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.
CONTENTS ___ Page Technical data ........................................................................................................................................................................... 3 Troubleshooting ........................................................................................................................................................................ 4 00 Special tools...................................................................................................
TECHNICAL DATA ___ DCS3500 / DCS3501 1) 2) Stroke volume Bore Stroke Max. power at speed Max. torque at speed Idling speed / max.
TROUBLESHOOTING ___ Malfunction System Observation Cause Chain does not run Chain brake Engine runs Chain brake actuated, Chain too tight Engine does not start or Ignition system Ignition spark Malfunction in fuel supply system, pressure system, mechanical malfunction.
00 SPECIAL TOOLS ___ 1 Torx screwdriver Grip T-grip 200 mm T-grip 100 mm 2 Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread 1 2 (944.500.860) (944.500.862) (944.500.861) (944.500.880) 3 3 Setting gauge Gauge for measuring the gap between flywheel and armature (944.500.891) 4 Torque wrench 3/8” Drive socket Bit 152 mm Bit 49 mm Torque wrench 3/8” Drive 5 5 (944.500.864) (944.500.865) (944.500.866) (950.230.
00 SPECIAL TOOLS ___ 6 Piston ring tensioner Piston ring band and assembly tool for cylinders 7 (944.600.001) 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 10 9 Installation/removal of Spark plug, clutch (944.500.
00 SPECIAL TOOLS ___ 14 Sealing plate For sealing intake side (944.603.020) 15 Sealing plate For sealing exhaust side 14 (944.603.
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM ___ 1 Remove the sprocket guard, bar, and chain. CAUTION: Do not work on the chain brake unless the spring is detensioned! If necessary, turn adjusting screw 1 clockwise, until the fastening screw is accessible. Unscrew the fastening screw and pull the chain tensioner up and out. Assembly Grease spindle and worm gear with multipurpose grease (944.360.000). Chain tensioner Carefully take the chain guide cover off the guide bar bolts.
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: 3 Before installing a new saw chain, always check the condition of the chain sprocket. A worn chain sprocket will damage a new saw chain, and must be replaced. Check the clutch drum needle bearing for wear and damage. 2 Remove the sprocket guard, bar, and chain. Check the inside of the clutch drum for damage and wear.
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 prevent cuts! Using the disassembly hook (Chap. 00, Pos. 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.
03 CHAIN BRAKE / GUIDE BAR BOLT 6 ___ 7 5 4 Remove the circlip 7. Replacing the guide bar bolt Unscrew bolt 4 and pull out the sleeve 5. Pull the disengagement mechanism up in parallel with the axes. Screw two nuts onto the bar bolt and counterlock them. Push handguard arm 6 from its position over the hood towards the muffler. Pull off the handguard with gentle back-andforth motion. Unscrew the bar bolt. Assembly: Apply Loctite 243 (980.009.
04 CLUTCH 2 ___ 1 3 4 Disassembly CAUTION: To prevent cuts, wear protective gloves! Remove the sprocket guard, bar and chain. Pull the handguard towards the front handle to release the chain brake if necessary. Remove the clutch drum, see Chapter 02. Remove the muffler. To do this, unscrew the 3 screws 1 and remove the upper muffler half 2. 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.
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 and be engaged. Then press the flyweights onto the guide. To do this, first push on two flyweights half-way, then put on the third flyweight by setting it on its edge. Press the flyweights all the way onto the guide. CAUTION: Note the position of the springs.
05 OIL PUMP ___ 1 2 4 2 9 1 3 A 4 3 The suction line 4 remains in the crankcase. It extends into the oil tank. To remove it, carefully pull on the connection to the oil pump. General The oil pump is driven by the clutch drum. Lugs on the clutch drum transfer the power to the drive arms of the oil pump drive 1. The drive worm of the oil pump drive engages in the teeth of the oil pump 3. This means that oil is pumped only when the chain is running.
06 STARTER ___ If the spring pops out, put it back into the plastic housing as shown in the schematic. 5 6 7 1 8 2 Disassembly 9 Unscrew four screws 1. 4 Remove fan housing 2. Remove air guide 3 from fan housing. Detension the return spring. Injury hazard! Unscrew screw 5 only after detensioning the return spring! Unscrew screw 5 and remove actuator 6 and spring 7. Pull off the cable drum 8.
07 IGNITION SYSTEM (TROUBLE-SHOOTING) Is the spark plug dry and properly installed? ___ no yes Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Is there carbon on the electrodes? yes no Is the spark gap correct? (should be 0.5 mm) no Install ignition testing lamp. Alternatively, insert universal wrench between cylinder and hood. The wrench must have metallic contact with the cylinder. Caution: Do not insert the wrench into the spark plug hole or hold with hand.
