Transcript
Repair Manual
___
PS-32 (2013-11)
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! www.dolmar.de Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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CONTENTS
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Page Technical data ............................................................................................................................................................................. 3 Troubleshooting........................................................................................................................................................................... 4 00
Special tools ........................................................................................................................................................................... 5 - 7
01
Sprocket guard / Chain tensioning system .................................................................................................................................. 8
02
Clutch drum with chain sprocket.................................................................................................................................................. 9
03
Chain brake ........................................................................................................................................................................ 10 - 11
04
Clutch ................................................................................................................................................................................. 12 - 13
05
Oil pump .................................................................................................................................................................................... 14
06
Starter........................................................................................................................................................................................ 15
07
Ignition system (trouble-shooting) ............................................................................................................................................. 16
07
Ignition system................................................................................................................................................................... 17 – 18
08
Carburetor ......................................................................................................................................................................... 19 – 20
09
Vibration damper ....................................................................................................................................................................... 22
10
Tank................................................................................................................................................................................... 23 – 24
11
Cylinder / Piston ................................................................................................................................................................ 25 – 26
12
Torques ..................................................................................................................................................................................... 27
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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TECHNICAL DATA
Stroke volume Bore Stroke Max. power at speed Max. torque at speed Idling speed / max. engine speed with bar and chain Clutch engagement speed Sound pressure level at the workplace LpA eq per ISO 22868 1) 3) Sound power level LWA eq per ISO 228681) 3) Vibration acceleration ah,w eq per ISO 22867 1) 3) - Tubular handle - Rear handle Carburetor Ignition system Spark plug Electrode gap or spark plug Fuel consumption at max. load per ISO 7293 Specific consumption at max. load per ISO 7293 Fuel tank capacity Chain oil tank capacity Mixture ratio (fuel/two-stroke oil) - when using DOLMAR oil - when using Aspen Alkalyt (two-stroke fuel) - when using other oils Chain brake Chain speed at max. power Sprocket pitch Number of teeth Chain type Pitch / gauge Guide bar, length of a cut Guide-bar type Weight (fuel tank empty, without chain, guide bar and accessories)
___
cm3 mm mm kW / 1/min Nm / 1/min 1/min 1/min dB (A) dB (A) m/s2 m/s2 Typ Typ Typ mm Typ kg/h g/kWh l l
m/s inch Z inch (mm) cm kg
PS-32
32 38 28.2 1.35 / 10,000 1.6 / 7,000 2,700 / 12,800 4,100 102.6 / KpA = 2.5 109.8 / KWA = 2.5 4.8 / K = 2.0 4.8 / K = 2.0 membrane carburetor electronic NGK CMR7A-5 0.5 -0.68 500 0.4 0.28 50 : 1 / 100: 1 (HP-100) 50 : 1 (2%) 50 : 1 (quality grade JASO FC or ISO EGD) engages manually or in case of kickback 18.9 3/8 6 see the spare-parts list 3/8 / 0.050 (1.3) / 3/8 / 0.043 (1.1) 30, 35, 40 see the spare-parts list 4.0 / 4.1 2)
Figures derived in equal part from idling, full-load and racing speed. On models with catalytic converter. 3) Uncertainty (K=). 1) 2)
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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TROUBLESHOOTING Malfunction
System
___ Observation
Cause
Chain does not run
Chain brake
Engine runs
Chain brake actuated
Engine does not start or only with difficulty
Ignition system
Ignition spark
Malfunction in fuel supply system, pressure system, mechanical malfunction.
No ignition spark
Combination switch in pos. , fault or short-circuit in the wiring, plug cap or spark plug defective, between ignition module and flywheel uneven or too wide, wrong spark plug
Fuel supply
Fuel tank is filled
Combination switch in Choke position, carburetor defective, suction head dirty, fuel line bent, leaky or interrupted.
Compression
Inside system
Cylinder base piston ring defective, radial shaft packings defective, cylinder or piston rings defective
Outside
Spark plug does not seal.
Mechanical malfunction
Starter does not engage
Spring in starter broken, broken parts inside the engine.
