................................................

15

07

Ignition system (trouble-shooting) ............................................................................................................................................

16

07

Ignition system .................................................................................................................................................................

17 – 18

08

Carburetor........................................................................................................................................................................

19 – 20

09

Vibration damper......................................................................................................................................................................

21

10

Tank .................................................................................................................................................................................

22 – 23

11

Cylinder / Piston ..............................................................................................................................................................

24 – 26

12

Crankcase / Crankshaft ...........................................................................................................................................................

27

13

Torques ...................................................................................................................................................................................

28

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

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TECHNICAL DATA

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PS-350

PS-420

Stroke volume

cm3

34.7

42.4

Bore

mm

38

42

Stroke

mm

30.6

30.6

Max. power at speed

kW / 1/min

1.5 /

9,500

2.0 /

9,500

Max. torque at speed

Nm / 1/min

1.9 /

6,500

2.4 /

6,500

Idling speed / max. engine speed with bar and chain

1/min

2,800 /

13,500

2,800 /

13,500

Clutch engagement speed

1/min

5,100

5,100

Sound pressure level at the workplace LpA av per ISO/CD 22868 1)

dB (A)

100.8

100.8

Sound power level LWA av per ISO/CD 22868 1)

dB (A)

110

110

Vibration acceleration ah,w eq per ISO 22867 1)

m/s2

4.3

3.6

 

- Tubular handle

 

- Rear handle

m/s2

3.6

3.2

Carburetor (diaphragm, choke flap carburetor)

Typ

membrane carburetor

membrane carburetor

Ignition system

Typ

electronic

electronic

Spark plug

Typ

NGK BPMR 7A

NGK BPMR 7A

Electrode gap

mm

0.5

0.5

or spark plug

Typ

BOSCH WSR 6F, CHAMPION RCJ 6Y

BOSCH WSR 6F, CHAMPION RCJ 6Y

Fuel consumption at max. load per ISO 7293

kg/h

0.79

0.96

Specific consumption at max. load per ISO 7293

g/kWh

526

480

Fuel tank capacity

l

0.48

0.48

Chain oil tank capacity

l

0.28

0.28

Mixture ratio (fuel/two-stroke oil)

 

50 : 1 / 100: 1 (HP-100)

50 : 1 / 100: 1 (HP-100)

 

- when using DOLMAR oil

 

 

- when using Aspen Alkalyt (two-stroke fuel)

 

50 : 1 (2%)

50 : 1 (2%)

 

 

 

 

 

 

- when using other oils

 

40 : 1 (quality grade JASO FC or ISO EGD)

40 : 1 (Qualitätsstufe JASO FC oder ISO EGD)

 

 

 

 

Chain brake

 

engages manually or in case of kickback

engages manually or in case of kickback

Chain speed at max. power

m/s

18.1

18.3

Sprocket pitch

inch

3/8

.325

Number of teeth

Z

6

7

Chain type

 

see the spare-parts list

see the spare-parts list

Pitch / gauge

inch

3/8 / 0.050 (1.3)

.325 / 0.050 (1.3)

Guide bar, length of a cut

cm

30, 35, 40

33, 38, 45

Guide-bar type

 

see the spare-parts list

see the spare-parts list

Weight (fuel tank empty, without chain, guide bar and accessories)

kg

4.7 /

4.8 2)

4.7 /

4.8 2)

1)Figures derived in equal part from idling, full-load and racing speed.

2)On models with catalytic converter.

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

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TROUBLESHOOTING

 

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Malfunction

System

Observation

Cause

 

 

 

 

 

 

 

 

Chain does not run

Chain brake

Engine runs

Chain brake actuated, Chain too tight

 

 

 

 

 

 

 

 

Engine does not start

Ignition system

Ignition spark

Malfunction in fuel supply system, pressure system,

 

 

or

 

 

mechanical malfunction.

 

 

only with difficulty

 

 

 

 

 

No ignition spark

STOP switch stuck in service position, fault or short-

 

 

 

 

 

 

 

 

 

 

 

circuit in the wiring,

 

 

 

 

 

 

plug cap or spark plug defective,

 

 

 

 

 

 

gap between ignition module and flywheel uneven or too

 

 

 

 

 

 

wide

 

 

 

 

Fuel supply

Fuel tank is filled

Combination switch in Choke position,

 

 

 

 

 

 

carburetor defective, suction head dirty,

 

 

 

 

 

 

fuel line bent, leaky or interrupted.

 

 

 

 

Compression

Inside system

Cylinder base packing ring defective, radial shaft

 

 

 

 

 

 

packings defective,

 

 

 

 

 

Outside

cylinder or piston rings defective

 

 

 

 

 

Spark plug does not seal.

 

 

 

 

Mechanical malfunction

Starter does not engage

 

 

 

 

 

 

 

 

 

 

 

 

Spring in starter broken, broken parts inside the engine.

 

 

 

 

 

 

 

 

Engine speed gets

Multiple systems

Engine speed about

Carburetor too lean

 

 

“stuck”

 

4,500 - 6,000 rpm

Bleed air at cylinder and/or rubber induction piece

 

 

 

 

 

 

 

 

 

 

 

Fuel line bent, throttle link stuck

 

 

 

 

 

 

 

 

Warm engine won’t

Carburetor

Fuel tank is filled

Wrong carburetor adjustment

 

 

start

 

Ignition spark

Flooded from choke use

 

 

 

 

 

 

 

 

 

 

 

Piston ring worn (max. thrust play 0.5 mm)

 

 

 

 

 

 

 

 

Engine starts, but

Fuel supply

Fuel tank is filled

Wrong idling adjustment, suction head or carburetor dirty,

 

 

dies immediately

 

 

tank venting defective, fuel line interrupted, cable

 

 

 

 

defective, Choke flap closed, decompression valve dirty

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Insufficient power

Several systems

Engine is idling

Air filter dirty, incorrect carburetor setting, muffler

 

 

 

 

may be involved

 

clogged, exhaust channel in cylinder clogged, spark

 

 

 

 

 

arrester screen clogged.

