Dolmar PS-35 C Repair Manual Download

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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

Summary of Contents for PS-35 C

Page 1: ...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 ...

Page 2: ... 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 ...

Page 3: ...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 kickbac...

Page 4: ... 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...

Page 5: ...erpressure 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 8 9 10 11 12 13 14 15 ...

Page 6: ...in 1 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 If necessary turn adjusting screw 2 clockwise until the fastening screw 4 is 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 ...

Page 7: ...oner Unscrew bolt 5 and 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 4 with spring 3 into the sprocket guard Press the carrier with folding handle 1 into t...

Page 8: ...e washer 2 Clutch drum with sprocket and needle bearing Check the chain sprocket 1 for 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 ...

Page 9: ... 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 Lift the brake band 3 upward 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 2 1 1 3 4 5 03 CHAIN BRAKE ...

Page 10: ...ee 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 as...

Page 11: ...converter is being used the muffler will be very hot after operation 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 5 to turn in the direction of the arrow left hand thread to loose...

Page 12: ...ay 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 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 da...

Page 13: ...il pump Unscrew screw 4 and remove the oil pump 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 Removing the oil pump Push the adjusting screw A up against the spring pressure and turn it until the pin 6 goes into the assembly slit 6 If necessary press the supply piston 7 in somewhat Note When assembling put the...

Page 14: ...g 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...

Page 15: ...ong 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 radi...

Page 16: ... 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 ...

Page 17: ...tic 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 t...

Page 18: ...e spark plug Completely unscrew cylinder head bolts Turn the flywheel so that the magnets are NOT on the ignition armature Pull the cylinder intermediate flange and ignition armature up and off Assembly Note Carefully remove old cylinder base gasket fragments When assembling install a new cylinder base gasket The gasket tab must point towards the outlet side Before assembly coat the cylinder path ...

Page 19: ...holder 8 Install the contact spring with short circuit cable Tighten the cylinder head bolts by hand evenly alternating crosswise and then tighten to the right torque 10 0 5 Nm likewise alternating crosswise Screw in screws 4 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 hori...

Page 20: ...mination 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 Poor acceleration No maximum power If the control lever is too high Carburetor flooding Starting problems Poor idling Poor transition Check the pump diaphragm If ...

Page 21: ...Spring 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 3 4 1 2 ...

Page 22: ...tubular handle 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 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 The catch lever 4 can easily be pushed through...

Page 23: ...n be used to localise leaks Vacuum testing ventilation valve 6 Attach the over underpressure pump as described 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 t...

Page 24: ... 08 Remove crankcase 4 bolts on underside and remove it from the engine mount Note Install cylinder on crankcase again see Chap 08 Always perform sealing tests with underpressure If a leak is diagnosed it can be found using overpressure and detergent or similar liquid 11 CYLINDER PISTON Vacuum testing If correct carburetor setting is not possible it will be necessary to test a leakage of the engin...

Page 25: ...ial seal rings Remove the radial seal rings with the puller Chap 00 Item 15 Fill new radial seal rings 5 with grease and place in housing Crankcase Crankcase CS 1 and MS 2 are replaceable as separate parts and are bolted with 3 bolts 3 10 0 5 Nm Insert crankcase gasket 4 dry The crankcase is bolted to the engine mount with 4 bolts 6 10 0 5 Nm Ball bearing Heat both crankcase sides CS and MS to 150...

Page 26: ...x M5x20 with clamp washer 2 5 0 5 flywheel fastening by nut 165 888 140 SW 13 M8x1 1 20 5 0 starter cpl to engine housing 913 455 164 Torx 5 5x16 3 4 0 5 hood 908 605 205 Torx M5x20 1 3 0 5 grip shell at tank 913 455 164 Torx 5 5x16 1 3 0 5 fastening of tubular handle at side of tank 913 455 164 Torx 5 5x16 2 4 0 5 fastening of tubular handle on bottom of tank 913 455 164 Torx 5 5x16 2 4 0 5 faste...

Page 27: ...27 Repair Manual PS 35 NOTES ...

Page 28: ...DOLMAR GmbH Postfach 70 04 20 D 22004 Hamburg Germany ...

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