Engine speed gets “stuck”
Multiple systems
Engine speed about 4,500 - 6,000 rpm
Carburetor too lean Bleed air at cylinder and/or rubber intake hose Fuel line bent, throttle link stuck
Warm engine won’t start
Carburetor
Fuel tank is filled Ignition spark
Wrong carburetor adjustment Flooded from choke use, no half throttle function Piston ring worn (max. thrust play 0.5 mm)
Engine starts, but dies immediately
Fuel supply
Fuel tank is filled
Wrong idling adjustment, suction head or carburetor dirty, tank venting defective, fuel line interrupted, Choke flap closed
Insufficient power, no max. engine speed
Several systems may be involved simultaneously
Engine is idling
Air filter dirty, incorrect carburetor setting, muffler clogged, exhaust channel in cylinder clogged, spark arrester screen clogged.
No chain lubrication
Oil tank/pump
No oil on the chain
Oil tank empty, oil guide groove dirty, oil suction head dirty, oil line defective, oil pump worm drive gear defective, oil pump defective
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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00 SPECIAL TOOLS
___ 1
Torx screwdriver Grip T-grip 200 mm T-grip 100 mm
2
1
2
Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread
3 3
(944.500.860) (944.500.862) (944.500.861)
(944.500.880)
Setting gauge Gauge for measuring the gap between flywheel and armature (944.500.891)
4
5
5
4
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
Torque wrench 3/8” Drive socket Bit 152 mm Bit 49 mm
(944.500.864) (944.500.865) (944.500.866)
Torque wrench 3/8” Drive
(950.230.000)
Piston stop wedge Wedge for blocking the engine through the exhaust port
(944.602.001)
5
00 SPECIAL TOOLS
___ 6
Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch (944.500.695)
7
Electronic tachometer for measuring the engine speed of 2- and 4-stroke engines (950.233.220)
7
6
Tachometer
8
Needle-nose pliers Various assembly/ disassembly tasks
9
(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
8
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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(957.004.001)
10
6
00 SPECIAL TOOLS
___ 11 Sealing plate For sealing intake side
(944.603.040)
12 Sealing plate For sealing exhaust side
13 Ignition tester
M4 x 20
Checking the ignition
11
(944.603.140)
(950.233.230)
12 14 Mounting tool Bearings on crankshaft
13
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
(944.500.903)
14
7
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM
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2
1
4
3
Remove the sprocket guard, bar, and chain.
If necessary, turn adjusting screw 2 clockwise, until the fastening screw 4 is accessible.
Chain tensioner
Unscrew the fastening screw and pull the chain tensioner up and out.
Carefully pull the chain guide plate off the front bar pin 1 .
Assembly Grease spindle and worm gear with multipurpose grease (944.360.000).
Chain tensioner function An angled worm drive converts the turns of the adjustment screw 2 to forward or backward motion of the tensioning pin 3.
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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02 CLUTCH DRUM AND CHAIN SPROCKET
___ Clutch drum with sprocket and needle bearing
3
Check the chain sprocket 1 for damage and wear. Check the clutch drum needle bearing for wear and damage.
2
Assembly the bearing with multi-purpose highperformance grease (944.360.000). Note: If using a new clutch drum, lubricate the needle bearing.
1 Remove the sprocket guard, bar, and chain. Remove the circlip 3 with a blade screwdriver. Remove cup washer 2. Pull the handguard towards the front grip only as far as necessary so the clutch drum can be removed.
Reparaturanleitung Repair Manual PS-32 PS-4600 / PS-5000
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)!
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03 CHAIN BRAKE
1
2
___ 1
Removing the brake band CAUTION: Wear protective gloves to prevent cuts!
3
4
Lift the brake band 3 upward and turn it out of the disengagement mechanism 4.
5
Secure the chain saw from slipping (vise). Using the disassembly hook (Chap. 00, Pos. 9), disengage the brake band spring 5.
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 1 and remove the cover 2.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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03 CHAIN BRAKE 10
9
___ 7
8
6
Pull the handguard off pin 8 using light backand-forth motions.
10
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.
Removing the hand guard and disengagement mechanism
ca. 4 mm
Assemble the disengagement mechanism, brake band, and brake band spring in the reverse order.
