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Repair Manual

11/99

PS-34

Table of contents

Index Technical Data page 3

Special tools 4

Repair instructions, general 5

01 Chain brake 6

02 Centrifugal clutch 8

03 Oil pump 9 -11

04 Ignition system 11-13

05 Starting system 14-15

06 Carburetor / intake system 16-19

08 Rubber buffer, handles 20

09 Fuel tank, exhaust 21

10 Pistons and cylinders 22-23

11 Crankcase, crankshaft 24-25

Torques 26

Technical Data

Stroke volume cm3 33Bore mm 37Stroke mm 31Max. power at speed kW / rpm 1.3 / 9,000Max. torque at speed Nm / rpm 1.7 / 6,500Idling speed / Max. engine speed with guide bar and chain rpm 2,800 / 12,200Coupling speed rpm 4,500Sound pressure level LpA av at the workplace per ISO 7182 1) dB (A) 99Sound power level LwA av per ISO 9207 1) dB (A) 105Vibration acceleration ah av per ISO 7505 1)

- Tubular handle m/s2 4- Rear handle m/s2 6

Carburetor (diaphragm carburetor) Type ZAMAIgnition system Type PHELONSpark plug Type NGK BPMR 7AElectrode gap mm 0.5or spark plug Type BOSCH WSR 6FFuel consumption at max. load per ISO 7293 kg/h 0.71Specific consumption at max. load per ISO 7293 g/kWh 550Fuel tank capacity l 0.37Chain oil tank capacity I 0.25Mixture ratio (fuel/two-stroke oil)

- when using DOLMAR oil 50 : 1- when using other oils 40 : 1

Chain brake engages manually or in case of kickbackChain speed 2) m/s 17,1Sprocket pitch inch 3/8Number of teeth Z 6Chain type - see the Extract from the spare-parts listPitch / Driving element strength inch 3/8 / .043Guide bar, length of a cut cm 30Guide-bar type - see the Extract from the spare-parts listWeight (fuel tank empty, without chain and guide bar) kg 4.71) Figures derived in equal part from idle, full-load, and top-speed operation.2) At max. power

Technical data PS-34

4

Setting gauge for split sizeFlywheel / ignition armature

944 500 890

Special tools

Piston stop wedge

944 602 001

Assembly wrench forclutch blades944 500 695

Flywheel remover

944 500 880

Assembly and disassembly tool foroil pump worm950 500 060

Assembly sleeve 944 500 580

Torx bits unit T27 150 mm944 500 865

Torx bits unit T27 50 mm944 500 866

Oil and fuel tankTo remove the starter, the oil and fueltank cover must be removed. If a residueis to be left in the tanks, screw tank coverback on after removing the starter.

StarterFor all work on the motor, ignition andcarburetor, oil pump and starter, thestarter must be removed after 4 screws(5) have been removed.

5

General information on repairing the PS-34

The PS-34 chain saw is a small reasonably chain saw.

The objective in developing this saw was to provide a low-priced appliance that couldbe assembled as easily as possible. Many of the design features are therefore basedon the concept of easy assembly.

The following tips summarise our experience in terms of carrying out repairs rapidly.In general, we recommend that you use an electric screwdriver.

The air filter hood is fixed with 3 screws andmust be removed for all work on the motor. Inorder to keep out dirt and foreign bodies,always close the suction duct which is open tothe top.

1 42

3

Remove tubular handle.The tubular handle is removed if work iscarried out on the carburetor, ignition ormotor. For this, remove 2 screws on theclutch side (2) + (3), plus (4) on theunderside out of the motor housing.

5 5

5

x

1

32

4

5

8

710 9a

9b

01-01 Removing the chain brakeRemove sprocket guard, nose bar and chair,clear the chain intake area.

01-01 Removing the chain brakeCarefully lever out 4 pivots (x) on thecover plate from the housing sleevesusing a long screw driver.

01-01 Removing the chain brakeThe pivots (1) are fixed by a thickersection in holes in the housing and holdthe cover plate. If pivots break off duringdismantling, replace the cover plate.

01-01 Removing the chain brakeRemove clutch drum (2) and centrifugalclutch (3, see 02-01), take straining screw(4) from housing pocket.

01-01 Removing the chain brakePush out rear sleeve (6) with screw (5), re-move front sleeve (7), remove Seeger ring (8)of upper bolt (9a), pull out both bolts (9a + 9b),remove spring (10) from brake lever fromhousing.

