Repair Manual

___

DCS3500
DCS3501
DCS4300
DCS4301
EA3500F
EA3501F
EA4300F
EA4301F
MEA3500L
MEA3500M
MEA4300G
MEA4300L

Caution:
Before doing any maintenance or service work, the combination switch must be engaged in the service position, in
order to prevent unintended starting by the easy start system!

www.dolmar.de

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 1

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 CONTENTS ___

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 / Guide bar bolt ............................................................................................................................................ 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...................................................................................................................................................................... 21
10 Tank ................................................................................................................................................................................. 22 – 23
11 Cylinder / Piston .............................................................................................................................................................. 24 – 26
12 Crankcase / Crankshaft ........................................................................................................................................................... 27
13 Torques ................................................................................................................................................................................... 28

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 2

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 TECHNICAL DATA ___

EA3500F / EA3501F EA4300F / EA4301F

DCS3500 / DCS3501 DCS4300 / DCS4301
MEA3500M / MEA 3500L MEA4300G / MEA4300L
3
Stroke volume cm 34.7 42.4
Bore mm 38 42
Stroke mm 30.6 30.6
Max. power at speed kW / 1/min 1.5 / 9,500 1.7 / 9,500 2.0 / 9,500 2.2 / 9,500
Max. torque at speed Nm / 1/min 1.9 / 6,500 2.1 / 6,500 2.4 / 6,500 2.6 / 6,500
Idling speed / max. engine speed with bar and chain 1/min 2,800 / 13,500 2,800 / 13,500
Clutch engagement speed 1/min 5,100 5,100
Sound pressure level at the workplace LpA av per ISO/CD 22868 1) dB (A) 100.8 100.8
Sound power level LWA av per ISO/CD 22868 1) dB (A) 110 110
Vibration acceleration ah,w eq per ISO 22867 1)
- Tubular handle m/s2 4.3 3.6
- Rear handle m/s2 3.6 3.2
Carburetor (diaphragm, choke flap carburetor) Typ membrane carburetor membrane carburetor
Ignition system Typ electronic electronic
Spark plug Typ NGK BPMR 7A NGK CMR7A-5 NGK BPMR 7A NGK CMR7A-5
Electrode gap mm 0.5 0.5
BOSCH WSR 6F, BOSCH WSR 6F,
or spark plug Typ -- --
CHAMPION RCJ 6Y CHAMPION RCJ 6Y
Fuel consumption at max. load per ISO 7293 kg/h 0.79 0.96
Specific consumption at max. load per ISO 7293 g/kWh 526 480
Fuel tank capacity l 0.48 0.48
Chain oil tank capacity l 0.28 0.28
Mixture ratio (fuel/two-stroke oil)
- when using DOLMAR oil 50 : 1 / 100: 1 (HP-100) 50 : 1 / 100: 1 (HP-100)
- when using Aspen Alkalyt (two-stroke fuel) 50 : 1 (2%) 50 : 1 (2%)
- when using other oils 50 : 1 (quality grade JASO FC or ISO EGD) 50 : 1 (Qualitätsstufe JASO FC oder ISO EGD)
Chain brake engages manually or in case of kickback engages manually or in case of kickback
Chain speed at max. power m/s 18.1 18.3
Sprocket pitch inch 3/8 .325
Number of teeth Z 6 7
Chain type see the spare-parts list see the spare-parts list
Pitch / gauge inch 3/8 / 0.050 (1.3) .325 / 0.050 (1.3)
Guide bar, length of a cut cm 30, 35, 40 33, 38, 45
Guide-bar type see the spare-parts list see the spare-parts list
Weight (fuel tank empty, without chain, guide bar and accessories) kg 4.7 / 4.8 2) 4.8 / 4.9 2) 4.7 / 4.8 2) 4.8 / 4.9 2)

1) Figures derived in equal part from idling, full-load and racing speed.
2) On models with catalytic converter.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 3