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.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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04 CLUTCH 2
___ 1
3
4 Disassembly 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.
Press the piston stop wedge 3 (cap. 00, pos. 5) into the exhaust opening.
Pull the handguard towards the front handle to release the chain brake if necessary.
Position of gasket and cooling plate for muffler assembly:
Remove the clutch drum, see Chapter 02.
5
Insert wrench 4 (Chap. 00, Pos. 7) into the clutch and use a socket wrench 5 to turn in the direction of the arrow (left-hand thread) to loosen and remove the clutch. Remove the guide washer and spacer washer. The flyweights can now be pushed off the guide axially in one direction.
Remove the muffler. To do this, unscrew the 3 screws 1 and remove the upper muffler half 2. Caution: If a catalytic converter is being used, the muffler will be very hot after operation!
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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04 CLUTCH
___
Inserting the flyweights
Installing the clutch
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 the second flyweight. Press the flyweights all the way onto the guide. CAUTION: Note the position of the springs. Do not replace springs individually! If a spring breaks or is fatigued, all two springs must be replaced.
Torque: 35 ± 2.5 Nm CAUTION: Before installing the clutch, disassemble the starter (see chap. 06), in order to prevent damage to the starting catches.
The illustration shows the inside of the clutch.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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05 OIL PUMP
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1 5
9 10 A
4
3
3
1
2
2
General Flathead screw No.: 165.888.110
The oil pump is driven by the drive worm gear 1 on the crankshaft.
Removing the oil pump Push the adjusting screw 6 up against the spring pressure and turn it until the pin 7 goes into the assembly slit 7. If necessary press the supply piston 8 in somewhat.
This gear engages the oil pump piston 3. Consequently, the oil pump operates only when the engine is on. 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. Remove brake band, see chapter 03. Move the drive worm gear 1 gently back and forth and work it off the shaft. Pull the oil pressure line 2 from the oil pump. Unscrew screw 4 and remove the oil pump. Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
The suction line 5 remains in the crankcase. It extends into the oil tank. To remove it, carefully pull on the connection to the oil pump.
Note: When assembling put the adjusting screw 6 counterclockwise to stop.
8
Removing the oil tank vent
6
7
Note: The ventilation valve 9 must be punched into the tank. Press in a new valve about 2 mm deep under the housing surface. Make sure that the ventilation channel 10 is free of deposits. Clean if necessary.
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06 STARTER
___ If the spring pops out, put it back into the plastic housing as shown in the schematic. 5
Assembly
6
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). Thread in a new starter cable (dia 3.5 mm / 1/8“, length 900 mm / 35.4“) as shown in the illustration, tie a knot in both ends, and tighten both knots. Put on the cable drum 8 and turn it slightly until the return spring engages. Insert spring 7 in the cam 6 and place them together in the cable drum 8 while turning gently counter-clockwise until they engage. Insert and tighten screw 5. Tension the return spring clockwise. Turn the return spring about 6 turns with the aid of the cable, which should be pressed into the gap in the cable drum. Place the air guide 3 in the fan housing and make sure the three recesses 4 engage. Pull the opening 10 on the fan housing over the pin on the hood. Position the fan housing correctly on the saw, press against it slightly, and pull the starter handle until the starter catches. Tighten screws 1.
7
8
1
2
Disassembly Unscrew three screws 1. Remove fan housing 2. Remove air guide 3 from fan housing. Detension the return spring. Injury hazard! Unscrew screw 5 only after detensioning the return spring! Unscrew screw 5 and remove cam 6 and spring 7. Pull off the cable drum 8. Carefully turn the fan housing over and pull the return spring cassette 9 out of the fan housing. Caution! The return spring can jump out of the plastic cassette! Always wear protective goggles and gloves!
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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3 4
10
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07 IGNITION SYSTEM (TROUBLE-SHOOTING)
Is the spark plug dry and properly installed?
___ no Dry spark plug connector and fasten firmly to spark plug.
yes Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Is there carbon black on the electrodes?
yes
no Is the spark gap correct? (should be 0.5 mm)
no
yes Is the spark plug oily or does it have carbon deposits on it?
no
Adjust spark gap.
yes Wash spark plug in acetone. Do not sandblast! If necessary, replace spark plug. Eliminate cause: wrong carburetor setting, too much oil in fuel, frequent short operations.