01-01 Removing the chain brakeLoosen chain brake to relax packingspring, loosen screw for hand guard (5)and unscrew 2-3 rounds.

01 Chain brake

6

01 Chain brake / clutch drum

02-01 Removing the centrifugal clutchRemove guard ring (4) and washer (5)and pull clutch drum with bearing off thecrankshaft.

02-01 Checking the clutch drumCheck drive pinion (6), running surface(7) and external contour (8) (-> brakespring) for wear and damage. Replaceworn or damaged clutch drums.

01-01 Removing the chain brakePush cylindrical pin (1) from housing andremove brake spring holder (2) with jointpiece.

12

01-07 Replacing the boltTighten the 2 M8 nuts (3) on the boltagainst each other and unscrew bolt

3

45

6

78

02-01 Replacing the clutch drumBefore assembly, lightly grease thebearings of the clutch drum (9) withgrease no. 944.360.000.

9

01-01 Checking the brake springCheck brake spring for wear and dam-age. Note: the chain brake is a safetycomponent, so worn or damaged brakesprings must be replaced.

1

2

3

4

65

7

8

02-01 Removing the centrifugal clutchRemove exhaust, block motor with piston stopwedge (1). Loosen blades (2) individually withspecial nut 944.500.695.

02-01 Mounting the centrifugal clutchThe thrust washer (3) must be insertedbefore the cover washer (4). Make surethat the assembly sequence is followedand the blades properly installed.

02-01 Mounting the centrifugal clutchBlade (5) + (6) w. DOLMAR markingpointing towards the motor, blade (7) withmarking (8) outwards.

02-01 Mounting the centrifugal clutchTighten blades individually with the assem-bly tool 944.500.695 to 20 +5 Nm.

02 Centrifugal clutch

03-02 Removing the oil pumpTo remove the oil pump, remove thesuction hose and cylinder, see 10-01.

03-02 Removing the oil pumpPull oil pump out of oil suction pipe.Check oil pump piston (3) for damage.

03-02 Removing the oil pumpEmpty oil tank if necessary, pull suctionhose out of tank.

03-03 Assembling the oil pumpBefore assembly, grease the oil pumppiston (3) and the housing well withsilicon past 980 007 100.

03-04 Air supply to and removal fromoil tankClean splint and hole.

1

2

2

3

03-02 Removing the oil pumpThe oil pump piston is driven by the worm (1)on the crankshaft. The pivot in the holder (2)fixes the oil pump in the right position andcontrols the lifting movement of the piston.

03 Oil pump

x

3

21

4

--->

5

6

03-04 Removing the oil suction pipeRemove the oil suction pipe from thehousing.

03-04 Replacing the oil suction pipeInsert guide tie (1) into the housingpocket, push connection nipple (2) firmlyinto the hole (3).

03-04 Replacing the oil suction pipeGrease the flange areas (x) for bettersealing and easier assembly with siliconepaste 980.001.100.

03-04 Installing the oil pumpPosition oil pump on worm, insert holderpivot into the hold (4) of the oil pump andscrew up.

03-04 Removing the wormTwist the removal and assembly tool950.500.060 onto the worm (left-handedthread) and remove from the crankshaft.

03-05 Replacing the wormTwist the worm (5) into the removal and as-sembly tool until it is flush (left-handed thread).Position assembly sleeve 944.500.580 (6)onto the crankshaft. Push the worm onto thecrankshaft as far as it will go.

03 Oil pump

04-04 Removing the spark plugRemove motor hood. Remove spark plugcap. Loosen and unscrew the spark plug witha universal wrench 941 719 131 or similartool w. 19 mm opening.

04-04 Testing the ignition system withtest deviceConnect test device. Operating lever (3)must be in position ‘I’. Pull starter rope (4)out quickly. If no power registered, checkwiring, repeat test with new ignition coil.

04-04 Removing the ignition systemRemove motor cover and tubular handleand starter cover as described in intro-duction.

04-04 Replacing the spark plugTighten the spark plug using universalwrench 941.719.131 only or max. 20 Nm ifother tools are used.

04-04 Check spark plugCheck whether a spark (5) jumps acrossat the electrode. If no spark, repeat testwith new spark plug. Clean or replacedirty or damaged spark plugs.

1

2 3

4

04-04 Check spark plugConnect spark plug (1) with spark plug cap(2) and connect to earth Operating lever (3)must be in position ‘I’. Pull starter rope (4)quickly.

