Dolmar PS-6400 Repair Manual Download Page 6 | Manualshive

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Repair Manual PS-6400/PS-7300/PS-7900

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SPECIAL TOOLS

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Piston ring tensioner

Piston ring band and
assembly tool for cylinders

(944.600.001)

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Assembly and disassembly wrench

Wrench for disassembling and assembling
the centrifugal clutch

(944.500.570)

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Pressure gauge

Pressure guage for checking
the carburetor fuel valve

(956.004.000)

10 Tachometer

Electronic tachometer for measuring
the engine speed of
2- and 4-stroke engines

(950.233.210)

11 Installation sleeve

for radial rings

(944.603.410)

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Summary of Contents for PS-6400

Page 1: ...1 Repair Manual PS 6400 PS 7300 PS 7900 02 05 Repair Manual www dolmar com PS 6400 PS 6400 H PS 7300 PS 7300 H PS 7900 PS 7900 H ...

Page 2: ... 02 Clutch drum Rim sprocket 8 03 Chain brake 9 14 04 Clutch 15 16 05 Oil pump 17 19 06 Starter 20 22 07 Ignition system 23 26 08 Carburetor 27 31 09 Vibration damper Tubular handle 32 33 10 Tank 34 35 11 Cylinder Piston 36 12 Outside components Crankcase Crankshaft 37 38 13 Handle Heating 39 41 14 Torques 42 15 Check operation 43 CONTENTS ...

Page 3: ...pe electronic Spark plug Type NGK BPMR 7A Electrode gap mm 0 5 or spark plug Type BOSCH WSR 6F Fuel consumption at max load per ISO 7293 3 kg h 1 72 2 33 2 3 Specific consumption at max load per ISO 7293 3 g kWh 500 510 505 Fuel tank capacity l 0 75 Chain oil tank capacity I 0 42 Mixture ratio fuel two stroke oil when using DOLMAR oil 50 1 when using other oils 40 1 Chain brake engages manually or...

Page 4: ...e Outside Spark plug does not seal Mechanical Starter does not engage Spring in starter broken broken parts malfunction inside the engine Warm engine doesn t Carburetor Fuel tank is filled Wrong carburetor adjustment start Ignition spark flooded by usage of the ckoke Engine starts but Fuel supply Fuel tank is filled Wrong idling adjustment fuel filter or dies immediately carburetor dirty Tank vent...

Page 5: ...xx xxx Spindle 950 203 020 3 Mandrel Disassembly mandrel for knocking the flywheel loose without damage to the crankshaft thread 944 500 880 4 Setting gauge Gauge for measuring the gap between flywheel and ignition armature 944 500 891 5 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 6 Piston stop wedge Wedge for blocking...

Page 6: ...001 8 Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch 944 500 570 9 Pressure gauge Pressure guage for checking the carburetor fuel valve 956 004 000 10 Tachometer Electronic tachometer for measuring the engine speed of 2 and 4 stroke engines 950 233 210 11 Installation sleeve for radial rings 944 603 410 ...

Page 7: ... is worn Mount the housing 2 in the sprocket guard with slotted screw 3 3 5 x 9 5 NOTE The worm drive is available only as a set 5 Grease the spindle and worm with multipurpose grease 944 360 000 Chip guide The chip guide ensures that chips are deflected away from the cut This is especially important for rip cuts to prevent clogging To replace it push the catch 4 inwards from the outside of the ch...

Page 8: ...efore installing a new chain the sprocket must be inspected Worn sprockets will damage a new saw chain and must always be replaced Check the clutch drum bearing for damage and wear Assemble with multipurpose high performance grease 944 360 000 Check the clutch drum for damage and wear and replace if worn Note Always use a new circlip 927 408 000 02 CLUTCH DRUM RIM SPROCKET ...

Page 9: ... PS 7300 PS 7900 1 2 03 CHAIN BRAKE Chain brake The chain brake stops the chain within 0 1 seconds in the event of kickback The brake band 2 encircles the clutch drum 380 A spring 1 pulls the brake band around the clutch drum ...

Page 10: ...6400 PS 7300 PS 7900 03 CHAIN BRAKE Engage the chain brake Push the hand guard forward so that the linkage release the spring tension Safety note Strong spring Never work on the chain brake when the spring is under tension ...