 

 

 

 

simultaneously

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No chain lubrication

Oil tank/pump

No oil on the chain

Oil tank empty

 

 

 

 

 

 

Oil guide groove dirty, Oil suction head dirty

 

 

 

 

 

 

Oil pump adjusting screw incorrectly adjusted

 

 

 

 

 

 

Oil pump worm drive gear defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

 

4

 

00 SPECIAL TOOLS

 

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1

Torx screwdriver

 

 

Grip

(944.500.860)

 

T-grip 200 mm

(944.500.862)

 

T-grip 100 mm

(944.500.861)

2

Mandrel

 

 

Disassembly mandrel for

 

 

tapping out the flywheel

 

 

without damage to

 

 

the crankshaft thread

(944.500.880)

1

2

3

5

4

3 Setting gauge

 

Gauge for measuring the gap

 

between flywheel and

 

armature

(944.500.891)

4 Torque wrench

 

3/8” Drive socket

(944.500.864)

Bit 152 mm

(944.500.865)

Bit 49 mm

(944.500.866)

Torque wrench

 

3/8” Drive

(950.230.000)

5 Piston stop wedge

Wedge for blocking

 

the engine through the

 

exhaust port

(944.602.001)

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

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00 SPECIAL TOOLS

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6

7

8

9

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

12

13

6

Piston ring tensioner

 

 

Piston ring band and

 

 

assembly tool for cylinders

(944.600.001)

7

Assembly and disassembly wrench

 

Wrench for disassembling and

 

assembling the centrifugal

 

 

clutch

(944.500.590)

8

Pressure gauge

 

 

Pressure guage for checking

 

 

the carburetor fuel valve

(956.004.000)

9

Tachometer

 

 

Electronic tachometer for measuring

 

the engine speed of

 

 

2- and 4-stroke engines

(950.233.220)

10

3/8” socket

 

 

Installation/removal of

 

 

Spark plug, clutch

(944.500.864)

11

Needle-nose pliers

 

 

Various assembly/

 

 

disassembly tasks

(944.603.400)

12

Disassembly hook

 

 

Removal/installation

 

 

Brake band spring

(950.237.000)

13

Over/underpressure pump

 

For checking sealing of

 

 

radial rings and gaskets

(957.004.001)

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

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00 SPECIAL TOOLS

 

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14

Sealing plate

 

 

For sealing intake side

(944.603.020)

15

Sealing plate

 

 

For sealing exhaust side

(944.603.170)

14

15

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

7

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

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1

 

Remove the sprocket guard, bar, and chain.

If necessary, turn adjusting screw 1 clockwise,

Assembly

CAUTION: Do not work on the chain brake

until the fastening screw is accessible.

Grease spindle and worm gear with multi-

Unscrew the fastening screw and pull the

unless the spring is detensioned!

purpose grease (944.360.000).

chain tensioner up and out.

 

 

Chain tensioner

 

 

Carefully take the chain guide cover off the guide bar bolts.

Unscrew 4 screws, and remove the spike bar and the cover.

Chain tensioner function

An angled worm drive converts the turns of the adjustment screw 1 to forward or backward motion of the tensioning pin.

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

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02 CLUTCH DRUM AND CHAIN SPROCKET

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Remove the sprocket guard, bar, and chain.

Remove the circlip 4 with the universal wrench.

Remove cup washer 3.

Pull the handguard towards the front grip only as far as necessary so the clutch drum can be removed.

 

Clutch drum with sprocket and needle

 

bearing

4

Check the chain sprocket 2 for damage and

 

wear.

 

Important customer information:

Before installing a new saw chain, always check the condition of the chain sprocket. A

3 worn chain sprocket will damage a new saw chain, and must be replaced.

 

Check the clutch drum needle bearing for

 

wear and damage.

2

Assembly the bearing with multi-purpose high-

performance grease (944.360.000).

 

 

Check the inside of the clutch drum for

 

damage and wear.

1

Replace the clutch drum if damaged or worn.

 

Note: Always use a new circlip 4

 

(927.408.000)!

 

When assembling the clutch drum, make

 

sure that the lug of the oil pump drive 1 is

 

not positioned on the oil pump drive. When

 

inserting, turn the clutch drum slightly.

RepairReparaturanleitungmanual PS-350PS/ PS-4600-420/ PS-5000

9

03 CHAIN BRAKE / GUIDE BAR BOLT

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1

2

Removing the brake band

CAUTION: Wear protective gloves to prevent cuts!

Remove the sprocket guard, bar, and chain.

Remove the clutch drum, see Chapter 02.

Push the hand guard forward to engage the chain brake. This tensions the brake band spring.

Remove the cover plate, see Chapter 01.

Fold the brake band 1 upward and turn it out of the disengagement mechanism 2.

3

Secure the chain saw from slipping (vise).

Using the disassembly hook (Chap. 00, Pos. 12), disengage the brake band spring 3.

Repairaturanleitungmanual PS-350PS/-4600PS-420/ PS-5000

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+ 22 hidden pages