34

5

04 Ignition system

Warning: high voltageWear protective glovesand use insulated tools!

04-04 Mounting the flywheelBefore assembly, clean crankshaft pivot (1)and flywheel cone (2). The flywheel contains adevice to prevent torsion. When positioning,insert the torsion guard into the groove of thecrankshaft (3).

04-04 Removing the flywheelBlock motor with piston stop wedge (x)944.602.001 and loosen flywheel nut.

04-04 Removing the ignition systemPull off the short-circuit cable flat plug andunscrew the 2 screws of the ignitionsystem.

04-04 Removing the flywheelScrew flywheel remover 944.500.880onto the crankshaft, pull flywheel upwardsand remove the flywheel from the cone bytapping on the remover.

3

2 1

04-04 Mounting the flywheelSet the crack between the flywheel mag-net and the poles of the ignition coil at 0.2mm using the setting gauge 944.500.890(4).

4

04-04 Mounting the flywheelTighten the flywheel nut with 20 + 2.5 Nm.

04 Ignition system, flywheel

x

04-04 Removing the short-circuit cableRemove the contact spring (4) from thehousing pocket.

04-04 Replacing the short-circuit cableThe 2 core short-circuit cable connects thecontacts of the ignition coil (1) and earth (2)with the stop switch (3).

1

2

3

04-04 Replacing the short-circuit cableThe short-circuit cable is taken under thecarburetor sleeve in a clamping strip to thechoke and operating lever.

4

55

04-04 Removing the choke leverRemove the cable with the flat plug (5)from the guide pocket (6). Push the chokelever in the direction of ‘stop’ in order toswing the arm from the housing pocket.

04-04 Removing the short-circuit cableThe flat plug contact (5) is connected withthe contact spring. The round contact (6) isinserted from the clutch side into the open-ing in the choke lever.

5

6

04-04 Mounting the short-circuit cableCheck whether, in the STOP position, theround contact in the choke lever is posi-tioned on the metal tongue of the contactspring.

7

04 Ignition system, short-circuit cable

05-02 Removing the starting systemRemove the motor hood and tubularhandle as described in introduction.

05-02 Removing the starting systemLoosen 4 screws and remove startercover.

05-02 Removing the cable drumPull out starter rope between cable drumand starter housing. Relax rewind springby slowly letting the cable drum run back.

05-02 Insert rewind springa) Wind up rewind spring by hand.Wind up spring in anti-clockwise direction.Insert spring eye in housing. Greasespring with grease no. 944.360.000.

05-02 Removing the starting systemPull out the starter rope as far as it will goand hold the drum tight.

05-02 Removing the cable drumLoosen screw (1) and remove cable drum.Take spring unit out of pocket with pincers.

1

05 Starting system

05-02 Mounting the starterInsert cable drum with knotted starterrope, let the spring click into the carrierand tighten screw.

05-02 Mounting the starterTo check the pretension of the rewindspring, pull the starter rope out completely.Cable roller must be able to turn at leastanother 1/2 turn further.

05-02 Inserting the rewind springb) as spare part. Insert the spring unit securedwith wire, insert spring eye in housing andpush spring into housing pocket. Grease withgrease no. 944.360.000.

05-02 Mounting the starterTake starter rope through the eyelet, pullstarter handle over the rope and securewith knot.

05-02 Mounting the starterTension rewind spring by turning severaltimes, allow starter rope to slide onto cabledrum.

05-02 Mounting the starterIf the cable drum cannot turn any further,reduce the pretensioning by letting out asection of starter rope.

05 Starting system

06-02 Removing the carburetorRemove the motor hood and tubularhandle as described in introduction.

06-02 Removing the carburetorEmpty tanks if necessary. Remove side coverafter loosing the 4 screws. If oil or fuel is left inthe tank, replace tank cover.

06-02 Removing the carburetorPull the fuel line to the carburetor (1) andthe hose to the primer (2) off the outletusing pliers.

06-01 Setting the carburetorThe injector needles L + H and the stopscrew S can be reached via holes in thetubular handle strut.

S

LH

2

1

06-02 Removing the carburetorPull fuel tank out of the housing openingand place so that no fuel can leak out.

06-01 Setting the carburetorFor the basic setting, screw in both screws as far asthey will go. Then unscrew both screws 1 turn. If themotor turns too quickly (taking the chain with it) or tooslowly (the motor dies off), adjust the screw S.