Page 11: ...and pull off the sprocket 4 with discs Pull the hand guard slightly towards the tubular handle do not let it disengage and hold it firmly to cancel the brake force on the clutch drum Important If the hand guard disengages push it forward again Never actuate the hand guard without the clutch drum This could break the linkage or the housing Remove the clutch drum 5 note needle bearing 6 and release ...

Page 12: ...en screw 2 Lever brake band 1 out of the housing and turn it 90 to disengage it from the lug 3 Check the inside of the brake band for signs of wear The chain brake is an important safety component Always check it for wear A worn brake band must be replaced 927 408 000 Tool 03 CHAIN BRAKE ...

Page 13: ...forth slightly and pulling up This will lever the linkage from the pin Pull the disengagement mechanism 2 out of the spring 3 Pull the spring 3 out of the spring housing 4 and pull the spring housing out of the housing Assembly Before assembly drive the slotted pin 5 out of the housing with a mandrel dia 4 mm in the direction of the muffler Install the disengagement mechanism and insert the groove...

Page 14: ...w 1 M5 x 20 Remove bushing 2 Unscrew Torx screw 3 908 005 206 M5 x 25 microencapsulated When reassembling always replace screw 3 or secure it with Loctite 243 980 009 000 Remove bushing 4 Push linkage arm 5 up slightly and disengage it may be necessary to hold the pin against it Remove hand guard Tool 03 CHAIN BRAKE 4 0 Nm 0 5 4 0 Nm 0 5 ...

Page 15: ...ld on the clutch hub with 3 tension springs The maximum idle is 2600 rpm If the clutch drum engages i e the chain turns under 3200 rpm clean and inspect the clutch It may be necessary to replace the springs Remove the muffler Block the engine with piston stop wedge 944 602 000 Remove the clutch drum see page 11 Loosen the clutch 1 with assembly tool 944 500 570 by turning clockwise Tool ...

Page 16: ...t the centrifugal weights with the TOP lettering towards the outside Careful The springs can fly out and cause injury Assembly note Disassemble the starter assy to prevent a damage of the starter ratchets Push the disc washer 1 into the clutch Use the assembly wrench 944 500 570 to tighten the clutch The lug 3 of the clutch drum should not be on the arms of the oil pump drive 2 Replace the muffler...

Page 17: ...nsfer power to the arms on the oil pump drive 2 The drive worm of the oil pump drive engages in the teeth of the oil pump piston 3 This means that oil is supplied only when the saw chain is moving The oil pump is attached to the crankcase with 2 Torx screws 4 M5 x 12 Removing the clutch drum see page 11 Removing the clutch see page 15 Tool 8 0 Nm 1 0 ...

Page 18: ...med by the halves of the crankcase The large oil tank cap 3 makes oil filling easy The oil tank is ventliated by valve 2 in the crankcase To replace it drive the valve into the tank with a mandrel dia 4 mm and press in a new valve from the outside with a mandrel dia 8 mm CAUTION Use mandrel with planar surface ...

Page 19: ...oil pressure line 6 links the oil pump and the guide bar connection Adjusting the supply rate CAUTION The adjustment range is smaller than 1 4 turn 70 The oil supply rate is regulated with the adjusting screw 7 The adjusting screw is on the bottom of the housing The oil pump is factory adjusted to a medium supply rate To change the setting use a screwdriver max 5 mm tip to turn the adjusting screw...

Page 20: ...0 Nm 1 0 4 5 Nm 1 0 2 06 STARTER Starter The fan housing is bolted onto the crankcase with 3 Torx slotted screws 1 M5x20 Induction channel The air duct 2 guides the inducted cool air to the cylinder for proper operation Tool 4 0 Nm 1 0 4 5 Nm 1 0 ...

Page 21: ...8 164 020 dia 3 5 mm 1 8 length 980 mm 39 as shown in the diagram don t forget washer 2 and knot both ends Put the cable drum on and turn it slgihtly until the return spring catches Screw in screw 1 with washer and tighten NOTE With the starter cable pulled out all the way it must still be possible to turn the cable drum at least another quarter turn against the spring force CAUTION Injury hazard ...