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 TROUBLESHOOTING ___

Malfunction System Observation Cause

Chain does not run Chain brake Engine runs Chain brake actuated, Chain too tight
Engine does not start Ignition system Ignition spark Malfunction in fuel supply system, pressure system,
or mechanical malfunction.
only with difficulty No ignition spark STOP switch stuck in service position, fault or short-
circuit in the wiring,
plug cap or spark plug defective,
gap between ignition module and flywheel uneven or too
wide
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 packing ring defective, radial shaft
packings defective,
Outside cylinder or piston rings defective
Mechanical malfunction Starter does not engage Spark plug does not seal.
Spring in starter broken, broken parts inside the engine.
Engine speed gets Multiple systems Engine speed about Carburetor too lean
“stuck” 4,500 - 6,000 rpm Bleed air at cylinder and/or rubber induction piece
Fuel line bent, throttle link stuck

Warm engine won’t Carburetor Fuel tank is filled Wrong carburetor adjustment
start Ignition spark Flooded from choke use
Piston ring worn (max. thrust play 0.5 mm)
Engine starts, but Fuel supply Fuel tank is filled Wrong idling adjustment, suction head or carburetor dirty,
dies immediately tank venting defective, fuel line interrupted, cable
defective, Choke flap closed, decompression valve dirty

Insufficient power Several systems Engine is idling Air filter dirty, incorrect carburetor setting, muffler
may be involved clogged, exhaust channel in cylinder clogged, spark
arrester screen clogged.
simultaneously

No chain lubrication Oil tank/pump No oil on the chain Oil tank empty
Oil guide groove dirty, Oil suction head dirty
Oil pump adjusting screw incorrectly adjusted
Oil pump worm drive gear defective

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 4

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 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)

1 2 3
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
5 3/8” Drive (950.230.000)

5 Piston stop wedge

Wedge for blocking
the engine through the
exhaust port (944.602.001)
4

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 5

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 00 SPECIAL TOOLS ___
6 Piston ring tensioner
Piston ring band and
assembly tool for cylinders (944.600.001)

7 Assembly and disassembly wrench

Wrench for disassembling and
assembling the centrifugal
clutch (944.500.590)

6 7 8 8 Pressure gauge
Pressure guage for checking
the carburetor fuel valve (956.004.000)

9 Tachometer
Electronic tachometer for measuring
the engine speed of
2- and 4-stroke engines (950.233.220)

10 3/8” socket
Installation/removal of
10 Spark plug, clutch (944.500.864)
9
11 Needle-nose pliers
Various assembly/
Disassembly tasks (944.603.400)

12 Disassembly hook
Removal/installation
Brake band spring (950.237.000)

13 Over/underpressure pump
For checking sealing of
11 12 13 radial rings and gaskets (957.004.001)

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 6

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 00 SPECIAL TOOLS ___

14 Sealing plate
For sealing intake side (944.603.020)

15 Sealing plate
For sealing exhaust side (944.603.170)

14 15

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 7

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 01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM ___

Remove the sprocket guard, bar, and chain. If necessary, turn adjusting screw 1 clockwise, Assembly
CAUTION: Do not work on the chain brake until the fastening screw is accessible. Grease spindle and worm gear with multi-
unless the spring is detensioned! Unscrew the fastening screw and pull the purpose grease (944.360.000).
chain tensioner up and out.
Chain tensioner
Carefully take the chain guide cover off the
guide bar bolts.
Unscrew 4 screws, and remove the spike bar
and the cover.

Chain tensioner function

An angled worm drive converts the turns of
the adjustment screw 1 to forward or
backward motion of the tensioning pin.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 8

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 02 CLUTCH DRUM AND CHAIN SPROCKET ___

Clutch drum with sprocket and needle

bearing
4 Check the chain sprocket 2 for damage and
wear.
Important customer information:
Before installing a new saw chain, always
check the condition of the chain sprocket. A
3 worn chain sprocket will damage a new saw
chain, and must be replaced.
Check the clutch drum needle bearing for
wear and damage.
Assembly the bearing with multi-purpose high-
2 performance grease (944.360.000).
Remove the sprocket guard, bar, and chain.
Check the inside of the clutch drum for
Remove the circlip 4 with the universal damage and wear.
wrench.
1 Replace the clutch drum if damaged or worn.
Remove cup washer 3.
Pull the handguard towards the front grip only
as far as necessary so the clutch drum can be Note: Always use a new circlip 4
removed. (927.408.000)!
When assembling the clutch drum, make
sure that the lug of the oil pump drive 1 is
not positioned on the oil pump drive. When
inserting, turn the clutch drum slightly.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 9