06 Carburetor / intake system

06-02 Removing the carburetorPull the contact spring (1) of the chokelever from the eye in the motor housingusing pliers.

1

06-02 Removing the carburetorPush the choke lever in the direction of ‘Stop’in order to swing the arm out of the housingpocket. Remove cable with flat plug (2) fromguide pocket (3).

2

3

06-02 Removing the carburetorPull choke lever from housing with slightturning movements.

06-02 Removing the carburetorIf necessary, pull the round plug contactinserted from the back out of the pocketusing pliers.

06-02 Removing the carburetorThe cable is taken under the carburetor clip.To stop it getting in the way during subse-quent work, fix with adhesive tape positionunderneath, if nec. remove contact springand choke lever.

06-02 Removing the carburetorCompletely loosen 2 vertical fixing screwsfor the connecting muff (4).

4


06-02 Removing the carburetorThe carburetor clip (3) with the suctionhose (4) remains on the cylinder. Makesure that the loose insert (5) does not getlost.

06-02 Removing the carburetorRemove connecting muff upwards with aslight movement to the left.

06-02 Removing the carburetorRemove carburetor screw and remove thecarburetor from the carburetor carrier,twisting slightly.

06-02 Removing the carburetorLoosen 2 horizontal screws (1). The rightscrew is reached through the slit betweenthe tank and the motor housing.

1

06-02 Removing the carburetorLoosen the two horizontal screws until theheads are exactly on a level with theexternal contour of the connecting muff(2). Only in this way can the connectingmuff be removed.

2

3

4

5

06-02 Removing the carburetorLoosen the clip fixing of the primer (6)and remove with hose.

6


06-03 Pump side of the carburetorUnscrew cover (9), remove gasket (10)and diaphragm (11). Clean filter in bottomof carburetor (12).

06-02 Installing the carburetorPosition the connecting muff so that it is slightlytilted to the left so that the back right-handdouble strut of the connecting muff (1) is posi-tioned behind the plate of the carburetor clip.

1

06-02 Installing the carburetorInsert the connecting muff with a slighttwist to the right.

06-03 Control side of the carburetorUnscrew cover (2), remove diaphragm (3)and gasket (4). Remove screw (5). Removethe admission needle (6) with spring (7),arm and axle (8).

23

4

5 6

8

7

1211

109

06-03 Checking the admission needlesfor leaksPull fuel line off carburetor nipple and puton hose of test appliance 944.603.020.Check that 0.5 bar is maintained over aminute.

06-08 Removing the throttle linkageRemove the handle to the side (14). Withassembly, position the angle of the throttlelinkage (15) behind the plate of the throttlegrip (16). The throttle linkage is inserted inpockets on the housing floor (17).

14

15

16

17


08-02 Removing the rubber bufferRemove 2 screws (1) and sleeves (2).Fold back handle to the side so that thethrottle linkage slides out of the throttleguide.

08-08 Dismantling the handleThe throttle grip (10) and catch lever (11)are inserted in handle guides with aspring (11).

1

1

08-02 Rubber buffers3 hollow rubber buffers (4) on the clutchside are inserted in the housing.

4

08-08 Dismantling the handleThe grip shell (6) is built together with thehandle (9) with 2 brackets (7) and pins (8).Lever the housing apart from the inside.

5

5

7

69

11

10

12

08 Rubber buffer /handles

08-08 Dismantling the handleThe pivots of the grip are held tightly inthe sleeves. Increase leverage forcegradually until pivot clicks out. If bracketsor pivots break, replace housing.

08-02 Rubber buffersOn the magnet side, 1 hollow rubberbuffer (5) is inserted in the starter hous-ing.

09-01 Removing the fuel tankRemove the tubular handle, motor hoodand starter cover as described elsewhere.

09-01 Removing the fuel tankPull the fuel line and primer line off theconnector on the carburetor and primerusing pliers. Pull slot-in tank out of hous-ing.

09-02 Ventilation and air supply to tankThe air valve is pressed into a hole in thetank wall.

09-05 Fuel filterThe suction head (1) at the end of thesuction pipe (2) is inserted into the rubbershaped hose. replace suction head peri-odically.

Special parts forUSA, CDN, AUS, NZ

09-08 Removing and mounting theexhaustThe sound absorber is fixed to the cylin-der with 2 screws which also fix the insideparts. After test run, tighten the screws at12 Nm.

