Makita Dolmar DCS460 Repair Manual
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Also See for Dolmar DCS460:
- Owner's and safety manual (80 pages) ,
- Instruction manual (32 pages) ,
- Instruction manual (36 pages)
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Table of Contents
Related Manuals for Makita Dolmar DCS460
Summary of Contents for Makita Dolmar DCS460
- Page 1 REPAIR MANUAL DCS460 DCS510 DCS5121 EA5000P53G PS-460 PS-510 PS-5105...
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Page 2: Table Of Contents
CONTENTS Page Technical data ................................... 3 Troubleshooting ..................................4 Special tools..................................5 - 7 Sprocket guard / Chain tensioning system ..........................8 Clutch drum / Rim sprocket ............................... 9 Chain brake / Guide bar bolt ............................10 - 11 Clutch....................................12 - 13 Oil pump.................................... -
Page 3: Technical Data
TECHNICAL DATA DCS460/ DCS500 DCS4600 DCS5000 DCS510 DCS461 DCS501 DCS5001 Stroke volume 45.6 49.9 45.6 49.9 3.1 cu. in Bore 1.77 inch Stroke 31.4 1.24 inch Max. power at speed kW / 1/min 2.2 / 10,000 2.4 / 10,000 2.6 / 10,000 2.8 / 10,000 3.3 / 10,000 Max. -
Page 4: Troubleshooting
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, only with difficulty mechanical malfunction. No ignition spark Switch on STOP, fault or short-circuit in the wiring, plug cap or spark plug defective,... -
Page 5: Special Tools
00 SPECIAL TOOLS Torx screwdriver Grip (944.500.860) T-grip 200 mm (944.500.862) T-grip 100 mm (944.500.861) Radial ring puller 13 mm radial ring puller (944.500.871) Spindle (950.203.020) Mandrel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread (944.500.880) Setting gauge Gauge for measuring the gap... - Page 6 00 SPECIAL TOOLS Piston ring tensioner Piston ring band and assembly tool for cylinders (944.600.001) Assembly and disassembly wrench Wrench for disassembling and assembling the centrifugal clutch (944.500.590) Pressure gauge Pressure gauge for checking the carburetor fuel valve (956.004.000) 10 Tachometer Electronic tachometer for measuring the engine speed of 2- and 4-stroke engines...
- Page 7 00 SPECIAL TOOLS 15 Sealing plate For sealing intake side (944.603.170) 16 Sealing plate For sealing exhaust side (944.603.170)
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Page 8: Sprocket Guard / Chain Tensioning System
01 SPROCKET GUARD / CHAIN TENSIONING SYSTEM Unscrew screw and pull chain tensioner up Chip deflector in the sprocket guard CAUTION: Before removing the cover and out. plate, first set off the chain brake! CAUTION: To prevent cuts, wear protective gloves! Chain tensioner Assembly... -
Page 9: Clutch Drum / Rim Sprocket
02 CLUTCH DRUM / RIM SPROCKET Chain sprocket and clutch drum with needle bearing Check the chain sprocket 4 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, and must be replaced. -
Page 10: Chain Brake / Guide Bar Bolt
03 CHAIN BRAKE / GUIDE BAR BOLT Remove the handguard and Removing the brake band Secure the chain saw from slipping (vise). disengagement mechanism CAUTION: To prevent cuts, wear protective Using the disassembly hook (Chap. 00, Pos. Remove the hood. gloves and remove the spike bar (2 bolts)! 14), disengage the brake band spring 3. - Page 11 03 CHAIN BRAKE / GUIDE BAR BOLT Remove the circlip 7. Replacing the guide bar bolt Pull the handguard and disengagement Screw two nuts onto the bar bolt and mechanism up and out parallel to their axes. counterlock them. When reassembling always use a new Unscrew the bar bolt.
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Page 12: Clutch
04 CLUTCH Insert wrench 7 (Chap. 00, Pos. 8) into the Disassembly Remove the hood. clutch and use a socket wrench 8 to turn in CAUTION: To prevent cuts, wear protective Move piston to bottom dead centre (visible the direction of the arrow (left-hand thread) to gloves! through the exhaust opening). - Page 13 04 CLUTCH Inserting the flyweights Press the disc onto the clutch. It must be flat and be engaged. Hook the springs as shown in the illustration. Installing the clutch The press the flyweights onto the guide. To do this, first push on two flyweights half-way, then Install the clutch with the arrow marking point put on the third flyweight by setting it on its edge.