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 03 CHAIN BRAKE / GUIDE BAR BOLT ___

3
1 2

Removing the brake band Secure the chain saw from slipping (vise).
CAUTION: Wear protective gloves to Using the disassembly hook (Chap. 00, Pos.
prevent cuts! 12), disengage the brake band spring 3.
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.
Remove the cover plate, see Chapter 01.
Fold the brake band 1 upward and turn it out
of the disengagement mechanism 2.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 10

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 03 CHAIN BRAKE / GUIDE BAR BOLT ___

6 5 7

Remove the handguard and Remove the circlip 7. Replacing the guide bar bolt
disengagement mechanism Pull the disengagement mechanism up in Screw two nuts onto the bar bolt and
Unscrew bolt 4 and pull out the sleeve 5. parallel with the axes. counterlock them.
Push handguard arm 6 from its position over Pull off the handguard with gentle back-and- Unscrew the bar bolt.
the hood towards the muffler. forth motion. Assembly: Apply Loctite 243 (980.009.000) to
When reassembling always use a new the guide bar bolts and turn them all the way
circlip 7 (927.304.000)! in.
Assemble the handguard and disengagement
mechanism, brake band and brake band
spring in reverse order.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 11

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 04 CLUTCH ___

2 1
3

4 5

Disassembly Move piston to bottom dead centre (visible Insert wrench 4 (Chap. 00, Pos. 7) into the
through the exhaust opening). clutch and use a socket wrench 5 to turn in
CAUTION: To prevent cuts, wear protective
the direction of the arrow (left-hand thread) to
gloves! Press the piston stop wedge 3 (cap. 00, pos.
loosen and remove the clutch.
Remove the sprocket guard, bar and chain. 5) into the exhaust opening.
Turn the clutch over and remove the disc.
Pull the handguard towards the front handle to Note: Before the piston stop wedge is
The flyweights can now be pushed off the
release the chain brake if necessary. pressed into the exhaust opening, it is
guide axially in one direction.
Remove the clutch drum, see Chapter 02. necessary to remove the carbon insert in the
exhaust.
Remove the muffler. To do this, unscrew the 3
screws 1 and remove the upper muffler half 2.
CAUTION: If a catalytic converter is being
used, the muffler will be very hot after
operation!

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 12

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 04 CLUTCH ___

Inserting the flyweights Installing the clutch

Hook the springs as shown in the illustration. Press the disc onto the clutch. It must be flat
Then press the flyweights onto the guide. To and be engaged.
do this, first push on two flyweights half-way, Installing the clutch
then put on the third flyweight by setting it on Install the clutch with the arrow marking point
its edge. up.
Press the flyweights all the way onto the CAUTION: Before installing the clutch,
guide. disassemble the starter in order to prevent
damage to the starting ratchets
CAUTION: Note the position of the springs.
Do not replace springs individually! If a
spring breaks or is fatigued, all three
springs must be replaced. The springs
must not touch the cover.
The illustration shows the inside of the clutch.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 13

