REPAIR MANUAL EA3201S35B PS-32C
CONTENTS Page Technical data ............................................................................................................................................................................. 3 Troubleshooting........................................................................................................................................................................... 4 00 Special tools ...................................................................................................
TECHNICAL DATA Stroke volume Bore Stroke Max. power at speed Max. torque at speed Idling speed / max. engine speed with bar and chain Clutch engagement speed Sound pressure level at the workplace LpA eq per ISO 22868 1) 3) Sound power level LWA eq per ISO 228681) 3) Vibration acceleration ah,w eq per ISO 22867 1) 3) - Tubular handle - Rear handle Carburetor Ignition system Spark plug Electrode gap or spark plug Fuel consumption at max. load per ISO 7293 Specific consumption at max.
TROUBLESHOOTING Malfunction System ___ Observation Cause Chain does not run Chain brake Engine runs Chain brake actuated Engine does not start or only with difficulty Ignition system Ignition spark Malfunction in fuel supply system, pressure system, mechanical malfunction. No ignition spark Combination switch in pos.
00 SPECIAL TOOLS ___ 1 Torx screwdriver Grip T-grip 200 mm T-grip 100 mm 2 1 2 Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread 3 3 (944.500.860) (944.500.862) (944.500.861) (944.500.880) Setting gauge Gauge for measuring the gap between flywheel and armature (944.500.891) 4 5 5 4 Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000 Torque wrench 3/8” Drive socket Bit 152 mm Bit 49 mm (944.500.864) (944.500.865) (944.500.
00 SPECIAL TOOLS ___ 6 Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch (944.500.695) 7 Electronic tachometer for measuring the engine speed of 2- and 4-stroke engines (950.233.220) 7 6 Tachometer 8 Needle-nose pliers Various assembly/ disassembly tasks 9 (944.603.400) Disassembly hook Removal/installation Brake band spring (950.237.
00 SPECIAL TOOLS 11 Sealing plate For sealing intake side (944.603.040) 12 Sealing plate For sealing exhaust side 13 Ignition tester M4 x 20 Checking the ignition 11 (944.603.140) (950.233.230) 12 14 Mounting tool Bearings on crankshaft 13 Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000 (944.500.
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM 2 1 4 3 Remove the sprocket guard, bar, and chain. If necessary, turn adjusting screw 2 clockwise, until the fastening screw 4 is accessible. Chain tensioner Unscrew the fastening screw and pull the chain tensioner up and out. Carefully pull the chain guide plate off the front bar pin 1 . Assembly Grease spindle and worm gear with multipurpose grease (944.360.000).
02 CLUTCH DRUM AND CHAIN SPROCKET Clutch drum with sprocket and needle bearing Check the chain sprocket 1 for damage and wear. 3 2 1 Remove the sprocket guard, bar, and chain. Remove the circlip 3 with a blade screwdriver. Remove washer 2. Pull the handguard towards the front grip only as far as necessary so the clutch drum can be removed. Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000 Check the clutch drum needle bearing for wear and damage.
03 CHAIN BRAKE 1 2 1 Removing the brake band CAUTION: Wear protective gloves to prevent cuts! 3 4 Lift the brake band 3 upward and turn it out of the disengagement mechanism 4. 5 Secure the chain saw from slipping (vise). Using the disassembly hook (Chap. 00, Pos. 9), disengage the brake band spring 5. 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.
03 CHAIN BRAKE 10 9 7 8 6 Pull the handguard off pin 8 using light backand-forth motions. 10 Note: When reassembling, always use a new circlip 6 (927.304.000)! Install the handguard in the reverse order. Make sure that the handguard guide 10 is not unhooked. If necessary, push it back into position with a screwdriver (about 4 mm from pin 9). The handguard can only be assembled when the rest piece is in this position. Removing the hand guard and disengagement mechanism ca.
04 CLUTCH 2 1 3 4 Disassembly CAUTION: To prevent cuts, wear protective gloves! Move piston to bottom dead centre (visible through the exhaust opening). Remove the sprocket guard, bar and chain. Press the piston stop wedge 3 (cap. 00, pos. 5) into the exhaust opening. Pull the handguard towards the front handle to release the chain brake if necessary. Position of gasket and cooling plate for muffler assembly: Remove the clutch drum, see Chapter 02. 5 Insert wrench 4 (Chap. 00, Pos.
04 CLUTCH ___ Inserting the flyweights Installing the clutch Hook the springs as shown in the illustration. Install the clutch with the arrow marking point outside. The press the flyweights onto the guide. To do this, first push on one flyweight, then put on the second flyweight. Press the flyweights all the way onto the guide. CAUTION: Note the position of the springs. Do not replace springs individually! If a spring breaks or is fatigued, all two springs must be replaced. Torque: 35 ± 2.
05 OIL PUMP 1 5 9 10 A 4 3 3 1 2 2 General Flathead screw No.: 165.888.110 The oil pump is driven by the drive worm gear 1 on the crankshaft. Removing the oil pump Push the adjusting screw 6 up against the spring pressure and turn it until the pin 7 goes into the assembly slit 7. If necessary press the supply piston 8 in somewhat. This gear engages the oil pump piston 3. Consequently, the oil pump operates only when the engine is on.
06 STARTER ___ If the spring pops out, put it back into the plastic housing as shown in the schematic. 5 Assembly 6 Note: If installing a new return spring cassette, grease it on the spring side. Carefully insert new return spring cassette 9. Lightly grease the surface of the spring and spring cassette with multipurpose grease (944.360.000). Thread in a new starter cable (dia 3.5 mm / 1/8“, length 900 mm / 35.4“) as shown in the illustration, tie a knot in both ends, and tighten both knots.
