Dolmar PS-35 C Repair Manual
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Also See for PS-35 C:
- Operator's and safety manual (48 pages) ,
- Original instruction manual (212 pages)
Related Manuals for Dolmar PS-35 C
Summary of Contents for Dolmar PS-35 C
- Page 1 Repair Manual PS-35 C PS-35 C TLC 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!
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Page 2: Table Of Contents
CONTENTS Page Technical data ...................................... 3 Special tools ....................................4 - 5 Sprocket guard / Chain tensioning system ............................6 Clutch drum with chain sprocket ................................8 Chain brake ....................................9 - 10 Clutch ......................................11 - 12 Oil pump ......................................13 Starter ......................................... -
Page 3: Technical Data
Fuel tank capacity 0,40 Chain oil tank capacity 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... -
Page 4: Special Tools
00 SPECIAL TOOLS Torx screwdriver Grip 944.500.860 T-grip 200 mm 944.500.862 T-grip 100 mm 944.500.861 Mandrel Disassembly mandrel for tapping out the fl ywheel without damage to the crankshaft thread 944.500.880 Setting gauge Gauge for measuring the gap between fl ywheel and armature 944.500.891 Torque wrench... -
Page 5: Special Tools
00 SPECIAL TOOLS Needle-nose pliers Various assembly/ disassembly tasks 944.603.400 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... -
Page 6: Sprocket Guard / Chain Tensioning System
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM Remove the sprocket guard, bar, and chain. If necessary, turn adjusting screw 2 clockwise, Assembly until the fastening screw 4 is accessible. Grease spindle and worm gear with multi- Chain tensioner purpose grease (944.360.000). Unscrew the fastening screw and pull the Carefully pull the chain guide plate off the front bar pin 1 . - Page 7 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 2 up out of the sprocket guard. Pull folding handle 1 out of the sprocket guard. Remove spring 3 and locknut 4.
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Page 8: Clutch Drum With Chain Sprocket
02 CLUTCH DRUM AND CHAIN SPROCKET Clutch drum with sprocket and needle bearing Check the chain sprocket 1 for damage and wear. Check the clutch drum needle bearing for wear and damage. Note: If using a new clutch drum, lubricate the needle bearing. -
Page 9: Chain Brake
03 CHAIN BRAKE Removing the brake band Lift the brake band 3 upward and turn it out of Secure the chain saw from slipping (vise). the disengagement mechanism 4. CAUTION: Wear protective gloves to Using the disassembly hook (Chap. 00, Pos. prevent cuts! 9), disengage the brake band spring 5. -
Page 10: Chain Brake
03 CHAIN BRAKE 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 ca. -
Page 11: Clutch
04 CLUTCH Disassembly Move piston to bottom dead centre (visible Insert wrench 4 (Chap. 00, Pos. 7) into the through the exhaust opening). clutch and use a socket wrench 5 to turn in CAUTION: To prevent cuts, wear protective the direction of the arrow (left-hand thread) to gloves! Press the piston stop wedge 3 (cap. -
Page 12: Clutch
04 CLUTCH Inserting the fl yweights Installing the clutch Hook the springs as shown in the illustration. Install the clutch with the arrow marking point outside. The press the fl yweights onto the guide. To do this, fi rst push on one fl yweight, then put on Torque: 35 ±... -
Page 13: Oil Pump
05 OIL PUMP General The suction line 5 remains in the crankcase. It extends into the oil tank. To remove it, The oil pump is driven by the drive worm gear carefully pull on the connection to the oil 1 on the crankshaft. pump. -
Page 14: Starter
06 STARTER If the spring pops out, put it back into the plastic housing as shown in the schematic. Assembly 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). -
Page 15: Ignition System (Trouble-Shooting)