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 05 OIL PUMP ___

1 2 4

2
1 9
3

A 4 3

General The suction line 4 remains in the crankcase. It

The oil pump is driven by the clutch drum. Lugs extends into the oil tank. To remove it, carefully
on the clutch drum transfer the power to the pull on the connection to the oil pump.
drive arms of the oil pump drive 1. Removing the oil pump
The drive worm of the oil pump drive engages Pull the plastic housing off the oil pump by
in the teeth of the oil pump 3. carefully spreading it apart in the area of the
This means that oil is pumped only when the holes marked 5 in the illustration.
chain is running. Push the adjusting screw 6 up against the
The oil flow rate can be adjusted with adjusting 5 spring pressure and turn it until the pin 7 goes
screw A: into the assembly slit 7. If necessary press the
• Turn right for more oil supply piston 8 in somewhat.
• Turn left for less oil Note: For assembly put the adjusting screw in
stop positions 2 or 3, not in one of the outer
Disassembly 8 stops.
Remove the clutch drum and clutch, see
Removing the oil tank vent
chapter 04. Remove brake band, see chapter 03.
Turn the oil pump drive 1 counter-clockwise Note: The ventilation valve must be pulled out.
and pull it off the shaft. It cannot be knocked into the tank.
Pull the oil pressure line 2 from the oil pump.
6 7
Unsrew 2 screws 4 and remove the oil pump.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 14

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 06 STARTER ___

If the spring pops out, put it back into the plastic

housing as shown in the schematic.
Assembly
5
Note: If installing a new return spring cassette,
6
grease it on the spring side.
Carefully insert new return spring cassette 9
7 and push it in. 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 /
8 1/8“, length 980 mm / 38.5“) as shown in the
1 2 illustration, tie a knot (as shown in the
illustration) in both ends, and tighten both knots.
Disassembly 9 Put on the cable drum 8 and turn it slightly until
Unscrew four screws 1. the return spring engages.
Remove fan housing 2. 4 Insert spring 7 in actuator 6 and insert together
3 into the cable drum 8 while turning slightly
Remove air guide 3 from fan housing.
counter-clockwise. Insert and tighten screw 5.
Detension the return spring.
Tension the return spring clockwise. Turn the
Injury hazard! Unscrew screw 5 only after
return spring about 6 turns with the aid of the
detensioning the return spring!
cable, which should be pressed into the gap in
Unscrew screw 5 and remove actuator 6 and the cable drum.
spring 7.
Place the air guide 3 in the fan housing and
Pull off the cable drum 8.
make sure the two recesses 4 engage.
Knock the fan housing against a tabletop with
the entire contact surface of the hollow side, Position the fan housing 2 correctly on the saw,
so that the return spring cassette 9 pops out press against it slightly, and pull the starter
of the fan housing. handle until the starter catches.
CAUTION! The return spring can jump out Tighten screws 1.
of the plastic cassette! Always wear
protective goggles and gloves!

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 15

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 07 IGNITION SYSTEM (TROUBLE-SHOOTING) ___

no
Is the spark plug dry and properly installed? Dry spark plug cap and fasten firmly to spark plug.
If needed, replace the cap or cap spring.
yes

Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Replace spark plug. Use ONLY a spark plug approved by DOLMAR.
Is there carbon on the electrodes? yes See operating manual! Otherwise the ignition module might be damaged.
Eliminate the causes for carbon deposits on electrodes (bad two-stroke oil, wrong mix,
no defective air filter, check carburetor adjustment).
Use DOLMAR high-performance two-stroke oil.
Is the spark gap correct? (should be 0.5 mm) no
yes Adjust spark gap.
Is the spark plug oily or does it have carbon deposits on it?
yes
no Wash spark plug in acetone. Do not sandblast!
If necessary, replace spark plug.
Install ignition testing lamp.
Eliminate cause: wrong carburetor setting, too much oil in fuel,
Alternatively, insert universal wrench between cylinder and hood. The wrench must
frequent short operations.
have metallic contact with the cylinder. Caution: Do not insert the wrench into the spark
plug hole or hold with hand.
Using insulated pliers, hold the unscrewed spark plug against the wrench. no
Caution: Do not hold the spark plug directly against the hole. Detonation hazard! Replace spark plug and check ignition module for corrosion, if necessary replace.
Pull the starting cable smartly. Is there an ignition spark? Has the defect been remedied?