Page 22: ...able drum CAUTION Injury hazard Broken springs can pop out Wear protective goggles and protective gloves Replacement return springs are delivered pre ten sioned in the cable drum CAREFUL the spring can pop out If it does it can be put back in as shown in the diagram Before installing the new return spring and the spring cartridge in the fan housing grease both lightly with multipurpose grease 944 ...

Page 23: ...he opening Unscrew the spark plug 7 Remove fan housing 4 and air duct 5 Remove the flywheel 6 with the disassembly mandrel 944 500 880 see Page 26 Unscrew the vibration damper 8 3 pieces see Page 33 Separate the tank and engine unit To do this pull the wire terminals off the short circuit switch and pull the fuel line 9 from the carburetor and then out of the carburetor base 10 Loose the bowden ca...

Page 24: ...e electrodes sooted no yes no yes no no no no no no no no yes yes yes yes yes yes no no no Dry plug and fasten firmly on ignition plug If needed replace plug or spring in the ignition plug Replace ignition plug Use ONLY ignition plugs approved by DOLMAR See operating manual Otherwise the ignition module might get damaged remove the causes for sooted electrodes bad two tact oil wrong mix defect air...

Page 25: ...l fill the in screw hole with silicone paste NOTE Make sure that switch 1 is in the correct position with the stop arrow in direction to the starter Use clamp 2 just once Push it into the hole in the crankcase with a screwdriver Ground connection with slotted screw 3 3 5 x 9 5 mm Always make sure there is a good ground connection Spark plug NGK BPMR 7 A 965 603 021 BOSCH WSR 6F 965 603 014 Electro...

Page 26: ...on a soft surface and loosen the flywheel with a hammer blow on the disassembly mandrel Use pawl set 108 166 051 with pin 2 for replacement The woodruff key is cast into the flywheel CAUTION Watch for the right fitting of the flywheel Clean the cranksahft cone well Tighten flat nut 1 M8 x 1 with torque wrench Set gap to 0 3 mm Place gap gauge 944 500 891 between the flywheel magnets and the igniti...

Page 27: ...or out of the cylinder chamber for winter operation 5 The clamps 2 must be tight enough to require a tool for loosening Air filter Clean the air filter 3 see Instruction manual Protective hood Disassamble hand guard see page 14 The protective hood 4 and carburetor base are fastened to the crankcase with 2 Torx screws 5 M5 x 20 with loss proof washers Tool 6 0 Nm 0 5 ...

Page 28: ...r base with silicone paste The adjustment guide 4 is pushed in from the outside with the starter assembly removed Airmaster In idle the rubber flap valves 5 open Any dirt in the carburetor area will fall out through the rubber flaps and the carburetor base As engine speed increases the valves will shut Periodically check the rubber valves for damages and replace when necessary For disassambling pr...

Page 29: ...1 08 CARBURETOR Removing the carburetor Disengage the choke lever pull out and turn clockwise Use needle nose pliers to remove Plug 1 Bowden cable 4 Fuel hose 6 Impulse hose 5 Unscrew fastening screws 2 Pull carburetor up and out with the manifold Tool ...

Page 30: ...5 08 CARBURETOR Induction channel The carburetor and the manifold are screwed to the flange ring 2 with two 2 screws 3 M4 x 55 with countersunk square nut 1 During assembly tighten screws 3 only to 1 0 Nm 0 5 CAUTION Don t forget the bushing 4 Tool 1 0 Nm 0 5 ...

Page 31: ...USA EPA L H 08 CARBURETOR Carburetor Carburetor with choke valve USA Version with Limiter Caps Factory setting L 1 H 1 1 8 Idle speed 2500 rpm Max speed 13500 rpm Electronic speed limiter NOTE Always use a tachometer when adjusting the carburetor ...

Page 32: ...UBULAR HANDLE Handles Forward tubular handle of aluminum tubing with synthetic sleeve Assembly with 4 Torx screws 1 5 5 x 20 Clamp is fastened to the tubular handle with a Torx screw 2 6 x 14 Clamp is asymetric fixing Point of the clamp must face off the cylinder Tool 5 0 Nm 0 5 ...

Page 33: ...withTorx screw 2 M6 x 14 Replace forward clutch side spring 3 038 114 130 complete with screw and cap Rear clutch side spring is fastened with Torx screws 4 M5 5 x 20 small screw head Removing and reinstalling the spring caps First loosen the inside Torx screws then unscrew the caps with 10 mm Allen key If the Allen key is overwinging spray the cap with ice spray and try it again To assemble first...

