REPAIR MANUAL DCS460 DCS510 DCS5121 EA5000P53G PS-460 PS-510 PS-5105
CONTENTS Page Technical data ........................................................................................................................................................................... 3 Troubleshooting ........................................................................................................................................................................ 4 00 Special tools........................................................................................................
TECHNICAL DATA Stroke volume Bore Stroke Max. power at speed 3) Max. torque at speed 3) Idling speed / max. engine speed with bar and chain Clutch engagement speed Sound pressure level at the workplace LpA av per ISO/CD 22868 1) Sound power level LWA av per ISO/CD 22868 1) Sound Pressure Level at the operator‘s ear at full load according to ANSI B 175.1 Sound Pressure Level at the bystander‘s position (50 ft/15 m distance) according to ANSI B 175.
TROUBLESHOOTING Malfunction System ___ Observation Cause Chain does not run Chain brake Engine runs Chain brake actuated, Chain too tight Engine does not start or Ignition system Ignition spark Malfunction in fuel supply system, pressure system, only with difficulty mechanical malfunction.
00 SPECIAL TOOLS 1 Torx screwdriver Grip T-grip 200 mm T-grip 100 mm 2 Radial ring puller 13 mm radial ring puller Spindle 3 1 2 4 (944.500.871) (950.203.020) Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread 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.
00 SPECIAL TOOLS 7 Piston ring tensioner Piston ring band and assembly tool for cylinders 8 (944.600.001) Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch (944.500.590) 7 8 9 9 Pressure gauge Pressure gauge for checking the carburetor fuel valve (956.004.000) 10 Tachometer Electronic tachometer for measuring the engine speed of 2- and 4-stroke engines (950.233.220) 11 10 11 3/8” socket Installation/removal of Spark plug, clutch (944.500.
00 SPECIAL TOOLS 15 Sealing plate For sealing intake side (944.603.170) 16 Sealing plate For sealing exhaust side 15 (944.603.
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM 1 Chip deflector in the sprocket guard CAUTION: To prevent cuts, wear protective gloves! Remove the sprocket guard, bar, and chain. Use the combination wrench to disengage the chip deflector, and remove it. Note for changing the type of chain: If using a 3/8" saw chain, be sure to first cut out the the marked portion of the chip deflector 1! Before converting to a.325” chain it will be necessary to install a new chip deflector (957.213.220).
02 CLUTCH DRUM / RIM SPROCKET Chain sprocket and clutch drum with needle bearing 5 Check the chain sprocket 4 for damage and wear. Important customer information: 4 Before installing a new saw chain, always check the condition of the chain sprocket. A worn chain sprocket will damage a new saw chain, and must be replaced. Check the clutch drum needle bearing for wear and damage. Assemble the bearing with multi-purpose highperformance grease (944.360.000). Remove the sprocket guard, bar, and chain.
03 CHAIN BRAKE / GUIDE BAR BOLT 1 2 6 3 4 Removing the brake band Secure the chain saw from slipping (vise). CAUTION: To prevent cuts, wear protective gloves and remove the spike bar (2 bolts)! Using the disassembly hook (Chap. 00, Pos. 14), disengage the brake band spring 3. 5 Remove the handguard and disengagement mechanism Remove the hood. Remove the sprocket guard, bar, and chain. Unscrew bolt 4 and pull out the sleeve 5.
03 CHAIN BRAKE / GUIDE BAR BOLT 7 Remove the circlip 7. Replacing the guide bar bolt Pull the handguard and disengagement mechanism up and out parallel to their axes. Screw two nuts onto the bar bolt and counterlock them. When reassembling always use a new circlip 7 (927.304.000)! Unscrew the bar bolt. Assemble the handguard and disengagement mechanism, brake band and brake band spring in reverse order. Assembly: Screw in bar bolt to 20.5 ± 0.5 mm and secure with Loctite 243 (980.009.000).
04 CLUTCH 5 4 6 2 2 1 1 7 3 Disassembly Remove the hood. 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. Push the piston stop wedge 6 (944.602.000) into the exhaust opening. Pull the handguard towards the front handle to release the chain brake if necessary. Remove the clutch drum, see Chapter 02. Remove the muffler.
