Makita DCS3500, Repair Manual

Page 1: ...500M MEA4300G MEA4300L www dolmar de Repair Manual Caution Before doing any maintenance or service work the combination switch must be engaged in the service position in order to prevent unintended st...

Page 2: ...oting 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 Igniti...

Page 3: ...5 NGK BPMR 7A NGK CMR7A 5 Electrode gap mm 0 5 0 5 or spark plug Typ BOSCH WSR 6F CHAMPION RCJ 6Y BOSCH WSR 6F CHAMPION RCJ 6Y Fuel consumption at max load per ISO 7293 kg h 0 79 0 96 Specific consump...

Page 4: ...der or piston rings defective Spark plug does not seal Spring in starter broken broken parts inside the engine Engine speed gets stuck Multiple systems Engine speed about 4 500 6 000 rpm Carburetor to...

Page 5: ...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 3 Setting gauge Gauge for measuring the gap between flywhee...

Page 6: ...g and assembling the centrifugal clutch 944 500 590 8 Pressure gauge Pressure guage for checking the carburetor fuel valve 956 004 000 9 Tachometer Electronic tachometer for measuring the engine speed...

Page 7: ...epair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L 14 15 00 SPECIAL TOOLS 14 Sealing plate For sealing intake side 944 603 020 15 Sealing...

Page 8: ...ed 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...

Page 9: ...hain sprocket 2 for damage and wear Important customer information Before installing a new saw chain always check the condition of the chain sprocket A worn chain sprocket will damage a new saw chain...

Page 10: ...Pos 12 disengage the brake band spring 3 1 2 3 03 CHAIN BRAKE GUIDE BAR BOLT Removing the brake band CAUTION Wear protective gloves to prevent cuts Remove the sprocket guard bar and chain Remove the c...

Page 11: ...ing the guide bar bolt Screw two nuts onto the bar bolt and counterlock them Unscrew the bar bolt Assembly Apply Loctite 243 980 009 000 to the guide bar bolts and turn them all the way in 4 5 6 7 03...

Page 12: ...the clutch and use a socket wrench 5 to turn in the direction of the arrow left hand thread to loosen and remove the clutch Turn the clutch over and remove the disc The flyweights can now be pushed of...

Page 13: ...tarter in order to prevent damage to the starting ratchets 04 CLUTCH Inserting the flyweights Hook the springs as shown in the illustration Then press the flyweights onto the guide To do this first pu...

Page 14: ...ng screw in stop positions 2 or 3 not in one of the outer stops Removing the oil tank vent Note The ventilation valve must be pulled out It cannot be knocked into the tank 1 2 3 4 A 1 2 5 3 4 6 8 7 9...

Page 15: ...hile turning slightly counter clockwise Insert and tighten screw 5 Tension the return spring clockwise Turn the return spring about 6 turns with the aid of the cable which should be pressed into the g...

Page 16: ...nce two stroke oil Adjust spark gap Wash spark plug in acetone Do not sandblast If necessary replace spark plug Eliminate cause wrong carburetor setting too much oil in fuel frequent short operations...

Page 17: ...w 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 CAUT...

Page 18: ...1 can now be taken up and off 2 3 4 5 6 7 8 1 12 11 10 9 13 14 15 16 07 IGNITION SYSTEM Pull short circuit wire 15 Unscrew 2 screws on ignition armature 14 Remove ignition armature and wire Installing...

Page 19: ...carburetor as possible in order to prevent the wire from touching the cylinder Note Do not twist the fuel line during assembly Note If replacing the foam 10 in the carburetor base make sure the posit...

Page 20: ...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...

Page 21: ...orx screwdriver chap 00 pos 1 and remove cushion spring Spring 3 Remove starter housing see chap 06 and hood see chap 07 Loosen and remove screws with Torx screwdriver chap 00 pos 1 Pull out cushion s...

Page 22: ...h the lever onto the hinge iwth the slot The throttle 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...

Page 23: ...pull off the fuel nipple inside the 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 s...

Page 24: ...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 Connect the over underpressure pump to the connec...

Page 25: ...e 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...

Page 26: ...assembly tool chap 00 pos 6 Remove spring ring 5 with needle nose pliers Assembling the cylinder and piston Use a new gasket Note The protuberance on the gasket must point towards the induction side B...

Page 27: ...case to 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 pressure Note Befo...

Page 28: ...plug Pawls to magnet wheel Mounting bolt TLC 908 405 205 908 405 205 908 005 165 908 005 165 908 005 165 908 305 405 908 004 405 913 455 164 913 455 164 908 005 165 908 005 165 915 135 100 195 232 01...

Page 29: ...___ Reparaturanleitung PS 4600 PS 5000 29 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 30: ...___ Reparaturanleitung PS 4600 PS 5000 30 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 31: ...___ Reparaturanleitung PS 4600 PS 5000 31 Repair manual DCS3500 DCS3501 DCS4300 DCS4301 EA3500F EA3501F EA4300F EA4301F MEA3500L MEA3500M MEA4300G MEA4300L NOTES...

Page 32: ...ng PS 4600 PS 5000 32 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 F...