Dolmar PS-6400 Betriebsanleitung

1Repair Manual PS-6400/PS-7300/PS-7900

02/05

Repair Manual

www.dolmar.com

PS-6400, PS-6400 H

PS-7300, PS-7300 H

PS-7900, PS-7900 H

2Repair Manual PS-6400/PS-7300/PS-7900

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

Troubleshooting ...................................................................................... 4

00 Special tools ....................................................................................... 5 - 6

01 Sprocket guard / Chain tensioning system .......................................... 7

02 Clutch drum / Rim sprocket ................................................................... 8

03 Chain brake ....................................................................................... 9 - 14

04 Clutch .............................................................................................. 15 - 16

05 Oil pump .......................................................................................... 17 - 19

06 Starter .............................................................................................. 20 - 22

07 Ignition system ............................................................................... 23 - 26

08 Carburetor ....................................................................................... 27 - 31

09 Vibration damper / Tubular handle .............................................. 32 - 33

10 Tank ................................................................................................. 34 - 35

11 Cylinder / Piston .................................................................................... 36

12 Outside components / Crankcase / Crankshaft........................... 37 - 38

13 Handle Heating ................................................................................. 39-41

14 Torques .................................................................................................. 42

15 Check operation .................................................................................... 43

CONTENTS

3Repair Manual PS-6400/PS-7300/PS-7900

TECHNICAL DATA

Stroke volume cm364,2 72.6 78.5

Bore mm 47 50 52

Stroke mm 37 37 37

Max. power at speed 3) kW / 1/min 3.5 / 9,000 4.2 / 9,500 4.6 / 9,500

Max. torque at speed 3) Nm / 1/min 4.2 / 6,500 4.8 / 7,000 5.2 / 7,000

Idling speed / max. engine speed with bar and chain 1/min 2,500 / 13,500 2,500 / 13,500 2,500 / 13,500

Clutch engagement speed 1/min 3,200 3,200 3,200

Sound pressure level at the workplace LpA av per ISO/CD 22868 1) dB (A) 104.3 104.3 104.3

Sound power level LWA av per ISO/CD 22868 1) dB (A) 113.3 113.3 113.3

Vibration acceleration ah,w av per ISO 7505 1)

- Tubular handle m/s26.9 6.9 6.9

- Rear handle m/s27.7 7.7 7.7

Carburetor (diaphragm carburetor) Type ZAMA

Ignition system Type electronic

Spark plug Type NGK BPMR 7A

Electrode gap mm 0.5

or spark plug Type BOSCH WSR 6F

Fuel consumption at max. load per ISO 7293 3) kg/h 1.72 2.33 2.3

Specific consumption at max. load per ISO 7293 3) g/kWh 500 510 505

Fuel tank capacity l 0.75

Chain oil tank capacity I 0.42

Mixture ratio (fuel/two-stroke oil)

- when using DOLMAR oil 50 : 1

- when using other oils 40 : 1

Chain brake engages manually or in case of kickback

Chain speed 2) m/s 19.74 20.83 20.83

Sprocket pitch inch 3/8

Number of teeth Z 7

Chain type see the Extract from the spare-parts list 099

Pitch / gauge inch 3/8 / .058

Guide bar, length of a cut cm 38 / 45 / 50 / 60 / 70

Guide-bar type see the Extract from the spare-parts list

Weight (fuel tank empty, without chain and guide bar) kg 6.3 6.3 6.3

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

2) At max. power

3) For models without starting valve

Technical data PS-6400 PS-7300 PS-7900

4Repair Manual PS-6400/PS-7300/PS-7900

TROUBLESHOOTING

Malfunction System Observation Cause

Chain does not run Chain brake Engine runs Chain brake actuated.

Engine does not start or Ignition system Ignition spark Malfunction in fuel supply system, com-

only with difficulty pression system, mechanical malfunction.

No ignition spark Switch on STOP, fault or short-circuit in the

wiring, plug cap or spark plug defective.

Fuel supply Fuel tank is filled Choke in wrong position, carburetor defective,

fuel filter dirty, fuel line bent or interrupted, torn,

perforated

Compression Inside Cylinder base packing ring defective, radial

system shaft packings defective, cylinder or piston rings

defective

Outside Spark plug does not seal.

