Makita DOLMAR PS-32C Repair Manual
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Makita DOLMAR PS-32C Repair Manual

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REPAIR MANUAL
EA3201S35B
PS-32C

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Summary of Contents for Makita DOLMAR PS-32C

  • Page 1 REPAIR MANUAL EA3201S35B PS-32C...

  • Page 2: Table Of Contents

    CONTENTS Page Technical data ..................................... 3 Troubleshooting................................... 4 Special tools ................................... 5 - 7 Sprocket guard / Chain tensioning system ..........................8 Clutch drum with chain sprocket..............................9 Chain brake ..................................10 - 11 Clutch ....................................12 - 13 Oil pump ....................................14 Starter......................................

  • Page 3: Technical Data

    TECHNICAL DATA PS-32 Stroke volume Bore Stroke 28.2 Max. power at speed kW / 1/min 1.35 / 10,000 Max. torque at speed Nm / 1/min 1.6 / 7,000 Idling speed / max. engine speed with bar and chain 1/min 2,700 / 12,800 Clutch engagement speed 1/min 4,100...

  • Page 4: Troubleshooting

    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, pressure system, only with difficulty mechanical malfunction. No ignition spark Combination switch in pos.

  • Page 5: 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 flywheel without damage to the crankshaft thread (944.500.880) Setting gauge Gauge for measuring the gap between flywheel and armature (944.500.891) Torque wrench...
  • Page 6 00 SPECIAL TOOLS Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch (944.500.695) Tachometer Electronic tachometer for measuring the engine speed of 2- and 4-stroke engines (950.233.220) Needle-nose pliers Various assembly/ disassembly tasks (944.603.400) Disassembly hook Removal/installation Brake band spring (950.237.000) 10 Over/underpressure pump...
  • Page 7 00 SPECIAL TOOLS 11 Sealing plate For sealing intake side (944.603.040) 12 Sealing plate For sealing exhaust side (944.603.140) 13 Ignition tester M4 x 20 Checking the ignition (950.233.230) 14 Mounting tool Bearings on crankshaft (944.500.903) Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32...

  • Page 8: 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- Unscrew the fastening screw and pull the purpose grease (944.360.000).

  • Page 9: 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. Assembly the bearing with multi-purpose high- performance grease (944.360.000). Note: If using a new clutch drum, lubricate the needle bearing.

  • Page 10: 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 11 03 CHAIN BRAKE Pull the handguard off pin 8 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.

  • Page 12: Clutch

    04 CLUTCH Insert wrench 4 (Chap. 00, Pos. 7) into the Disassembly Move piston to bottom dead centre (visible clutch and use a socket wrench 5 to turn in through the exhaust opening). CAUTION: To prevent cuts, wear protective the direction of the arrow (left-hand thread) to gloves! Press the piston stop wedge 3 (cap.
  • Page 13 04 CLUTCH Installing the clutch Inserting the flyweights 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 Torque: 35 ±...

  • Page 14: Oil Pump

    05 OIL PUMP The suction line 5 remains in the crankcase. It General extends into the oil tank. To remove it, carefully Flathead screw The oil pump is driven by the drive worm gear 1 pull on the connection to the oil pump. No.: 165.888.110 on the crankshaft.

  • Page 15: 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 16: Ignition System (Trouble-Shooting)

    07 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 17: Ignition System

    07 IGNITION SYSTEM Removing the flywheel 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 flywheel.
  • Page 18 07 IGNITION SYSTEM Note: Check the starter pawls on the flywheel for easy movement, and clean if necessary. Installing the ignition armature Removing the ignition armature NOTE: The high-voltage cable is moulded Remove cover. onto the ignition system and cannot be Remove the starter.

  • Page 19: Carburetor

    08 CARBURETOR Removing the intake manifold and Removing the intermediate flange carburetor Disengage the combination switch 1. CAUTION: Completely empty the fuel tank Remove the front handle to simplify pulling off before disassembling the carburetor! the cylinder. Remove cover. Unscrew the spark plug. Move combination switch 1 to safety position.
  • Page 20 08 CARBURETOR Schematic diagram of the fuel lines Tighten the screws 4 by hand evenly alternating crosswise and then tighten to the right torque (10 +/- 0.5 Nm), likewise alternating crosswise. Screw in screws 9. Check the cylinder side annular spring on the flange for correct seating.
  • Page 21 08 CARBURETOR General check Base Setting Screen 7 for contamination L= 2 H= 4 Pulse hole for contamination 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 22: 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 23: Tank

    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. The catch lever 4 can easily be pushed through the chamfer on the seat.
  • Page 24 10 TANK Removal Pressure test Vacuum testing ventilation valve 6 Unscrew all middle screws of the damping Attach the over/underpressure pump (chap. 00 Attach the over/underpressure pump as springs (Chapter 09). Also remove the damping pos. 10) to one of the two fuel connections 5 . described.

  • Page 25: 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 26 11 CYLINDER / PISTON Assembling the cylinder and piston 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.

  • Page 27: Torques

    12 TORQUES Fastener Part No. Size Qty. Torque [Nm] Cylinder to engine mount 913.350.404 5 x 40/20 Torx/Schlitz 10 +/-0,5 Intermediate flange to engine mount 913.455.164 5,5 x 16 Torx 4 +/-0,5 Muffler fastening to cylinder 908.005.165 M 5 x 16 Torx 8 +/-1 Front shell to muffler 165.888.030...
  • Page 28 DOLMAR GmbH • Postfach 70 04 20 • D-22004 Hamburg • Germany Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32...

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Ea3201s35b

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