Makita DOLMAR PS-32C Operating instructions

REPAIR MANUAL
EA3201S35B
PS-32C

Reparaturanleitung PS-4600 / PS-5000 2
Repair Manual PS-32
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
CONTENTS

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Reparaturanleitung PS-4600 / PS-5000 3
Repair Manual PS-32
PS-32
Stroke volume cm3
32
Bore mm
38
Stroke mm
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
Sound pressure level at the workplace LpA eq per ISO 22868 1) 3) dB (A)
102.6 / KpA = 2.5
Sound power level LWA eq per ISO 228681) 3) dB (A)
109.8 / KWA = 2.5
Vibration acceleration ah,w eq per ISO 22867 1) 3)
-Tubular handle m/s2
4.8 / K = 2.0
-Rear handle m/s2
4.8 / K = 2.0
Carburetor Typ
membrane carburetor
Ignition system Typ
electronic
Spark plug Typ
NGK CMR7A-5
Electrode gap mm
0.5
or spark plug Typ
--
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
0.4
Chain oil tank capacity l
0.28
Mixture ratio (fuel/two-stroke oil)
-when using DOLMAR oil
50 : 1 / 100: 1 (HP-100)
-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 Z
6
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
4.0 / 4.1 2)
1) Figures derived in equal part from idling, full-load and racing speed.
2) On models with catalytic converter.
3) Uncertainty (K=).
TECHNICAL DATA

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Reparaturanleitung PS-4600 / PS-5000 4
Repair Manual PS-32
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
TROUBLESHOOTING

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Reparaturanleitung PS-4600 / PS-5000 5
Repair Manual PS-32
123
4
5
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 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 (944.602.001)

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Reparaturanleitung PS-4600 / PS-5000 6
Repair Manual PS-32
67
8 9 10
00 SPECIAL TOOLS
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)
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)

Reparaturanleitung PS-4600 / PS-5000 7
Repair Manual PS-32
11 12
13 14
M4 x 20
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
Checking the ignition (950.233.230)
14 Mounting tool
Bearings on crankshaft (944.500.903)

Reparaturanleitung PS-4600 / PS-5000 8
Repair Manual PS-32
1
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).

Reparaturanleitung PS-4600 / PS-5000 9
Repair Manual PS-32
02 CLUTCH DRUM AND CHAIN SPROCKET
Remove the sprocket guard, bar, and chain.
Remove the circlip 3with a blade screwdriver.
Remove washer 2.
Pull the handguard towards the front grip only
as far as necessary so the clutch drum can be
removed.
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.
Assembly the bearing with multi-purpose high-
performance grease (944.360.000).
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)!
1
2
3

Reparaturanleitung PS-4600 / PS-5000 10
Repair Manual PS-32
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
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.

Reparaturanleitung PS-4600 / PS-5000 11
Repair Manual PS-32
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.
67 8910
10
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. 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.
ca. 4 mm

Reparaturanleitung PS-4600 / PS-5000 12
Repair Manual PS-32
Move piston to bottom dead centre (visible
through the exhaust opening).
Press the piston stop wedge 3(cap. 00, pos.
5) into the exhaust opening.
Position of gasket and cooling plate for muffler
assembly:
Insert wrench 4(Chap. 00, Pos. 7) into the
clutch and use a socket wrench 5to 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.
12
3
4 5
04 CLUTCH
Disassembly
CAUTION: To prevent cuts, wear protective
gloves!
Remove the sprocket guard, bar and chain.
Pull the handguard towards the front handle to
release the chain brake if necessary.
Remove the clutch drum, see Chapter 02.
Remove the muffler. To do this, unscrew the 3
screws 1and remove the upper muffler half 2.
Caution: If a catalytic converter is being
used, the muffler will be very hot after
operation!

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Reparaturanleitung PS-4600 / PS-5000 13
Repair Manual PS-32
Installing the clutch
Install the clutch with the arrow marking point
outside.
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.
04 CLUTCH
Inserting the flyweights
Hook the springs as shown in the illustration.
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.
The illustration shows the inside of the clutch.