Page 34: ...cable The grip shell is attached to the tank with a Torx screw 1 4 x 20 mm Disengage the throttle lock 2 and spring 3 Check for ease of motion and functioning of the safety throttle lock spring 3 To replace the throttle trigger and throttle lockon lever drive out the cylinder pins 4 3 x 24 mm and 5 3 x 38 mm with a mandrel ø 2 mm 4 0 Nm 0 5 Tool ...

Page 35: ... wire from housing At machines with heated handles detach cable from heated handle switch Installation Push fuel line through carburetor base Position complete forward clutch side damper Insert rear clutch side and magneto side damper bushings start screws Tighten bushings Tighten screws Connect short circuit wire with switch Engage throttle Bowden cable Connect fuel line to carburetor Insert carb...

Page 36: ... rings 12 x 1 and drive out the piston pin with disassembly mandrel ø 10 mm Never use the c rings twice Check the ring groove clean if necessary Assembling the cylinder Use a new gasket 5 965 531 121 for each assembly instance Before assembly lubricate the big end bearing 6 and cylinder bore with two stroke oil Use the piston ring tension band and assembly tool 944 600 001 The cylinder is screwed ...

Page 37: ...ew 3 M5 x 12 above and Torx screw 4 M5 x 16 below Secure screws 3 and 4 with Loctite 243 980 009 000 Replacing the guide bar bolts The two guide bar bolts 5 can be replaced To disassamble the bar bolt counter two M8 nuts Carefully remove any residue without damaging the threads If necessary rework the threads If the threads are severely damaged the crankcase will have to be replaced Secure guide b...

Page 38: ...lways apply a dry new gasket 3 038 111 042 Cut off the excess gasket after crankcase assembly is complete Replacing the radial ring A new radial ring puller is in progress Fill new radial ring 5 with grease and insert in crankcase with the special tool Replacing the crankshaft Heat the crankcase clutch side and magneto side to 150 160 C 302 320 F Evenly coat the external ring of the ball bearing 4...

Page 39: ...insulation cap is damaged or is missing Free up cable for measuring Remove switch for handle heating 2 carefully with a small screwdriver from tank Remove carefully locking hook 3 on plug of the sec ond handle with a screwdriver and pull the plug up ward Test contact pins in plug These must be clean free of corrosion exposed and at the same height The contact pins of the plug or the sleeve are to ...

Page 40: ...onductivity between both connections Conductivity replace switch 975 001 250 Bend the connection points of the new switch in the same way as can be seen on the old switch Place the switch 1 for the handle heater in the ON posi tion and remove the pin in the middle of the switch Test conductivity between both connections on the switch No Conductivity replace switch 975 001 250 Bend the connection p...

Page 41: ...ront of the sleeve of the second handle Resistance 1 2 Ohm at approx 20 C Tank 038 114 070 must be replaced completely if resistance is incorrect Heating foil in tubular handle 3 Measure the resistance between both pin contacts of the tubular handle Resistance approx 5 Ohm at approx 20 C Tubular handle 038 310 030 must be replaced if resistance is incorrect Tools Conductivity tester or multi meter...

Page 42: ...Spike bar Chain catch crankcase bottom Torx M 5 x 16 1 x 12 0 5 Spike bar sprocket guard Torx M 5 x 12 2 x 10 0 5 Chain tensioning housing Slotted BZ 3 5 x 9 5 1 x 1 5 0 2 Grip shell tank Torx M 4 x 20 1 x 4 0 5 Tubular handle Torx 5 5 x 20 4 x 5 0 5 Damping spring cap attachment 3 7 5 0 5 Damping spring tank clutch and magneto side rearTorx 5 5 x 20 2 x 5 0 5 Damping spring tank clutch side forwa...

Page 43: ...43 Repair Manual PS 6400 PS 7300 PS 7900 15 CHECK OPERATION ...

Page 44: ...44 Repair Manual PS 6400 PS 7300 PS 7900 DOLMAR GmbH Postfach 70 04 20 D 22004 Hamburg Germany Form Nr 995 724 020 ...

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