09-08 Cleaning the spark arresterscreen(if provided)

Remove and clean the spark arresterscreen (3) regularly, or if power is reducedat the latest.

1

2

3

09 Fuel tank / exhaust

10-01 Removing the driving mechanismRemove the motor hood and tubular han-dle as described in introduction.

10-01 Removing the driving mechanismRemove the connecting muff as describedin 06-02.

10-01 Removing the driving mechanismOnly remove ignition and flywheel if cylin-der is to be replaced.

➪➪

➪

10-01 Removing the driving mechanismLoosen and unscrew the 4 cylinder screws.

➪

10-01 Removing the driving mechanismLift out motor unit upwards in direction ofarrow.

➪

10 Piston and cylinder

10-01 Dismantling the driving mechanismRemove carburetor clip (1) and checkpulse wire. for assembly, click the holdingclip (2) into place in the motor housing.

1

10-01 Dismantling the driving mechanismThe white insert ring (3) is positioned loosein the carburetor clip. Make sure that itdoes not get lost.

3

To prevent damage during mounting, the pulsewire (4) in the connecting muff should be lightlygreased before assembly.

For greasing, please use oil or DOLMAR sili-cone paste, order no. 980.007.100.

Note: If you use silicone paste, make sure thatthe pulse opening (3) is not blocked.

1

4

10-01 Dismantling the driving mechanismThe driving mechanism consists of thecylinder (5), piston (6), crankshaft (7) andthe crank case lower part (8).

10-01 Dismantling the driving mechanismRemove carburetor clip (1) and check pulsewire (4).

5 8

7

6

10-01 Dismantling the driving mechanismThe piston bolt is fixed by 2 snap rings (9).To dismantle, remove one snap ring andpush out piston bolt.

9

2

10 Piston / cylinder

10-01 Replacing the piston /crankshaftCheck running surfaces of the piston (1),connecting rod bearing (2), crankshaftbearing (3) and piston bolt (4) for wear ordamage. Replace faulty parts.

10-01 Replacing the radial sealing rings/bearingsFor the removal and mounting of the crankshaftbearing and sealing ring on the clutch side, pull offthe worm of the oil pump using the removal andmounting tool 950.500.060.

1

3

2

4

5

10-01 Replacing the piston/crankshaftCheck radial sealing rings and crankshaftbearings; if necessary pull off crankshaft bear-ings and replace radial sealing rings (5) by newones.

6

10-01 Mounting the driving mechanismInsert the crank case lower part into themotor housing, and insert the oil pumpdrive worm into the gearing of the oilpump.

--->

7

8

10-01 Mounting the wormTwist the worm (7) into the removal and as-sembly tool until it is flush (left-handed thread).Position assembly sleeve 944.500.580 (8)onto the crankshaft. Push the worm onto thecrankshaft as far as it will go.

11 Crankshaft

10-01 Mounting the driving mechanismReplace the crank case seal (1) andinsert dry without sealant.

1

10-01 Mounting the driving mechanismPosition piston ring joint (2) in the direction ofthe intake/carburetor side, the arrow on thepiston then points towards the exhaust, the oilpump worm points towards the right if thecarburetor side is upwards.

7

10-01 Mounting the driving mechanismThe cylinder has a cone so that the pistoncan be inserted into the cylinder guidewithout tools.

10-01 Mounting the driving mechanismTighten the 4 driving mechanism screwsfirmly with a force of 12 Nm.

11 Crankshaft

Exhaust at cylinder

Cylinder

Ignition

Tubular handle

Carburetor, vertical

Carburetor, horizontal

Flywheel

Clutch blades

Spark plug

Starter cover

Tubular handle

12,0 -0,5

12,0 -1,0

4,8 -0,5

3,5 -0,5

3,0 -0,5

3,0 -0,5

20,0 +2,5

20,0 +5,0

20,0 ± 3,0

4,5 +0,5

3,5 ± 0,5

Type torque Nm

Torques

DOLMAR GmbH • Postfach 70 04 20 • 22004 Hamburg Form-Nr. 995 725 020

11/99 - henigins.comhenigins.com/yahoo_site_admin/assets/docs/DOLMAR...Sound pressure level LpA av...

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Transcript of 11/99 - henigins.comhenigins.com/yahoo_site_admin/assets/docs/DOLMAR...Sound pressure level LpA av...