Dolmar PS-35 C Operating instructions

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

2
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

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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=).

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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

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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

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Repair Manual PS-35
2
34
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).
1

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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.
1
10
11
12
13
15
14
7
2
3
4
8
9
5 6
TLC

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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)!
3
2
1

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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
5
03 CHAIN BRAKE

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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