Install ignition testing lamp. Or unscrew the plug and use insulated pliers to hold it against the cylinder with the spark plug can firmly on. Caution: Do not hold the spark plug directly against the hole. Detonation hazard!
no
Pull the starting cable smartly. Is there an ignition spark?
yes
Replace spark plug. Use ONLY a spark plug approved by DOLMAR. See operating manual! Otherwise the ignition module might be damaged. Eliminate the causes for carbon deposits on electrodes (bad two-stroke oil, wrong mix, defective air filter, check carburetor adjustment). Use DOLMAR high-performance two-stroke oil.
Replace spark plug and check ignition module for corrosion, if necessary replace. Has the defect been remedied?
no
Is there damage to the insulation of the high-voltage cable or the ignition cable, or to the wires themselves?
no Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range? Is the gap uneven? Has the flywheel worn against the ignition module?
no Remove flywheel and check. Is the flywheel damaged? Is the positioning key damaged?
yes
Check radial play of drive shaft, and repair if needed. Replace ignition module if traces of overheating become visible. Adjust gap between flywheel and ignition module correctly.
no yes
Replace flywheel. Before installation wipe cone seat at drive shaft and flywheel with acetone or alcohol to remove any grease. Tighten fastening nut to the correct torque! Has the defect been remedied?
no Continue with troubleshooting in fuel system (tank, fuel hose, carburetor).
no
no Replace ignition module. Has the defect been remedied?
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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07 IGNITION SYSTEM
Removing the flywheel Remove starter see chap. 06. Block the piston, see chap. 04. Loosen the nut in the direction of the arrow and remove it along with the washer.
___
Screw the disassembly mandrel (chapter 00 pos. 2) 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. Hold the machine in one hand or place on a soft surface, and knock the flywheel loose with a tap on the mandrel. CAUTION: The cone of the crankshaft must always be degreased before assembly. Torque nut 20 +5 Nm
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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07 IGNITION SYSTEM
2
3
___ 4
Note: Check the starter pawls on the flywheel for easy movement, and clean if necessary.
1
Removing the ignition armature
Installing the ignition armature
Remove cover.
NOTE: The high-voltage cable is moulded onto the ignition system and cannot be replaced separately.
Remove the starter. See Chap. 06. Pull off short-circuit cable 2. Unscrew 2 screws on ignition armature 3. Note: Be aware of the 2 plastic washers between the cylinder and the ignition armature. Remove ignition armature and high-voltage cable.
Insert plastic pieces into the bolt holes on the cylinder. Insert the ignition armature, install the shortcircuit cable 1 under the top screw, and screw in the screws until just before they stop. Insert the setting gauge 4 (Kapitel 00 Pos. 3) between the ignition armature and the fylwheel. Position the flywheel so that the magnet is against the armature (gap 0.25 – 0.3 mm). Press the armature against the gauge towards the flywheel and tighten the armature screws (5 +/-0.5 Nm). Then check the gap again to make sure it is correct. Connect short-circuit cable 2.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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08 CARBURETOR
___
3 ON
4
2
1 Removing the intake manifold and carburetor CAUTION: Completely empty the fuel tank before disassembling the carburetor! Remove cover. Move combination switch 1 to safety position. Unscrew 2 screws 2. Remove the air filter and intake manifold 3. Pull the fuel lines and pulse line from the carburetor. CAUTION: There is fuel in the line. Catch escaping fuel with a cloth. Remove the carburetor and throttle linkage. Note: When reassembling, engage the linkage in the marked hole (arrow).
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
Removing the intermediate flange Disengage the combination switch 1. Remove the front handle to simplify pulling off the cylinder.
11
Unscrew the spark plug. Unscrew screws 9. Unscrew screws 4 from the crankcase. Turn the flywheel so that the magnets are NOT on the ignition armature. Pull the cylinder, intermediate flange and ignition armature up and off. Note: Before assembly, replace the crankcase gasket with crankshaft seal rings.
Assembly Bring piston to top dead centre and position the opening on the piston ring to the piston ring lock. Hold the piston firmly with one hand and carefully push the piston over it.