Reparaturanleitung PS-4600 / PS-5000 14
Repair Manual PS-32
The suction line 5remains in the crankcase. It
extends into the oil tank. To remove it, carefully
pull on the connection to the oil pump.
Removing the oil pump
Push the adjusting screw 6up against the
spring pressure and turn it until the pin 7goes
into the assembly slit 7. If necessary press the
supply piston 8in somewhat.
Note: When assembling put the adjusting screw
6counterclockwise to stop.
Removing the oil tank vent
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.
1
2
A4 3
1
2
3
5
6
8
7
9
10
05 OIL PUMP
General
The oil pump is drivenby the drive worm gear 1
on the crankshaft.
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 2from the oil pump.
Unscrew screw 4and remove the oil pump.
Flathead screw
No.: 165.888.110

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Reparaturanleitung PS-4600 / PS-5000 15
Repair Manual PS-32
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).
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 8and 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 3in the fan housing and
make sure the three recesses 4engage.
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.
12
5
6
7
3
10
8
9
4
06 STARTER
Disassembly
Unscrew three screws 1.
Remove fan housing 2.
Remove air guide 3from fan housing.
Detension the return spring.
Injury hazard! Unscrew screw 5 only after
detensioning the return spring!
Unscrew screw 5and remove cam 6and
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!

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Reparaturanleitung PS-4600 / PS-5000 16
Repair Manual PS-32
yes
Is the spark plug dry and properly installed?
Is the spark gap correct? (should be 0.5 mm)
Is the spark plug oily or does it have carbon deposits on it?
Is there damage to the insulation of the high-voltage cable or the ignition cable,
or to the wires themselves?
Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range?
Remove flywheel and check. Is the flywheel damaged?
Is the positioning key damaged?
Continue with troubleshooting in fuel system (tank, fuel hose, carburetor).
Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug?
Is there carbon black on the electrodes?
no
yes
no
yes
no
no
no
no
no
no
yes
yes
Dry spark plug connector and fasten firmly to spark plug.
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.
Adjust spark gap.
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.
Replace spark plug and check ignition module for corrosion, if necessary replace.
Has the defect been remedied?
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.
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?
Replace ignition module. Has the defect been remedied?
no
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!
Pull the starting cable smartly. Is there an ignition spark?
Is the gap uneven? Has the flywheel worn against the ignition module?
no
no
yes
yes
no
07 IGNITION SYSTEM (TROUBLE-SHOOTING)

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Reparaturanleitung PS-4600 / PS-5000 17
Repair Manual PS-32
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
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.

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Reparaturanleitung PS-4600 / PS-5000 18
Repair Manual PS-32
Removing the ignition armature
Remove cover.
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.
1
2 3
4
07 IGNITION SYSTEM
Installing the ignition armature
NOTE: The high-voltage cable is moulded
onto the ignition system and cannot be
replaced separately.
Insert plastic pieces into the bolt holes on the
cylinder.
Insert the ignition armature, install the short-
circuit 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.
Note: Check the starter pawls on the flywheel
for easy movement, and clean if necessary.

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Reparaturanleitung PS-4600 / PS-5000 19
Repair Manual PS-32
Removing the intermediate flange
Disengage the combination switch 1.
Remove the front handle to simplify pulling off
the cylinder.
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.
ON
3
2
1
4
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.
11
08 CARBURETOR
Removing the intake manifold and
carburetor
CAUTION: Completely empty the fuel tank
before disassembling the carburetor!
Remove cover.
Move combination switch 1to 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).

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Reparaturanleitung PS-4600 / PS-5000 20
Repair Manual PS-32
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.
Make sure that the return line (bottom
connection on primer) is behind the guide 12.
Install the combination switch 1 with the short-
circuit cable on top and then press the short-
circuit cable 7 under the holder 6.
Install the contact spring with short-circuit
cable.
ON
8
9
6
7
10
11
12
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.
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).
Schematic diagram of the fuel lines
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.
14
08 CARBURETOR
Red fuel line