Mechanical Starter does not engage Spring in starter broken, broken parts

malfunction inside the engine.

Warm engine doesn‘t Carburetor Fuel tank is filled Wrong carburetor adjustment,

start Ignition spark flooded by usage of the ckoke

Engine starts, but Fuel supply Fuel tank is filled Wrong idling adjustment, fuel filter or

dies immediately carburetor dirty. Tank venting defective, fuel

line interrupted, cable defective, STOP switch

defective. Decompression valve dirty

Insufficient power Several systems Engine is idling Air filter dirty, wrong carburetor adjustment,

may be involved muffler clogged, exhaust channel in cylinder

simultaneously clogged, spark arrester screen clogged, worn piston

No chain lubrication Oil tank/pump No oil on the chain Oil tank empty, oil guide groove dirty,

oil-pump adjusting screw incorrectly adjusted,

oil pump drive defective

5Repair Manual PS-6400/PS-7300/PS-7900

123

00 SPECIAL TOOLS

1 Torx screwdriver

Grip (944.500.860)

T-grip, 200 mm (944.500.862)

T-grip, 100 mm (944.500.861)

2 Radial ring puller

15 mm radial ring puller (944.xxx.xxx)

17 mm radial ring puller (944.xxx.xxx)

Spindle (950.203.020)

3 Mandrel

Disassembly mandrel for

knocking the flywheel

loose without damage to

the crankshaft thread (944.500.880)

4 Setting gauge

Gauge for measuring the gap

between flywheel and

ignition armature (944.500.891)

5 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)

6 Piston stop wedge

Wedge for blocking the motor

through the exhaust port (944.602.000)

6Repair Manual PS-6400/PS-7300/PS-7900

10 11

00 SPECIAL TOOLS

7 Piston ring tensioner

Piston ring band and

assembly tool for cylinders (944.600.001)

8 Assembly and disassembly wrench

Wrench for disassembling and assembling

the centrifugal clutch (944.500.570)

9 Pressure gauge

Pressure guage for checking

the carburetor fuel valve (956.004.000)

10 Tachometer

Electronic tachometer for measuring

the engine speed of

2- and 4-stroke engines (950.233.210)

11 Installation sleeve

for radial rings (944.603.410)

7Repair Manual PS-6400/PS-7300/PS-7900

01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM

How the chain tensioner works

The force applied to the adjusting screw is transferred

by the angle worm drive to the tensioning pin.

Replace the chain guide 1if it is worn.

Mount the housing 2in the sprocket guard with

slotted screw 3(3.5 x 9.5).

NOTE: The worm drive is available only as a set 5.

Grease the spindle and worm with multipurpose

grease (944.360.000).

Chip guide

The chip guide ensures that chips are deflected away

from the cut.

This is especially important for rip cuts, to prevent

clogging.

To replace it, push the catch 4inwards from the

outside of the chain guard.

Tool

(1,5 Nm ± 0,2)

(1.5 Nm ± 0.2)

8Repair Manual PS-6400/PS-7300/PS-7900

Sprocket, clutch drum and needle

bearing

Inspect the sprocket for damage and wear.

Important customer information:

Before installing a new chain the sprocket must be

inspected.

Worn sprockets will damage a new saw chain and

must always be replaced.

Check the clutch drum bearing for damage and wear.

Assemble with multipurpose high-performance

grease (944.360.000).

Check the clutch drum for damage and wear, and

replace if worn.

Note:

Always use a new circlip (927.408.000)!

02 CLUTCH DRUM / RIM SPROCKET

9Repair Manual PS-6400/PS-7300/PS-7900

03 CHAIN BRAKE

Chain brake

The chain brake stops the chain within 0.1 seconds

in the event of kickback.

The brake band 2encircles the clutch drum 380°.

A spring 1pulls the brake band around the clutch

drum.

10Repair Manual PS-6400/PS-7300/PS-7900

03 CHAIN BRAKE

Engage the chain brake

Push the hand guard forward so that the linkage

release the spring tension.

Safety note:

Strong spring!

Never work on the chain brake when the spring

is under tension!

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