no
yes Replace high-voltage cable and/or ignition cable. Has the defect been remedied?
yes
Is there damage to the insulation of the high-voltage cable or the ignition cable,
or to the wires themselves?
no
no Check radial play of drive shaft, and repair if needed.
yes Replace ignition module if traces of overheating become visible.
Is the gap between the flywheel and the ignition module outside of the 0.25-0.3 mm range? Adjust gap between flywheel and ignition module correctly.
Is the gap uneven? Has the flywheel worn against the ignition module?
no
no
Remove flywheel and check. Is the flywheel damaged? Replace flywheel or key. Before installation wipe cone seat at drive shaft
yes and flywheel with acetone or alcohol to remove any grease.
Is the positioning key damaged?
Tighten fastening nut to the correct torque! Has the defect been remedied?
no
Continue with troubleshooting in fuel system (tank, fuel hose, carburetor). no
no
Replace ignition module. Has the defect been remedied?

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 16

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 07 IGNITION SYSTEM ___

Removing the flywheel Screw the disassembly mandrel (chapter 00

Remove starter see chap. 06. pos. 2) onto the threaded end of the shaft.

Block the piston, see chap. 04. Do not screw the mandrel all the way down.
Leave about 2 mm between the mandrel and
Loosen the nut in the direction of the arrow the flywheel.
and remove it along with the washer.
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.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 17

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 07 IGNITION SYSTEM ___

13 1
15
12 2 16
14
3

4
11
5
10
6
9 7
8

Removing the ignition armature Pull short-circuit wire 15. Installing the ignition armature
Remove cover and air filter. Unscrew 2 screws on ignition armature 14. Note: The high-voltage cable is moulded onto
Unsrew screws 2 and 12. the ignition system and cannot be replaced
Remove ignition armature and wire.
Pull fuel lines 6 from the primer. separately.
Push detent 7 on the primer 8 slightly and pull Insert the armature and turn the screws in
out the primer. almost all the way.
Disengage short-circuit wire 10 from the
Insert the setting gauge 16 (Kapitel 00 Pos. 3)
rocker 11 and pull the rocker up and out.
between the ignition armature and the
Unscrew screws 5 and 9. fylwheel.
Unscrew screw 4.
Position the flywheel so that the magnet is
Pull off spark-plug cap 3 and unscrew spark against the armature (gap 0.25 – 0.3 mm).
plug.
Push the spark-plug cap wire grommet out Press the armature against the gauge towards
towards the spark.plug hole. the flywheel and tighten the armature screws.
Then check the gap again to make sure it is
The cover 1 can now be taken up and off.
correct.
Attach the short-circuit wire 15 and press the
rubber grommet into the carburetor base.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 18

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 08 CARBURETOR ___

Note: If replacing the foam 10 in the

2 carburetor base, make sure the position is
5
9 correct. The opening should be towards the
1 3 suction channel, as shown in the illustration.
6 8

4 7
10

Removing the intake manifold and Removing the carburetor bottom

carburetor Remove throttle linkage 4.
CAUTION: Completely empty the fuel tank Remove cover (see chapter 07).
before disassembling the carburetor!
Pull short.circuit wire 5 from the ignition
Remove cover and air filter. armature.
Move combination switch to safety position. Unscrew screw 6 and remove along with the
Unscrew 4 screws 1. contact spring 7.
Remove intake manifold 2. Unscrew screw 8.
Pull fuel lines and pulse line 3 from the Detach pulse line 9.
carburetor. The carburetor base can now be removed
CAUTION: There is fuel in the line. Catch along with the combination switch.
escaping fuel with a cloth. Note: When assembling, make sure that the
Disengage throttle link 4. short-circuit switch is pulled through the
Note: When reassembling, engage the rubber grommet as far towards the carburetor
linkage in the marked hole (arrow). as possible, in order to prevent the wire from
touching the cylinder.
Note: Do not twist the fuel line during
assembly.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 19

