Dolmar PS-6400 Istruzioni operative
1Repair 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
2Repair 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
3Repair Manual PS-6400/PS-7300/PS-7900
TECHNICAL DATA
Stroke volume cm364,2 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 LpA av per ISO/CD 22868 1) dB (A) 104.3 104.3 104.3
Sound power level LWA av per ISO/CD 22868 1) dB (A) 113.3 113.3 113.3
Vibration acceleration ah,w av per ISO 7505 1)
- Tubular handle m/s26.9 6.9 6.9
- Rear handle m/s27.7 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
4Repair 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
5Repair Manual PS-6400/PS-7300/PS-7900
123
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)
6Repair Manual PS-6400/PS-7300/PS-7900
78
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)
7Repair 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 1if it is worn.
Mount the housing 2in 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 4inwards from the
outside of the chain guard.
Tool
1
2
5
3
(1,5 Nm ± 0,2)
4
(1.5 Nm ± 0.2)
8Repair 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
9Repair Manual PS-6400/PS-7300/PS-7900
12
03 CHAIN BRAKE
Chain brake
The chain brake stops the chain within 0.1 seconds
in the event of kickback.
The brake band 2encircles the clutch drum 380°.
A spring 1pulls the brake band around the clutch
drum.
10Repair 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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