04 CLUTCH Inserting the flyweights Hook the springs as shown in the illustration. The press the flyweights onto the guide. To do this, first push on two flyweights half-way, then put on the third flyweight by setting it on its edge. Press the flyweights all the way onto the guide. Press the disc onto the clutch. It must be flat and be engaged. Installing the clutch Install the clutch with the arrow marking point up.
05 OIL PUMP 1 1 2 A 4 10 3 General The oil pump is driven by the clutch drum. Lugs on the clutch drum transfer the power to the drive arms of the oil pump drive 1. The drive worm of the oil pump drive engages in the teeth of the oil pump 3. This means that oil is pumped only when the chain is running. The oil flow rate can be adjusted with adjusting screw A: • Turn right for more oil • Turn left for less oil Disassembly Remove the clutch drum and clutch, see chapter 04.
06 STARTER Knock the fan housing against a tabletop with the entire contact surface of the hollow side, so that the return spring cassette 8 pops out of the fan housing. Caution! The return spring can jump out of the plastic cassette! Always wear protective goggles and gloves! If the spring pops out, put it back into the plastic housing as shown in the schematic. 1 2 3 Disassembly Unscrew four screws 1. 4 Remove fan housing 2. Remove air guide 3 from fan housing. 8 Detension the return spring.
07 IGNITION SYSTEM (TROUBLE-SHOOTING) Is the spark plug dry and properly installed? no yes Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Is there carbon on the electrodes? yes no Is the spark gap correct? (should be 0.5 mm) no Install ignition testing lamp. Alternatively, insert universal wrench between cylinder and hood. The wrench must have metallic contact with the cylinder. Caution: Do not insert the wrench into the spark plug hole or hold with hand.
07 IGNITION SYSTEM 2 1 Removing the flywheel Block the piston. To do this, see 04 CLUTCH. Loosen the nut in the direction of the arrow and remove it along with the washer. Screw the disassembly mandrel (944.500.880) 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. Removing the ignition armature Unscrew 2 screws on ignition armature 1. Unscrew ignition cable screw 2. Remove armature 1 and wire.
07 IGNITION SYSTEM 2 Installing the ignition armature NOTE: The high-voltage cable is moulded onto the ignition system and cannot be replaced separately. Insert the armature and turn the screws in almost all the way. Lay the high-voltage cable with the ingition cable as show. Fasten the ignition cable with screws 2. Insert the setting gauge (944.500.891) between the ignition armature and the fylwheel. Position the flywheel so that the magnet is against the armature (gap 0.25 – 0.3 mm).
08 CARBURETOR 13 9 1 6 8 14 7 15 16 10 12 5 A 11 4 3 18 2 Removing the carburetor CAUTION: Empty the fuel tank before disassembling the carburetor! Remove the hood and air filter. Move combination switch 4 to STOP drücken. Shut the choke valve 5. Remove carburetor adjusting guide 1. Disengage Bowden cable (arrow). Unscrew screws 2 and 3 and pull them out. CAUTION: There is fuel in the line. Briefly open the tank cap to reduce pressure in the fuel system.
08 CARBURETOR Pressure test Connect the pressure gauge (956.004.000) to the carburetor fuel connection 1. Base Setting (without Limiter Caps) L= 1 1/2 H= 1 1/2 Set up a pressure of max. 0.5 bar. NOTE: Adjust the carburetor only using a tachometer. If the pressure drops off, check the inlet needle 2 for damage or foreign objects. If necessary, replace control parts.
09 VIBRATION DAMPER Disassembly Spring 1 Unscrew screw on chain catcher. Loosen spring with Torx screwdriver (944.500.862) and remove. Spring 2 NOTE: To facilitate removal of the spring, unscrew the screw of spring 3. Remove fan housing. Unscrew screw. 1 5 3 Loosen spring with offset screwdriver (940.827.000) and remove. Spring 3 Remove hood. 2 Unscrew screw. Loosen spring with offset screwdriver (940.827.000) and remove. Impact dampers 4 and 5 Loosen screws and remove dampers.
10 TANK The throttle and throttle lock have slots 4 and 5 at their pivot points. When assembling the throttle and throttle lock, first press them onto the pivot axle by the slot. For this, the slot must point downwards when inserted. The Bowden clip 6 goes in after the throttle. 1 7 3 The lever is then attached to the Bowden clip. Guide the pivot axle 7 under the hook on the Bowden clip 6. 2 5 Grip mechanism Unscrew screw 1. 6 4 Before installing the throttle, engage the spring in the throttle.