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 08 CARBURETOR ___

Basic Setting (without Limiter Caps) General check

L= 1 1/2 • Screen 7 for contamination
H= 3 • Pulse hole for contamination
NOTE: Adjust the carburetor only Check control parts
using a tachometer. (control lever/inlet needle):
Check the tip of the inlet needle for wear.
Check control lever for correct installation, see
Pressure test
illustration to the left.
Connect the pressure gauge (chapter
If the control lever is too low:
00 item 8 oder 13) to the carburetor
fuel connection 1. • Lack of fuel
Set up a pressure of max. 0.5 bar. • Poor acceleration
If the pressure falls, check the • No maximum power
following parts: If the control lever is too high:
• Correct assembly of Control assy
• Carburetor flooding
(Control lever, Inlet needle, Lever
spring, lever axle) • Starting problems
• Check seat of inlet needle for • Poor idling
dirt/foreign parts, clean if necessary • Poor transition
• Replace control assy
Check the pump diaphragm:
• Replace gasket 6 and diaphragm 5
of the pump side Control lever • If pump diaphragm is dented, torn, or creased,
• If valve flaps are bent,
replace the diaphragm and gasket
Check control diaphragm:
• If control diaphragm is bent or torn, or there
is obvious wear at the button 8.
• If it does not return to its original position
when pulled out of it,
Control lever Control lever Control lever replace the diaphragm and gasket.
Correctly Too high Too low
installed

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 20

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 09 VIBRATION DAMPER ___

Disassembly

Springs 1 and 2
Remove the sprocket guard and chain brake
cover, see chap. 01.
Loosen screws with Torx screwdriver (chap.
00 pos. 1) and remove.cushion spring.

Spring 3
Remove starter housing (see chap. 06) and
3
hood (see chap. 07).
Loosen and remove screws with Torx
screwdriver (chap. 00 pos. 1).
4 Pull out cushion spring.

Spring 4
Remove the side brace cover.
Loosen and remove screw with Torx
1 screwdriver (chap. 00 pos. 1)
2
Remove cushion spring. Remove spring
retainer.
Note: During assembly, insert spring retainer
between the cushion spring and the cylinder.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 21

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 10 TANK ___

The throttle lever has a slot 2 at the hinge.

In assembly, first place the throttle lever
spring 3 on the throttle lever, then push the
lever onto the hinge iwth the slot. The throttle
1 lever must be turned by 180° to do this.
The throttle lever block 4 can easily be
pushed through the diagonals on the seat.
The spring is engaged in the throttle lever as
shown below.

Grip mechanism
Unscrew screw 1 and pull off the top grip half
near the screw seat. 2
Note: When removing the throttle the following
must be done:
• Remove intake manifold and carburetor
• Remove hood and carburetor base 4
See chapters 07 and 08.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 22

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 10 TANK ___

Removal Pressure test Vacuum testing ventilation valve 6

To remove the tank, first remove the hood (see Attach the over/underpressure pump (chap. 00 Attach the over/underpressure pump as
chap. 07), the starter housing (see chap. 06) pos. 13) to one of the two fuel lines 5 . Seal off described.
and the vibration damper. the second line. Close off the installation opening of the air valve
Before separating the engine unit and the tank, Set up a pressure of max. 0.3 bar. with your thumb (dampen it slightly).
the lateral fastening screws on the front grip will If the pressure drops off, check the following: Set up a negative pressure of max 0.5 bar.
have to be unscrewed. • Air valve This negative pressure must not change as long
• Bothe fuel lines as the opening is sealed. When you take your
• Fuel nipple thumb off the air valve, the negative pressure
must quickly return to normal.
• Tank cap seal
• Check tank for holes Parts
Note: Detergent can be used to localise leaks. To remove the suction head 7 pull it through the
tank opening with a hooked wire.
5
Note: Do not use pliers,as this may damage the
line. Do not pull on the suction head or fuel line,
as this can pull off the fuel nipple inside the
8 tank.
Fuel lines 5 can be pulled off the fuel nipple.
Fuel line length:
Return L = 118 mm (dia. 2.5/5.5)
Supply L = 93 mm (dia 5.5 / 3)
Carefully lever out fuel nipple 8 with a sharp
flat-bladed screwdriver.
Note: Do not lever against the line connections,
as this can break them off.
Lever off ventilation valve 6 with a small
screwdriver.