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Page 14: Oil Pump
05 OIL PUMP The suction line 5 remains in the crankcase. It General extends into the oil tank. To remove it, carefully The oil pump is driven by the clutch drum. Lugs pull on the connection to the oil pump. on the clutch drum transfer the power to the drive arms of the oil pump drive 1. -
Page 15: Starter
06 STARTER Knock the fan housing against a tabletop with the entire contact surface of the hollow side, so that the return spring cassette 8 pops out of the fan housing. Caution! The return spring can jump out of the plastic cassette! Always wear protective goggles and gloves! If the spring pops out, put it back into the plastic housing as shown in the schematic. -
Page 16: Ignition System (Trouble-Shooting)
07 IGNITION SYSTEM (TROUBLE-SHOOTING) 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. Remove spark plug. Is the spark plug damaged? Is it the wrong kind of spark plug? Replace spark plug. -
Page 17: Ignition System
IGNITION SYSTEM Removing the flywheel Removing the ignition armature Screw the disassembly mandrel (944.500.880) onto the threaded end of the Block the piston. To do this, see 04 CLUTCH. Unscrew 2 screws on ignition armature 1. shaft. Unscrew ignition cable screw 2. Loosen the nut in the direction of the arrow Do not screw the mandrel all the way down. - Page 18 IGNITION SYSTEM Installing the ignition armature NOTE: The high-voltage cable is moulded onto the ignition system and cannot be replaced separately. Insert the armature and turn the screws in almost all the way. Lay the high-voltage cable with the ingition cable as show.
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Page 19: Carburetor
08 CARBURETOR Removing the carburetor bottom Removing the carburetor Removing the intake manifold Unscrew 3 screws 12. Unscrew screws 7. CAUTION: Empty the fuel tank before disassembling the carburetor! The carburetor bottom 16 and flange 15 can Unscrew screws 8. now be removed. - Page 20 08 CARBURETOR Pressure test Connect the pressure gauge (956.004.000) to Base Setting (without Limiter Caps) the carburetor fuel connection 1. L= 1 1/2 Set up a pressure of max. 0.5 bar. H= 1 1/2 If the pressure drops off, check the inlet NOTE: Adjust the carburetor only needle 2 for damage or foreign objects.
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Page 21: Vibration Damper
09 VIBRATION DAMPER Disassembly Spring 1 Unscrew screw on chain catcher. Loosen spring with Torx screwdriver (944.500.862) and remove. Spring 2 NOTE: To facilitate removal of the spring, unscrew the screw of spring 3. Remove fan housing. Unscrew screw. Loosen spring with offset screwdriver (940.827.000) and remove. -
Page 22: Tank
10 TANK The throttle and throttle lock have slots 4 and 5 at their pivot points. When assembling the throttle and throttle lock, first press them onto the pivot axle by the slot. For this, the slot must point downwards when inserted. - Page 23 10 TANK Disassembly Pressure test Connect the over/underpressure pump to the To remove the tank it will first be necessary to fuel line 8. remove the carburetor, pull the fuel line out of the carburetor bottom, pull the Bowden cable Set up a pressure of max.
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Page 24: Cylinder / Piston
11 CYLINDER / PISTON Pressure test If it is not possible to adjust the carburetor properly, it will be necessary to check the sealing of the Drive. To seal off the exhaust side, insert the sealing plate 1 (944.603.160) between the cover plate and cylinder. - Page 25 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 after shutting off the oil line hole, for example with a rubber stopper (see 05 OIL PUMP), it is an indication that there is a defect in the crankcase gasket to the oil tank.
- Page 26 11 CYLINDER / PISTON Removing the cylinder and piston Remove spring ring 7 with needle-nose pliers. Assembling the cylinder and piston Use a new gasket! Disconnect the intake and exhaust sides. Before assembly, lightly oil the cylinder Unscrew the spark plug. race and piston! Unscrew 4 screws 6 and pull the cylinder up Push the assembly tool 9 under the piston.
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Page 27: Crankcase / Crankshaft
Assemble the crankcase halves. Put a wedge between the crankwebs Always use a new gasket. After bolting the crankcase sides together, cut off the flash 3. Makita is providing crankcases as a spare part where the ball bearings are already glued into the crankcase... -
Page 28: Handle Heating
13 HANDLE HEATING Diagnosis/Cause The handle heating is switched on when the red mark 1 on the switch is visible. Diagnosis: Heating in both rear and front handles not working. Cause: Generator defective, interruption of current. Diagnosis: Heating in rear or front handle not working. - Page 29 13 HANDLE HEATING Current testing Generator test 2 Switch off the handle heating. Check current between the plug located at the middle of the switch and the cylinder (ground). No current – Check wire and generator (181 148 060) for damage, replace if necessary. Handle heating switch 3 Both handles are constantly or intermittently heated, although the heating switch is turned...
- Page 30 13 HANDLE HEATING Resistance testing Heating film in rear handle 2 Unplug plug 1 in the front handle. Test resistance between the two solder points on the heating film in the handle. Resistance should be approx. 0.9 Ohm ( 10 % att approx.
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Page 31: Torques
14 TORQUES Fastener Part No. Size Qty. Torque Crankcase sides 908.905.205 M 5 x 20 Torx 9.5 -0.5 Cylinder on crankcase 908.405.205 M 5 x 20 Torx with lock teeth 12 +/-0.5 Carburetor bottom on crankcase 908.905.205 M 5 x 20 Torx 5 +/-0.5 Muffler on cylinder 908.905.205... - Page 32 Form: 995 726 620...