10 TANK 8 Disassembly Pressure test To remove the tank it will first be necessary to remove the carburetor, pull the fuel line out of the carburetor bottom, pull the Bowden cable out of the intake manifold and carburetor bottom (08 CARBURETOR) and remove the vibration and impact dampers (09 VIBRATION DAMPER). Connect the over/underpressure pump to the fuel line 8. If the saw has handle heating, the heating cable will likewise need to be removed. Set up a pressure of max. 0.3 bar.
11 CYLINDER / PISTON 1 2 3 Pressure test If it is not possible to adjust the carburetor properly, it will be necessary to check the sealing of the Drive. To seal off the exhaust side, insert the sealing plate 1 (944.603.160) between the cover plate and cylinder. To do this it will be necessary to loosen the muffler (see under 04 CLUTCH, page 12, left side of page). To seal off the intake side, install the sealing plate 2 (944.603.170) in the place of the carburetor.
11 CYLINDER / PISTON NOTE: If there is a leak into the oil tank, it will not be possible to fully identify the leak. If pressure remains steady in the crankcase after shutting off the oil line hole, for example with a rubber stopper (see 05 OIL PUMP), it is an indication that there is a defect in the crankcase gasket to the oil tank. 1 2 3 Vacuum test Since the radial gasket ring can also fail at negative pressure, a vacuum must be established in the crankcase to test the radial ring.
11 CYLINDER / PISTON 8 10 9 6 7 Removing the cylinder and piston Disconnect the intake and exhaust sides. Unscrew the spark plug. Unscrew 4 screws 6 and pull the cylinder up and off. Note: After pulling off the cylinder, support the piston with the assembly tool (944.600.001). Note:, The cylinder comes without thread as a No spare part, because the muffler screws are self forming screws Remove spring ring 7 with needle-nose pliers.
12 CRANKCASE / CRANKSHAFT The crankcase magnet side and cylinder side are held together with six screws 1. Two pins 2 ensure proper fitting. To assemble the ball bearings please note the following repair instructions MS 2 • Press a ball bearing onto the crankshaft clutch-side by using an assembling bush. Press only on the internal ring of the bearing. Note: Put a wedge between the crankwebs.
13 HANDLE HEATING Diagnosis/Cause The handle heating is switched on when the red mark 1 on the switch is visible. Diagnosis: Heating in both rear and front handles not working. Cause: Generator defective, interruption of current. Diagnosis: Heating in rear or front handle not working. Cause: Short-circuit in the affected handle. Diagnosis: Both handles are heated constantly or intermittently, although the heating switch is on OFF. Cause: Short-circuit at or in switch, insulation cap is damaged or missing.
13 HANDLE HEATING Current testing Generator test 2 Switch off the handle heating. Check current between the plug located at the middle of the switch and the cylinder (ground). No current – Check wire and generator (181 148 060) for damage, replace if necessary. Handle heating switch 3 Both handles are constantly or intermittently heated, although the heating switch is turned off: Check the insulation cap (038 146 030) on the middle contact for damage, replace if necessary.
13 HANDLE HEATING Resistance testing Heating film in rear handle 2 Unplug plug 1 in the front handle. Test resistance between the two solder points on the heating film in the handle. Resistance should be approx. 0.9 Ohm (± 10 % att approx. 20°C / 68°F) If the resistance is not correct, the tank (181 114 170) must be replaced. Heating film in front handle 3 Measure resistance between the two solder points on the heating film in the front handle. Resistance should be approx. 5.1 Ohm (± 10 % att approx.
14 TORQUES Fastener Crankcase sides Cylinder on crankcase Carburetor bottom on crankcase Muffler on cylinder Sheet-metal plate mounting on muffler Sheet-metal plate mounting on crankcase magnet side Carburetor / intake manifold in carburetor flange Intake manifold on carburetor bottom Carburetor flange on carburetor bottom Oil pump mounting on crankcase Clutch to crankshaft Transmission cover on crankcase Mounting bolt in bar flange Sprocket guard mounting Chain brake cover Ignition mounting in crankcase Fl
620 Form: 995 726 620