6
7

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 23

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 11 CYLINDER / PISTON ___

Vacuum testing
If correct carburetor setting is not possible, it will
be necessary to test the sealing of the engine.
1 Remove hood (see chap. 07).
Remove carburetor (see chap. 08).
To seal off the exhaust side, insert the sealing
lip 1 (chap. 00 pos. 15) between the muffler and
the cylinder. First remove the muffler and
unscrew the fastening bolt from the cylinder.
To seal off the intake side, install the sealing
plate 2 (chap. 00 pos. 14) in the place of the
2
carburetor.
Connect the over/underpressure pump to the
connection on the sealing plate 3.
3 Seal off the pulse line and bring the cylinder to
top dead center.
Set up a pressure of max. 0.3 bar.
If the pressure rises within 20 seconds, the
following conditions may exist:
• Radial ring leaking
• Cylinder base gasket leaking
• Crankcase gasket leaking
• Crack in crankcase
• Crack in cylinder
• Spark plug leaking
• Rubber intake on cylinder leaking
• Defective pulse line
Note: Detergent can be used to localise leaks.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 24

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 11 CYLINDER / PISTON ___

Note: If there is a leak into the oil tank, it will

not be possible to fully identify the leak. If
pressure remains steady in the crankcase
1 after shutting off the oil line hole, for example
with a rubber stopper (see chap. 05), it is an
indication that there is a defect in the
crankcase gasket to the oil tank.

Always perform sealing tests with

underpressure!
If a leak is diagnosed, it can be found
2 using overpressure and detergent or
similar liquid.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 25

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 11 CYLINDER / PISTON ___

7
6

4 8

Removing the cylinder and piston Remove spring ring 5 with needle-nose pliers. Assembling the cylinder and piston
Disconnect the intake and exhaust sides. Use a new gasket!
Note: The protuberance on the gasket must
Unscrew the spark plug. point towards the induction side.
Remove the ignition armature. Before assembly, lightly oil the cylinder race
Disassemble the vibration damper between and piston!
the cylinder and front grip. Push assembly tool 7 under the piston.
Unscrew 4 screws 4 and pull the cylinder up Turn the opening on the piston ring towards the
and off. piston ring lock.
Use the piston ring tensioner 8 to press the
Note: After pulling off the cylinder 6, support piston ring together.
the piston with the assembly tool (chap. 00 Push the cylinder onto the piston. Let the piston
pos. 6). ring tensioner slide down with it.
Remove the assembly tool and piston ring
tensioner and press the cylinder all the way
down.
Hand-tighten the screws 4 lightly crosswise,
and then tighten to the correct torque, again
crosswise.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 26

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 12 CRANKCASE / CRANKSHAFT ___

Crankcase sides MS and CS are attached with

six screws 1.
Two pins 2 ensure proper fitting.
When assembling the ball bearings, note the
following:
• Press one ball bearing onto the clutch side
MS of the crankshaft. Press the bearing onto the
shaft using an assembly sleeve, pressing
only on the inner bearing ring. Place a
wedge between the crank webs.
• Heat the clutch side of the crankcase to
2 150-160° C using a hot-air blower or in an
oven. Evenly apply Loctite 620 to the outer
ring of the bearing (on the crankshaft), and
insert into the heated housing without further
3 pressure.
KS Note: Before applying the Loctite 620,
degrease both bearings.
• Heat the magneto side of the crankcase to
150-160° C using a hot-air blower or in an
4 oven. Evenly apply Loctite 620 to the
bearings, and insert into the heated housing
5 without further pressure.
• Reattach the crankcase sides. Place a
wedge between the crank webs when
pressing.
Always use a new gasket. After bolting the
crankcase sides together, cut off the flash 3.
1 DOLMAR offers complete crankcases with
preinstalled bearings as replacement parts.