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08 CARBURETOR 9 8
___
10 11 12
ON
7 6
Make sure that the intermediate flange goes into its space on the cylinder side. When lowering the cylinder make sure that the pulse line 10 and the red fuel line 11 enter the carburetor area. Before completely lowering the cylinder make sure that the short-circuit cable is led into the openings 8.
Tighten the screws 4 by hand evenly alternating crosswise and then tighten to the right torque (10 +/- 0.5 Nm), likewise alternating crosswise.
Schematic diagram of the fuel lines
Screw in screws 9. Check the cylinder side annular spring on the flange for correct seating. Note: Before inserting the carburetor, make sure that the carburetor mounting flange is positioned horizontally. Insert the carburetor and pulse line, and connect the fuel lines. Install the intake manifold 3 (3 +/-0.5 Nm).
Red fuel line
14
Make sure that the return line (bottom connection on primer) is behind the guide 12. Install the combination switch 1 with the shortcircuit cable on top and then press the shortcircuit cable 7 under the holder 6. Install the contact spring with short-circuit cable.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
Note: When installing the tank suction line, make sure that the nose on the connection nipple 14 is pushed into the position on the connection as shown.
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08 CARBURETOR
___ General check Screen 7 for contamination Pulse hole for contamination
Base Setting L= 2 H= 4 NOTE: Adjust the carburetor only using a tachometer.
6
Pressure test Connect the pressure gauge (chapter 00 item 10) to the carburetor fuel connection 1. Set up a pressure of max. 0.5 bar. If the pressure drops, check the following components: Inlet needle, if necessary replace control set Inlet needle seat for dirt / foreign objects, if necessary clean Replace gasket 6 and diaphragm 5 on the pump side
5 7
1 Control lever
2 3 4 Control lever
Correctly
Control lever
Too high
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
Control lever
Too low
8
Check control parts (control lever/inlet needle): Check the tip of the inlet needle for wear. Check control lever for correct installation, see illustration to the left, check for wear. If the control lever is too low: Insufficient fuel Insufficient fuel No maximum power If the control lever is too high: Carburetor flooding Starting problems Poor idling Poor transition Check the pump diaphragm: If pump diaphragm is dented, torn, or creased, If valve flaps are bent, replace the diaphragm and gasket Check control diaphragm: If the control diaphragm is bent, hardened or torn, or if there is visible wear on the button 8. If the diaphragm is not flexible, replace the diaphragm and gasket.
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09 VIBRATION DAMPER
___ Disassembly Springs 1 and 2 Remove the sprocket guard. Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1).
4
Pull out damping spring. Spring 3
3
Remove starter housing (see chap. 06). Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). Pull out damping spring. Spring 4 Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). Remove damping spring. Remove spring bush. Note: During assembly, insert spring retainer between the cushion spring and the cylinder. Screw the metric-thread screw into the cylinder.
1 2
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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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.
1
The catch lever 4 can easily be pushed through the chamfer on the seat. The spring is engaged in the throttle lever as shown below.
3 Grip mechanism Unscrew screw 1 and pull the lower grip half slightly up and to the rear in the area of the screw hole. Note: When disassembling the throttle lever, the following must be performed: • Remove cover. • Unscrew all middle screws of the damping springs (Chapter 09). • Remove tubular handle.
2
4
The throttle lever has a slot 2 at the hinge. • Pull the tank and engine unit slightly apart (being careful of the fuel lines), swing the throttle lever up, and remove it. • Remove the catch lever 4.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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10 TANK
___
Removal
Pressure test
Vacuum testing ventilation valve 6
Unscrew all middle screws of the damping springs (Chapter 09). Also remove the damping spring 2.
Attach the over/underpressure pump (chap. 00 pos. 10) to one of the two fuel connections 5 . Seal off the second connection. Set up a pressure of max. 0.3 bar. If the pressure drops off, check the following: • Air valve • Both fuel lines • Fuel nipple • Tank cap O-ring • Check tank for holes Note: Detergent can be used to localise leaks.
Attach the over/underpressure pump as described.
Remove front handle. Using needle-nose pliers, carefully pull the fuel lines from the fuel nipple 8. Note: When assembling the fuel lines, follow the schematic diagram in Chapter 08.