Is the spark plug dry and properly installed? Dry spark plug connector and fasten firmly to spark plug. Replace spark plug. Use ONLY a spark plug approved by DOLMAR. Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? See operating manual! Otherwise the ignition module might be damaged. -
Page 16: Ignition System
07 IGNITION SYSTEM Removing the fl ywheel Screw the disassembly mandrel (chapter 00 pos. 2) onto the threaded end of the shaft. Remove starter see chap. 06. Do not screw the mandrel all the way down. Block the piston, see chap. 04. Leave about 2 mm between the mandrel and Loosen the nut in the direction of the arrow the fl... -
Page 17: Ignition System
07 IGNITION SYSTEM Note: Check the starter pawls on the fl ywheel for easy movement, and clean if necessary. Removing the ignition armature Installing the ignition armature Remove cover. NOTE: The high-voltage cable is moulded onto the ignition system and cannot be Remove the starter. -
Page 18: Carburetor
08 CARBURETOR Removing the intake manifold and Removing the intermediate fl ange Before assembly, coat the cylinder path and carburetor piston with oil. Disengage the combination switch 1. Push assembly tool 6 under the piston. CAUTION: Completely empty the fuel tank Remove the front handle to simplify pulling off before disassembling the carburetor! Position the opening on the piston ring to the... - Page 19 08 CARBURETOR Tighten the cylinder head bolts by hand Schematic diagram of the fuel lines evenly alternating crosswise and then tighten to the right torque (10 +/- 0.5 Nm), likewise alternating crosswise. Screw in screws 4. Check the cylinder side annular spring on the fl...
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Page 20: Carburetor
08 CARBURETOR Base Setting General check • Screen 7 for contamination L= 1 1/2 • Pulse hole for contamination H= 2 1/4 NOTE: Adjust the carburetor only Check control parts using a tachometer. (control lever/inlet needle): Check the tip of the inlet needle for wear. Check control lever for correct installation, see Pressure test illustration to the left, check for wear. -
Page 21: Vibration Damper
09 VIBRATION DAMPER Disassembly Springs 1 and 2 Remove the sprocket guard. Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). Pull out damping spring. Spring 3 Remove starter housing (see chap. 06). Loosen and remove screws with Torx screwdriver (chap. -
Page 22: Tank
10 TANK Grip mechanism In assembly, fi rst place the throttle lever spring 3 on the throttle lever, then push the lever onto Unscrew screw 1 and pull the lower grip half the hinge with the slot. The throttle lever must slightly up and to the rear in the area of the be turned by 180°... -
Page 23: Tank
10 TANK Vacuum testing ventilation valve 6 Removal Pressure test Unscrew all middle screws of the damping Attach the over/underpressure pump (chap. Attach the over/underpressure pump as springs (Chapter 09). Also remove the 00 pos. 10) to one of the two fuel connections described. -
Page 24: Cylinder / Piston
11 CYLINDER / PISTON Seal off the pulse line 6 and bring the cylinder to top dead center. Set up an underpressure of max. 0.3 bar. If the underpressure changes within 20 seconds, it may have the following causes: • Radial ring leaking •... -
Page 25: Cylinder / Piston / Crankcase
12 CYLINDER / PISTON / CRANKCASE Crankcase Use a new crankcase gasket, cylinder base gasket and radial seal rings. Remove the radial seal rings with the puller (Chap. 00 Item 15). Fill new radial seal rings 5 with grease and place in housing. -
Page 26: Torques
13 TORQUES Screw Part No. Size Qty. Torque [Nm] crank case MS with CS 908.405.255 Torx M5x25 10 +/-0,5 crank case MS with CS on engine housing 913.350.404 Torx 5x40 10 +/-0,5 crank case MS with CS on cylinder 908.405.205 Torx M5x20 10 +/-0,5 intermediate fl... -
Page 27: Notes
NOTES Repair Manual PS-35... - Page 28 DOLMAR GmbH • Postfach 70 04 20 • D-22004 Hamburg • Germany...
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what is the size or order number of the three starter housing screws
what is the size or order # of three screws on page 12, picture 75 item #1