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 27

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 13 TORQUES ___
Fastener Part No. Size Qty. Torque
Crankcase sides 908.405.205 M 5 x 20 Torx 6x 10 +/-1
Cylinder on crankcase 908.405.205 M 5 x 20 Torx with lock teeth 4x 12 +/-1
Carburetor bottom on crankcase 908.005.165 M 5 x 16 Torx 2x 5 +/-0,5
Muffler on cylinder 908.005.165 M 5 x 16 Torx 2x 8 +/-1
Front shell to muffler 908.005.165 M 5 x 16 Torx 2x 8 +/-1
Front shell to cylinder 908.305.405 M 5 x 20 x 40 Torx 1x 8 +/-1
Carburetor / intake manifold in carburetor flange 908.004.405 M 4 x 40 Torx 2x 3 +/-1
Intake manifold on carburetor bottom 913.455.164 5,5 x 16 Torx 1x 3 +/-1
Intake manifold to hood 913.455.164 5,5 x 16 Torx 1x 5 +/-1
Oil pump to crankcase 908.005.165 M 5 x 16 Torx 1x 5 +/-1
Oil pump cover to crankcase 908.005.165 M 5 x 16 Torx 1x 5 +/-1
Clutch to crankshaft --- M 12 x 1 L with assembly wrench for centrifugal clutch 1x 35 +/-2,5
Transmission cover chain tensioner to
crankcase 915.135.100 BZ 3,5 x 9,5 1x 1,5 +/-0,2
Mounting bolt in bar flange 195.232.010 M 8 SK 6 / M8 2x 15 +/-1
Mounting bolt in bar flange 195.232.020 M 8 SK 6 / M8 x 1 1x 15 +/-1
Sprocket guard mounting 923.208.004 M 8, SW 13, 6KT-nut with flange 2x 1 +/-0,5
Chain brake cover 908.105.126 M 5 x 12 Torx 2x 5 +/-0,5
Ignition mounting in crankcase 908.805.205 M 5 x 20 Torx 2x 5 +/-0,5
Flywheel nut fastening 920.308.024 M 8 x 1 / SW 13 1x 25 +/-1
Starter housing to crankcase 908.005.165 M 5 x 16 Torx 4x 5 +/-0,5
Hood 908.005.165 M 5 x 16 Torx 3x 5 +/-0,5
Handguard bearing to magneto side 908.005.165 M 5 x 16 Torx 1x 5 +/-0,5
Grip/rear handle to tank 913.455.164 5,5 x 16 Torx 1x 3 +/-1
Front handle on tank, side 913.455.164 5,5 x 16 Torx 2x 5 +/-1
Front handle on tank, bottom 913.455.164 5,5 x 16 Torx 2x 5 +/-1
Front handle side cover on tank 913.455.164 5,5 x 16 Torx 2x 3 +/-1
Damping spring fastening on cylinder 908.005.165 M 5 x 16 Torx 1x 5 +/-0,5
Damping spring / tank, mag. side rear 913.455.164 5,5 x 16 Torx 1x 5 +/-1
Damping spring / tank, cyl. side front 913.455.164 5,5 x 16 Torx 1x 5 +/-0,5
Damping spring cylinder / handle side cover 913.455.164 5,5 x 16 Torx 1x 5 +/-0,5
Damping spring / crankcase, mag. side 908.005.165 M 5 x 16 Torx 1x 5 +/-0,5
Damping spring / crankcase, cyl. side 908.005.165 M 5 x 16 Torx 2x 5 +/-0,5
Damping spring / crankcase, cyl. side 908.005.165 M 5 x 16 Torx 2x 5 +/-0,5
Spark plug 965.603.021 M 14 x 1,25 / SW 19 1x 15 +/-5
Pawls to magnet wheel 170.166.041 -- 2x 8 +/-1
Mounting bolt TLC 195.232.040 -- 1x 10 +/-1

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 28

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 NOTES ___

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 29

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 NOTES ___

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 30

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 NOTES ___

Reparaturanleitung
Repair PS-4600
manual DCS3500 / PS-5000
/ DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L 31

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 ___

Reparaturanleitung
Repair
Makita Werkzeug PS-4600
manual DCS3500
GmbH / PS-5000
• /Postfach
DCS3501 / DCS4300
70 04 / DCS4301
20 • D-22004 / EA3500F
Hamburg / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L
• Germany Form: 995 728 62032
620

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