5
8
When the pump is operated the underpressure must quickly dissipate. If underpressure builds, replace the ventilation valve. Pull out the ventilation valve 6 with a small screwdriver or wire. Before inserting a new valve, wet it with fuel. Parts To remove the suction head 7 pull it through the tank opening with a hooked wire. Note: Do not use pliers,as this may damage the line. Do not pull on the suction head or fuel line, as this can pull off the fuel nipple inside the tank. Turn the fuel nipple 8 slightly counter-clockwise out of the retainer and then carefully lift it out with a sharp flat point screwdriver. Note: Do not lever against the line connections, as this can break them off. Use always a new fuel nipple.
6
7
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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11 CYLINDER / PISTON
___ Seal off the pulse line 6 and bring the cylinder to top dead center.
6 1 M4 x 25
Set up an underpressure of max. 0.3 bar.
3 4
2 5 Vacuum testing If correct carburetor setting is not possible, it will be necessary to test a leakage of the engine. Remove hood. Remove the muffler. See Chap. 04. Remove carburetor (see chap. 08).
To seal the outlet side, screw on the sealing plate 4 (Chap. 00 Pos.12) and muffler gasket 3. To seal off the intake side, install the sealing plate 2 (chap. 00 pos. 11) in the place of the carburetor. Connect the over/underpressure pump to the connection on the sealing plate 1.
If the underpressure changes within 20 seconds, it may have the following causes: • • • • • • •
Radial ring leaking Crankcase gasket leaking Crack in crankcase Crack in cylinder Spark plug leaking Rubber intake on cylinder leaking Defective pulse line
Note: The engine must be removed in order to localize leaks. Remove clutch. See Chap. 04. Remove flywheel. See Chap. 07. Remove engine. See Chap. 08. Remove the bottom half of the crankcase (mark position) and press the bushings out of the engine holder. Mount the bottom half of the crankcase to the cylinder with bushings 5. Always perform sealing tests with underpressure! If a leak is diagnosed, it can be found using overpressure and detergent or similar liquid.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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11 CYLINDER / PISTON
___ Assembling the cylinder and piston
8
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.
7
Insert the bottom half of the crankcase. Position the crankshaft in the bottom half. Further procedure as described in “Chap. 08 Carburetor” under Assembly.
Remove and reinstall the circlip 7 with needlenose pliers. Install the piston with the arrow marking 8 on the outlet side of the crankshaft (piston ring lock on the inlet side). The piston pin is on one side. See the illustration for the installed position in the piston.
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
When installing the ball bearing, please note: Use only pressure (assembly mandrel, Chap. 00 Pos. 14) to press the ball bearing onto the bearing inside ring on the crankshaft. When pressing it on, place a wedge between the crank webs.
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12 TORQUES Fastener
___ Part No.
Size
Qty.
Torque [Nm]
Cylinder to engine mount
913.350.404
5 x 40/20 Torx/Schlitz
4x
10 +/-0,5
Intermediate flange to engine mount
913.455.164
5,5 x 16 Torx
2x
4 +/-0,5
Muffler fastening to cylinder
908.005.165
M 5 x 16 Torx
2x
8 +/-1
Front shell to muffler
165.888.030
M 5 x 16 Torx
2x
8 +/-1
Front shell to cylinder
165.888.040
M 5 x 40 Torx
1x
8 +/-1
Carburetor to flange ring
165.888.020
M 4 x 40 Torx
2x
3 +/-0,5
Clutch
165.180.200
M 10 x 1L
1x
35 +/-2,5
Ignition armature to cylinder
165.888.130
M 5 x 20 Torx
2x
5 +/-0,5
Flywheel nut fastening
920.308.024
6KT-nut M 8 x 1
1x
20 +5
Handle to tank
913.455.164
5,5 x 16 Torx
4x
4 +/-0,5
Spark plug
965.603.040
SW 16
1x
11 +/-2
Contact spring screw
165.888.120
Phillips head, M 3 x 10
1x
1 +/-0,2
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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___
DOLMAR GmbH • Postfach 70 04 20 • D-22004 Hamburg • Germany
Reparaturanleitung PS-4600 / PS-5000 Repair Manual PS-32
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