Dolmar PS-7300 Chainsaw Factory Service & Work Shop Manual

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

2 Repair Manual PS-6400/PS-7300/PS-7900 Technical data ......................................................................................... 3 Troubleshooting ...................................................................................... 4 00 Special tools ....................................................................................... 5 - 6 01 Sprocket guard / Chain tensioning system .......................................... 7 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

3 Repair Manual PS-6400/PS-7300/PS-7900 TECHNICAL DATA Stroke volume cm 3 64,2 72.6 78.5 Bore mm 47 50 52 Stroke mm 37 37 37 Max. power at speed 3) kW / 1/min 3.5 / 9,000 4.2 / 9,500 4.6 / 9,500 Max. torque at speed 3) Nm / 1/min 4.2 / 6,500 4.8 / 7,000 5.2 / 7,000 Idling speed / max. engine speed with bar and chain 1/min 2,500 / 13,500 2,500 / 13,500 2,500 / 13,500 Clutch engagement speed 1/min 3,200 3,200 3,200 Sound pressure level at the workplace L pA av per ISO/CD 22868 1) dB (A) 104.3 104.3 104.3 Sound power level L WA av per ISO/CD 22868 1) dB (A) 113.3 113.3 113.3 Vibration acceleration a h,w av per ISO 7505 1) - Tubular handle m/s 2 6.9 6.9 6.9 - Rear handle m/s 2 7.7 7.7 7.7 Carburetor (diaphragm carburetor) Type ZAMA Ignition system Type 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 in case of kickback Chain speed 2) m/s 19.74 20.83 20.83 Sprocket pitch inch 3/8 Number of teeth Z 7 Chain type see the Extract from the spare-parts list 099 Pitch / gauge inch 3/8 / .058 Guide bar, length of a cut cm 38 / 45 / 50 / 60 / 70 Guide-bar type see the Extract from the spare-parts list Weight (fuel tank empty, without chain and guide bar) kg 6.3 6.3 6.3 1) Figures derived in equal part from idling, full-load and racing speed. 2) At max. power 3) For models without starting valve Technical data PS-6400 PS-7300 PS-7900

4 Repair Manual PS-6400/PS-7300/PS-7900 TROUBLESHOOTING Malfunction System Observation Cause Chain does not run Chain brake Engine runs Chain brake actuated. Engine does not start or Ignition system Ignition spark Malfunction in fuel supply system, com- only with difficulty pression system, mechanical malfunction. No ignition spark Switch on STOP, fault or short-circuit in the wiring, plug cap or spark plug defective. Fuel supply Fuel tank is filled Choke in wrong position, carburetor defective, fuel filter dirty, fuel line bent or interrupted, torn, perforated Compression Inside Cylinder base packing ring defective, radial system shaft packings defective, cylinder or piston rings defective 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 venting defective, fuel line interrupted, cable defective, STOP switch defective. Decompression valve dirty Insufficient power Several systems Engine is idling Air filter dirty, wrong carburetor adjustment, may be involved muffler clogged, exhaust channel in cylinder simultaneously clogged, spark arrester screen clogged, worn piston No chain lubrication Oil tank/pump No oil on the chain Oil tank empty, oil guide groove dirty, oil-pump adjusting screw incorrectly adjusted, oil pump drive defective

5 Repair Manual PS-6400/PS-7300/PS-7900 1 2 3 4 5 6 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 Radial ring puller 15 mm radial ring puller (944.xxx.xxx) 17 mm radial ring puller (944.xxx.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 the motor through the exhaust port (944.602.000)

6 Repair Manual PS-6400/PS-7300/PS-7900 7 8 10 11 9 00 SPECIAL TOOLS 7 Piston ring tensioner Piston ring band and assembly tool for cylinders (944.600.001) 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)

7 Repair Manual PS-6400/PS-7300/PS-7900 01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM How the chain tensioner works The force applied to the adjusting screw is transferred by the angle worm drive to the tensioning pin. Replace the chain guide 1 if it 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 chain guard. Tool 1 2 5 3 (1,5 Nm – 0,2) 4 (1.5 Nm – 0.2)

8 Repair Manual PS-6400/PS-7300/PS-7900 P O W E R M A T E 3 / 8 - 7 Sprocket, clutch drum and needle bearing Inspect the sprocket for damage and wear. Important customer information: Before 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

9 Repair Manual PS-6400/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.

10 Repair Manual PS-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!

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Dolmar PS-7300 Chainsaw Factory Service & Work Shop Manual

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