07 IGNITION SYSTEM (TROUBLE-SHOOTING) Is the spark plug dry and properly installed? ___ no Dry spark plug connector and fasten firmly to spark plug. yes Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Is there carbon black on the electrodes? yes no Is the spark gap correct? (should be 0.5 mm) no yes Is the spark plug oily or does it have carbon deposits on it? no Adjust spark gap. yes Wash spark plug in acetone. Do not sandblast! If necessary, replace spark plug.
07 IGNITION SYSTEM Removing the flywheel Remove starter see chap. 06. Block the piston, see chap. 04. Loosen the nut in the direction of the arrow and remove it along with the washer. ___ Screw the disassembly mandrel (chapter 00 pos. 2) onto the threaded end of the shaft. Do not screw the mandrel all the way down. Leave about 2 mm between the mandrel and the flywheel. Hold the machine in one hand or place on a soft surface, and knock the flywheel loose with a tap on the mandrel.
07 IGNITION SYSTEM 2 3 ___ 4 Note: Check the starter pawls on the flywheel for easy movement, and clean if necessary. 1 Removing the ignition armature Installing the ignition armature Remove cover. NOTE: The high-voltage cable is moulded onto the ignition system and cannot be replaced separately. Remove the starter. See Chap. 06. Pull off short-circuit cable 2. Unscrew 2 screws on ignition armature 3. Note: Be aware of the 2 plastic washers between the cylinder and the ignition armature.
08 CARBURETOR ___ 3 ON 4 2 1 Removing the intake manifold and carburetor CAUTION: Completely empty the fuel tank before disassembling the carburetor! Remove cover. Move combination switch 1 to safety position. Unscrew 2 screws 2. Remove the air filter and intake manifold 3. Pull the fuel lines and pulse line from the carburetor. CAUTION: There is fuel in the line. Catch escaping fuel with a cloth. Remove the carburetor and throttle linkage.
08 CARBURETOR 9 8 ___ 10 11 12 ON 7 6 Make sure that the intermediate flange goes into its space on the cylinder side. When lowering the cylinder make sure that the pulse line 10 and the red fuel line 11 enter the carburetor area. Before completely lowering the cylinder make sure that the short-circuit cable is led into the openings 8. Tighten the screws 4 by hand evenly alternating crosswise and then tighten to the right torque (10 +/- 0.5 Nm), likewise alternating crosswise.
08 CARBURETOR ___ General check Screen 7 for contamination Pulse hole for contamination Base Setting L= 2 H= 4 NOTE: Adjust the carburetor only using a tachometer. 6 Pressure test Connect the pressure gauge (chapter 00 item 10) to the carburetor fuel connection 1. Set up a pressure of max. 0.5 bar.
09 VIBRATION DAMPER ___ Disassembly Springs 1 and 2 Remove the sprocket guard. Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). 4 Pull out damping spring. Spring 3 3 Remove starter housing (see chap. 06). Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). Pull out damping spring. Spring 4 Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). Remove damping spring. Remove spring bush.
10 TANK ___ In assembly, first place the throttle lever spring 3 on the throttle lever, then push the lever onto the hinge with the slot. The throttle lever must be turned by 180° to do this. 1 The catch lever 4 can easily be pushed through the chamfer on the seat. The spring is engaged in the throttle lever as shown below. 3 Grip mechanism Unscrew screw 1 and pull the lower grip half slightly up and to the rear in the area of the screw hole.
10 TANK ___ Removal Pressure test Vacuum testing ventilation valve 6 Unscrew all middle screws of the damping springs (Chapter 09). Also remove the damping spring 2. Attach the over/underpressure pump (chap. 00 pos. 10) to one of the two fuel connections 5 . Seal off the second connection. Set up a pressure of max. 0.3 bar. If the pressure drops off, check the following: • Air valve • Both fuel lines • Fuel nipple • Tank cap O-ring • Check tank for holes Note: Detergent can be used to localise leaks.
11 CYLINDER / PISTON ___ Seal off the pulse line 6 and bring the cylinder to top dead center. 6 1 M4 x 25 Set up an underpressure of max. 0.3 bar. 3 4 2 5 Vacuum testing If correct carburetor setting is not possible, it will be necessary to test a leakage of the engine. Remove hood. Remove the muffler. See Chap. 04. Remove carburetor (see chap. 08). To seal the outlet side, screw on the sealing plate 4 (Chap. 00 Pos.12) and muffler gasket 3.
11 CYLINDER / PISTON ___ Assembling the cylinder and piston 8 Before assembly, wet the cylinder path, piston and needle bearing with oil! Use a new crankcase gasket and new seal rings. If the engine was removed to localize leaks, insert the bushings (base to cylinder) into the engine housing. 7 Insert the bottom half of the crankcase. Position the crankshaft in the bottom half. Further procedure as described in “Chap. 08 Carburetor” under Assembly.
12 TORQUES Fastener ___ Part No. Size Qty. Torque [Nm] Cylinder to engine mount 913.350.404 5 x 40/20 Torx/Schlitz 4x 10 +/-0,5 Intermediate flange to engine mount 913.455.164 5,5 x 16 Torx 2x 4 +/-0,5 Muffler fastening to cylinder 908.005.165 M 5 x 16 Torx 2x 8 +/-1 Front shell to muffler 165.888.030 M 5 x 16 Torx 2x 8 +/-1 Front shell to cylinder 165.888.040 M 5 x 40 Torx 1x 8 +/-1 Carburetor to flange ring 165.888.020 M 4 x 40 Torx 2x 3 +/-0,5 Clutch 165.180.
___ DOLMAR GmbH • Postfach 70 04 20 • D-22004 Hamburg • Germany Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32 28
