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.