Dolmar PS-35 C Betriebsanleitung

Repair Manual

Caution:

Before doing any maintenance or service work, the combination switch must be in STOP position, in order to

prevent unintended starting by the easy start system!

PS-35 C

PS-35 C TLC

Repair Manual PS-35

CONTENTS

Page

Technical data ...................................................................................................................................................................................... 3

00 Special tools .................................................................................................................................................................................... 4 - 5

01 Sprocket guard / Chain tensioning system .......................................................................................................................................... 6

02 Clutch drum with chain sprocket .......................................................................................................................................................... 8

03 Chain brake ..................................................................................................................................................................................9 - 10

04 Clutch........................................................................................................................................................................................... 11 - 12

05 Oil pump ............................................................................................................................................................................................. 13

06 Starter ................................................................................................................................................................................................. 14

07 Ignition system (trouble-shooting)....................................................................................................................................................... 15

07 Ignition system............................................................................................................................................................................ 16 – 17

08 Carburetor................................................................................................................................................................................... 18 – 20

09 Vibration damper ................................................................................................................................................................................ 21

10 Tank ............................................................................................................................................................................................ 22 – 23

11 Cylinder / Piston ................................................................................................................................................................................. 24

12 Cylinder / Piston / Crankcase ............................................................................................................................................................ 25

13 Torques .............................................................................................................................................................................................. 26

Notes ................................................................................................................................................................................................. 27

Repair Manual PS-35

TECHNICAL DATA

PS-35 C PS-35 C TLC

Stroke volume cm335

Bore mm 38

Stroke mm 30,6

Max. power at speed kW / 1/min 1,7 / 10.000

Max. torque at speed Nm / 1/min 2,0 / 7.000

Idling speed / max. engine speed with bar and chain 1/min 2.800 / 12.800

Clutch engagement speed 1/min 4.100

Sound pressure level at the workplace LpA eq per ISO 22868 1) 3) dB(A) 102,6 / KpA = 2,5

Sound power level LWA, Fl + Ra per ISO 22868 2) 3) dB(A) 109,8 / KWA = 2,5

Vibration acceleration ahv, eq per ISO 22867 1) 3)

- Tubular handle m/s24,9 / K = 2

- Rear handle m/s25,0 / K = 2

Carburetor Type membrane carburetor

Ignition system Type electronic

Spark plug Type NGK CMR6A

or spark plug Type -

Electrode gap mm 0,5

Fuel consumption at max. load per ISO 7293 kg/h 0,68

Speciﬁc consumption at max. load per ISO 7293 g/kWh 500

Fuel tank capacity l 0,40

Chain oil tank capacity l 0,29

Mixture ratio (fuel/two-stroke oil)

- when using DOLMAR oil 50 : 1 / 100: 1 (EXTRA)

- when using Aspen Alkalyt (two-stroke fuel) 50 : 1 (2%)

- when using other oils 50 : 1 (quality grade JASO FC or ISO EGD)

Chain brake engages manually or in case of kickback

Chain speed at max. power m/s 18,9

Sprocket pitch inch 3/8

Number of teeth Z6

Chain type see the spare-parts list

Pitch / gauge inch / (mm) 3/8 / 0,050 (1,3) / 3/8 / 0,043 (1,1)

Guide bar, length of a cut cm 30, 35, 40

Guide-bar type see the spare-parts list

Weight (fuel tank empty, without chain, guide bar and accessories) kg 4,4 4,5

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

2) Figures derived in equal part from full-load and racing speed.

3) Uncertainty (K=).

Repair Manual PS-35

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

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 944.602.000

6 Assembly and disassembly wrench

Wrench for disassembling and

assembling the centrifugal

clutch 944.500.695

7 Tachometer

Electronic tachometer for measuring

the engine speed of

2- and 4-stroke engines 950.233.220

123

4567

00 SPECIAL TOOLS

Repair Manual PS-35

00 SPECIAL TOOLS

8 Needle-nose pliers

Various assembly/

disassembly tasks 944.603.400

9 Disassembly hook

Removal/installation

Brake band spring 950.237.000

10 Over/underpressure pump

For checking sealing of

radial rings and gaskets 957.004.001

11 Sealing plate

For sealing intake side 944.603.040

12 Sealing plate

For sealing exhaust side 944.603.140

13 Ignition tester

Checking the ignition 950.233.230

14 Mounting tool

Bearings on crankshaft 944.500.903

15 Radial ring puller

13 mm radial ring puller (944.500.871)

Spindle (950.203.020)

8910 11

12 13 14 15

Repair Manual PS-35

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

Remove the sprocket guard, bar, and chain.

Chain tensioner

Carefully pull the chain guide plate off the front

bar pin 1 .

Chain tensioner function

An angled worm drive converts the turns

of the adjustment screw 2to forward or

backward motion of the tensioning pin 3.

If necessary, turn adjusting screw 2clockwise,

until the fastening screw 4is accessible.

Unscrew the fastening screw and pull the

chain tensioner up and out.

Assembly

Grease spindle and worm gear with multi-

purpose grease (944.360.000).

Repair Manual PS-35

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

Disassembly

Folding handle

Remove the sprocket guard, guide bar and chain.

Fold up folding handle 1.

Using a small screwdriver, carefully pry the plastic

ring 2up out of the sprocket guard.

Pull folding handle 1out of the sprocket guard.

Remove spring 3and locknut 4.

Chain tensioner

Unscrew bolt 5and remove chain guide plate 6.

Unscrew bolt 7.

Remove cover 8, locking bolt 10 and clamping nut 9.

Unscrew bolt 11 and remove it and washer 12.

Remove tensioning handle 13 and driver 14.

Note: Do not misplace spring with ball 15.

Assembly in reverse order.

Installing the folding handle

Insert locknut 4with spring 3into the sprocket guard.

Press the carrier with folding handle 1into the

sprocket guard, making sure it engages with

locknut 4.

Insert plastic ring 2into the sprocket guard.

5 6

TLC

Repair Manual PS-35

02 CLUTCH DRUM AND CHAIN SPROCKET

Remove the sprocket guard, bar, and chain.

Release chain brake.

Remove the circlip 3with a blade screwdriver.

Remove washer 2.

Clutch drum with sprocket and needle

bearing

Check the chain sprocket 1for damage and

wear.

Check the clutch drum needle bearing for

wear and damage.

Note: If using a new clutch drum, lubricate the

needle bearing.

Check the inside of the clutch drum for

damage and wear.

Replace the clutch drum if damaged or worn.

Note: Always use a new circlip 3

(927.306.000)!

Repair Manual PS-35

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.

Unscrew screws 1and remove the cover 2.

Lift the brake band 3upward and turn it out of

the disengagement mechanism 4.

Secure the chain saw from slipping (vise).

Using the disassembly hook (Chap. 00, Pos.

9), disengage the brake band spring 5.

21 1 34

03 CHAIN BRAKE

Repair Manual PS-35

Removing the hand guard and

disengagement mechanism

Remove the starter. See Chap. 06.

Unscrew the handguard screw on the fan side.

Remove the circlip 6.

Lift the spacer plate 7 over the pin 8, push it

back a little, and remove it from pin 9.

Remove the bushing from pin 8 and 9.

Pull the disengagement mechanism off the

shafts in parallel.

Remove the mufﬂer. See Chap. 04.

Disengage the fan-side handguard arm

towards the mufﬂer.

Pull the handguard off pin 9 using light back-

and-forth motions.

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.

Assemble the disengagement mechanism,

brake band, and brake band spring in the

reverse order.

03 CHAIN BRAKE

67 8910 10

ca. 4 mm

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