07 IGNITION SYSTEM Removing the flywheel Remove starter see chap. 06. Block the piston, see chap. 04. Loosen the nut in the direction of the arrow and remove it along with the washer. ___ Screw the 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.
07 IGNITION SYSTEM ___ 13 1 12 2 15 14 16 3 11 10 9 4 5 6 7 8 Removing the ignition armature Remove cover and air filter. Unsrew screws 2 and 12. Pull fuel lines 6 from the primer. Push detent 7 on the primer 8 slightly and pull out the primer. Disengage short-circuit wire 10 from the rocker 11 and pull the rocker up and out. Unscrew screws 5 and 9. Unscrew screw 4. Pull off spark-plug cap 3 and unscrew spark plug. Push the spark-plug cap wire grommet out towards the spark.plug hole.
08 CARBURETOR ___ 2 1 5 9 3 6 4 Note: If replacing the foam 10 in the carburetor base, make sure the position is correct. The opening should be towards the suction channel, as shown in the illustration. 8 7 10 4 Removing the intake manifold and carburetor CAUTION: Completely empty the fuel tank before disassembling the carburetor! Remove cover and air filter. Move combination switch to safety position. Unscrew 4 screws 1. Remove intake manifold 2.
08 CARBURETOR ___ General check • Screen 7 for contamination • Pulse hole for contamination Basic Setting (without Limiter Caps) L= 1 1/2 H= 3 Check control parts NOTE: Adjust the carburetor only using a tachometer. Pressure test Connect the pressure gauge (chapter 00 item 8 oder 13) to the carburetor fuel connection 1. Set up a pressure of max. 0.5 bar.
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 hood (see chap. 07). 3 Loosen and remove screws with Torx screwdriver (chap. 00 pos. 1). 4 Pull out cushion spring. Spring 4 Remove the side brace cover. 2 1 Loosen and remove screw with Torx screwdriver (chap. 00 pos. 1) Remove cushion spring.
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 lever must be turned by 180° to do this. 1 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. 3 Grip mechanism Unscrew screw 1 and pull off the top grip half near the screw seat.
10 TANK ___ Removal Pressure test Vacuum testing ventilation valve 6 To remove the tank, first remove the hood (see chap. 07), the starter housing (see chap. 06) and the vibration damper. Attach the over/underpressure pump (chap. 00 pos. 13) to one of the two fuel lines 5 . Seal off the second line. Set up a pressure of max. 0.3 bar.
11 CYLINDER / PISTON 1 2 3 ___ Vacuum testing If correct carburetor setting is not possible, it will be necessary to test the sealing of the engine. 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 carburetor.
11 CYLINDER / PISTON 1 2 ___ 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 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 using overpressure and detergent or similar liquid.
11 CYLINDER / PISTON ___ 7 6 8 4 5 Removing the cylinder and piston Disconnect the intake and exhaust sides. Unscrew the spark plug. Remove the ignition armature. Disassemble the vibration damper between the cylinder and front grip. Unscrew 4 screws 4 and pull the cylinder up and off. Note: After pulling off the cylinder 6, support the piston with the assembly tool (chap. 00 pos. 6). Remove spring ring 5 with needle-nose pliers.
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 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 150-160° C using a hot-air blower or in an oven.
13 TORQUES Fastener Crankcase sides Cylinder on crankcase Carburetor bottom on crankcase Muffler on cylinder Front shell to muffler Front shell to cylinder Carburetor / intake manifold in carburetor flange Intake manifold on carburetor bottom Intake manifold to hood Oil pump to crankcase Oil pump cover to crankcase Clutch to crankshaft Transmission cover chain tensioner to crankcase Mounting bolt in bar flange Mounting bolt in bar flange Sprocket guard mounting Chain brake cover Ignition mounting in crankca
NOTES Reparaturanleitung PS-4600 / PS-5000 Repair manual DCS3500 / DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L ___ 29
NOTES Reparaturanleitung PS-4600 / PS-5000 Repair manual DCS3500 / DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L ___ 30
NOTES Reparaturanleitung PS-4600 / PS-5000 Repair manual DCS3500 / DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L ___ 31
___ Reparaturanleitung PS-4600 / PS-5000 Repair manual DCS3500 DCS3501 / DCS4300 / DCS4301 / EA3500F / EA3501F / EA4300F / EA4301F / MEA3500L / MEA3500M / MEA4300G / MEA4300L Makita Werkzeug GmbH • /Postfach 70 04 20 • D-22004 Hamburg • Germany 620 Form: 995 728 62032
