Dolmar 109 HappyStart User manual

DOLMAR GmbH • Postfach 70 04 20 • D-2000 Hamburg 70 • Germany

Service Manual

2/93

DOLMAR 109

DOLMAR 110i

DOLMAR 111

DOLMAR 111i

DOLMAR 115i

Table of contents

Index Technical data Page 3

Special tools 4

01 Chain brake 5

02 Clutch, clutch drum 6

03 Oil pump 7

04 Ignition system 8

05 Starter assembly 10

06 Carburettor, intake system 11

07 Cover system, air filter 13

08 Vibration dampers, handle 14

09 Fuel tank 15

10 Cylinder and piston 16

11 Crankcase, crankshaft 17

12 Checking operations 18

Torques 19

DOLMAR GmbH

- Bumper Depth Gauge Bumper Bumper

Drive Link Drive Link Drive Link

Type Spur (fixed) Rim (loose) Spur (fixed) Rim (loose)

Cutting length cm 38 33/38 38 45

Drive Link count 56 56/64 56 64

Sprocket Z 7877

Model

109 110i 115i

Displacement cm343 43 52 52

Bore mm 40 40 44 44

Stroke mm 34 34 34 34

Rating kW 2,0 2,3 2,4 2,7

Idling 1/min 2500 2500 2500 2500

Allowed max. engine speed

with bar and chain 1/min 12500 13200 12500 13000

(* with speed limitation)

Gap Flywheel / Coil mm 0,2-0,3 0,2-0,3 0,2-0,3 0,2-0,3

High tension wire length mm 180 180 180 180

Spark plug NGK BPMR-7A BPMR-7A BPMR-7A BPMR-7A

BOSCH WSR-6F WSR-6F WSR-6F WSR-6F

CHAMPION

Elektrode gap mm 0,5 0,5 0,5 0,5

Fuel tank capacity Ltr. 0,56 0,56 0,56 0,56

Oil tank capacity Ltr. 0,28 0,28 0,28 0,28

Carb. adjustment L / H 1/1 1/ 1 1/8 1/1 1/ 1 1/8

Starter rope ø / length mm 3,5 / 980 3,5 / 980 3,5 / 980 3,5 / 980

Saw chain Model 093 084 093 099

Normal profil Low profil Normal profil Low profil

Cutter type

Semi chisel Chisel Semi chisel Chisel

Gauge inch 3/8 .325 3/8 3/8

mm (9,52) (8,2) (9,52) (9,52)

Drive link inch 0.58 0.58 0.58 0.58

mm (1,5) (1,5) (1,5) (1,5)

Filling Angle 35°30°35°25°

Side Angle 85°75°85°60°

Cutting Angle 60°60°60°60°

File Guide Angle 90°10°90°90°

Depth Gage Setting mm 0,65 0,65 0,65 0,65

File ø mm 5,5 4,5 5,5 5,5

Technical data

Kick back reduction

r.p.m.

Max.

90°10°

r.p.m.

From 1/2 Cutter mm 4,8 4,0 4,8 4,8

DOLMAR GmbH

111/111i

Special tools

Puller for tension spring

of chain brake

950 237 000

Mounting tool for

clutch hub

944 500 690

Mounting tool for

clutch hub

944 500 680

Special socket wrench

for rubber buffer

944 500 621

Drift for piston pin

944 603 260

Sealing plate for

leakage test of crankcase

944 603 020 / 944 603 030

Mounting for roler bearing

crankcase

950 500 050

Puller for drive worm

of oil pump

957 433 000

Snap ring pincer for external snap

rings of starting system

946 101 010

Radial ring extractor

944 500 900

Mounting sleeve

for radial rings

944 500 550

Setting gauge for

ignition armature

944 500 890

DOLMAR GmbH

01-04 Removing the hand guard

Remove the nut (11) and push the screw (12)

in direction of the cylinder. Unscrew screw

(13) on the starter side and remove the insert

(14).

01-02 Relieving the tension spring

To remove the brake band it is necessary to

remove the cover plate (3). For this purpose

unscrew screws (4) and remove retaining

rings (5). Relieve the tension spring (6) by

levering it off the housing peg (7).

01-02 Replacing the brake band

A damaged or defective brake band (8) and a

damaged or defective tension spring must be

replaced without delay (6).

Caution: Safety components

01-04 Fitting the hand guard

When fitting the hand guard, ensure that the

compression spring (16) is installed correctly.

01-02 Pretensioning the tension spring and

the brake gate

Following the installation of the brake band,

engage the tension spring in the brake gate

(9) and using the pulling hook (10) no.

950.237.000 pass the spring over the peg (7).

01-02 Releasing the chain brake

Insert the clutch drum (1) and by levering

down the brake gate, using a screwdriver (2),

release the chain brake.

01 Chain brake

DOLMAR GmbH

02-03 Checking the clutch drum /sprocket

of models 109 / 111

Worn sprockets or clutch drums (arrows)

must be replaced.

02-01 Removing the clutch drum

For the removal of the clutch/clutch drum it is

necessary to immobilize the cylinder unit.

For this purpose unscrew the silencer and

insert the piston stopper wedge (1) into the

exhaust duct of the cylinder.

02-01 Unscrewing the clutch

Use spanner (2), no. 944 500 680 for clutch

(3) and use spanner (4) no. 944 500 690

for clutch (5) .

Caution: Left-hand thread

02-01 Differing clutch designs

Clutch (5) for models 109, 110, 111.

Clutch (3) for model 115.

Clutch springs may be replaced as a

complete set (6) or individually (7).

02-03 Mounting the clutch drum and clutch

Prior to installation, lightly grease the clutch

drum bearing and tighten the clutch using a

torque of 35 Nm.

02-03 Checking the clutch drum /sprocket

Worn sprockets (arrows) or clutch drums must

be replaced.

Ring pinion system (8) is standard equipment

only for models 110/115. As replacement also

available for models 109/111.

02 Clutch drum

DOLMAR GmbH

121

03-02 Adjusting the oil pump delivery

Turn the screw:

clockwise for less chain oil

anti-clockwise for more chain oil.

03-02 Removing the oil pump

Unscrew screw (1) and remove the pump

housing (2) from the crankcase. Separate the

intake pipe from the angular nipple (3).

03-03 Checking the oil pump for wear

Unscrew the set screw (4) and check the

condition (5). Unscrew the guide bush (6) and

check the pump plunger (7) for damage.

Replace defective parts and clean the housing

prior to assembling.

03-04 Removing the intake pipe

Unscrew the chain guide plate (9) and

withdraw the intake pipe (10) from the oil

reservoir.

03-03 Cleaning the intake pipe

Withdraw the oil filter (11) prior to cleaning the

intake pipe (10).

When installing the oil filter, pass the spring

over the intake pipe against the stop (arrow).

03-05 Withdrawing the worm

To remove the worm (8), screw the tool (12)

onto the worm against the stop. Withdraw the

worm from the crankshaft by tightening the

screw.

Caution: Use the protective cap!

03 Oil pump

DOLMAR GmbH

04 Ignition system

04-01 Checking the spark plug

Unscrew the spark plug (1) and connect it to

the spark plug terminal (2). Hold the spark

plug against cylinder ground and withdraw the

starter rope (3). If no spark is generated,

repeat using new spark plug.

04-01 Checking the spark plug

Clean or renew contaminated or defective

spark plugs.

04-02 Replacing the spark plug terminal

Remove the hood (07-01) for removing the

spark plug terminal. Using a pair of pointed

pliers hold the spring (7) of the plug connector

and pass the rubber cap (5) towards the rear

over the ignition cable (6).

04-02 Installing the spark plug terminal

First pass the rubber cap (5) over the ignition

cable. Then engage the spring (7) in the

existing hole of the ignition cable. In case of

new ignition cables, press in the tip of the

spring (refer to arrow).

04-03 Replacing the short-circuiting switch

To remove the short-circuiting switch (8) first

remove the filter hood, carburettor and bottom

part (07-06). Uns-

crew the nut (10) and withdraw the switch from

the short-circuiting cable.

04-03 Installing the short-circuiting switch

Push the short-circuiting cable (11) into the

switch and install the rubber cap (12) in place.

Install the switch in the crankcase ensuring

that the flat side faces upwards. Screw on nut

(10) with the toothed side facing the housing.

DOLMAR GmbH

04 Ignition system

04-04 Removing the ignition armature and

the flywheel

For the removal of the ignition armature

unscrew the cover (07-01) and the starting

assembly (1).

04-04 Removing ignition armature/flywheel

Withdraw short-circuiting cable (2) from the

armature and unscrew screws (3). When

replacing, remove ignition cable from the

ignition armature (4). Screw new ignition cable

forcefully into the ignition armature.

04-04 Installing the ignition armature

Install the ignition armature and secure in

place using screws (3). For setting the air gap,

fit gauge (5), no. 944 500 890, between fly-

wheel and armature. Turn the N/S marking of

the flywheel towards the ignition armature.

04-04 Replacing the short-circuiting cable

For the removal of the short-circuiting cable

(2) it is necessary to remove carburettor (7)

and bottom part (8). When installing the cable,

ensure that it is not caught when fitting the

bottom part.

04-04 Withdrawing the flywheel

Unscrew nut (9). Screw the punch (10),

944 500 880, on the crankshaft and remove

the flywheel by striking a jarring blow.

04-04 Installing the flywheel

Ensure that the cone on the flywheel and on

the crankshaft is free from grease.

Tighten the nut using a torque of 25 Nm (refer

to table 995 709 180).

DOLMAR GmbH

05 Starter assembly

05-02 Removing the starter assembly

Relieve the return spring before removing the

starter assembly. For this purpose slightly

withdraw the starter rope (1), while holding the

rope drum (2). Remove the rope from the

drum and allow the drum to rewind slowly.

05-02 Removing the return spring

Remove retaining ring (3) and washer (4).

Separate handle (5) from rope (7), lift the rope

drum from housing (6). Return spring and cas-

sette (8) are secured to the ventilator housing

by means of three screws.

05-02 Attachment of the starter rope in the

rope drum

In case of this rope drum a knot prevents the

starter rope from being withdrawn.

05-02 Pretensioning the return spring

After fitting the starting assembly, completely

withdraw the starter rope and hold it in this

position. It must now be possible to turn the

rope drum by another 1/2 turn. Reduce the

pretensioning force, when this is not possible.

05-03 Replacing the starter ratchets

Using a punch, remove the locating pin of the

starter ratchet from the flywheel.

05-03 Replacing the starter ratchets

Starter ratchet (9) with spring (10) and pin (11)

must be replaced as a complete assembly

only. Push the pin into the flywheel until it is

flush with the inner edge. Before installing the

pin, apply locking agent 980 009 000.

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