Service Manual DOLMAR 109 DOLMAR 110i DOLMAR 111
Contents
1. 22 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 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 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 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 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 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 DOLMAR 255505 05 02 Removing the starter assembly Relieve the return spring before removing the starter assembly For this purpose sli2. 06 02 Removing the carburettor Remove filter cover and hood Separate the fuel pipe 1 from the connection nipple Unscrew the screws 2 Remove the choke lever 3 and carburettor linkage 4 after removal of the carburettor 06 01 Adjusting the carburettor Adjustment of engine speed during idling is by idling adjustment screw S When the engine speed is excessive moving chain or too low engine stops correct accordingly by means of the idling adjustment screw 06 03 Adjusting the control lever The control lever 5 must be aligned so that its surface is in parallel with the carburettor body refer to arrow 06 03 Carburettor Tillotson control side Remove cover 5 control diaphragm 6 and seal 7 Unscrew the screw 8 The control assembly 9 comprises the inlet needle rocker arm spring and shaft 06 03 Carburettor Walbro control side Remove cover 10 control diaphragm 11 and seal 12 Unscrew the screw 13 The control assembly 14 comprises the inlet needle rocker arm and shaft DOLMAR GmbH DOLMAR 06 Carburettor 06 04 Carburettor Tillotson pump side 06 04 Carburettor Walbro pump side Unscrew cover 6 Remove seal 7 and Unscrew cover 5 with idling adjustment diaphragm 8 Carefully remove the fuel filter screw S Remove seal 6 and diaphragm 9 for cleaning 7 Carefully remove the fuel filter 8 for cleaning 06 05 Removing the injection valve 06 08 Rem
3. damper MS 08 02 Damping system design Remove screws 7 8 and using a Torx Three identical vibration dampers 9 are Spanner unscrew the screws located under provided on the tank housing neath Note screw 8 is located under the auxiliary filter 08 03 Damper system design The fourth vibration damper 6 with pot 10 and catching band 4 is located between the supporting web 11 and the crankcase DOLMAR GmbH O9 Fuel tank DOLMAR 2 22 09 01 Removing and installing the fuel tank For the removal of the fuel tank 1 it is necessary to remove the vibration damper 08 02 Separate the fuel pipe 2 from the carburettor 06 02 Install seal 7 between tank and bottom part 09 02 Replacing the ventilation valve Remove carburettor 06 02 and bottom 07 06 Using a pair of pointed pliers remove the ventilation valve 3 from the tank Seal 4 will prevent contamination of the ventilation valve 09 03 Replacing the fuel pipe For the removal of the fuel pipe 2 withdraw the intake head 5 and withdraw the fuel pipe from the tank When installing the fuel pipe ensure that the sealing face 6 rests close against the tank starting throttle locking system For this purpose push out the cylindrical pins 9 10 Remove the throttle lever and torsion spring 11 09 04 Replacing the intake head Separate the intake head 5 from the fuel pipe Note The felt 8 can be replaced as an indi
4. ss a oom oom File 5 5 4 5 5 5 5 5 From 1 2 Cutter mm 4 8 4 0 4 8 4 8 Drive Link Drive Link Drive Link Type _ Spur fixed Rim loose Spur fixed Rim loose Drive Link count 56 64 Sprocket 2 zz 7 j Kick back reduction DOLMAR GmbH DOLMAR Special tools Mounting tool for Mounting tool for Puller for tension spring clutch hub clutch hub of chain brake 944 500 680 944 500 690 950 237 000 Sealing plate for Drift for piston pin Special socket wrench leakage test of crankcase for rubber buffer 944 603 020 944 603 030 944 603 260 944 500 621 Mounting for roler bearing Puller for drive worm Snap ring pincer for external snap crankcase of oil pump rings of starting system 950 500 050 957 433 000 946 101 010 Radial ring extractor Mounting sleeve Setting gauge for for radial rings ignition armature 944 500 900 944 500 550 944 500 890 DOLMAR GmbH 01 Chain brake 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 DOLMAR 2 22 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 defectiv
5. to be performed at max 0 5 bar Cylinder base screw crankcase screws silencer screws the flywheel nut and the clutch hub must be tightened using the prescribed torque 12 05 Checking the crankcase with cylinder For pressure testing the crankcase blank off the exhaust duct using flange no 944 603 030 Screw flange no 944 603 020 to the inlet duct DOLMAR GmbH DOLMAR 2 22 Torques Assy set 109 1101 111 1111 1151 Muffler 8 5 0 5 10 0 1 0 Cylinder 10 0 1 0 Ignition Coil 6 0 1 0 Turbular handle 2 7 0 3 Rubber buffer 2 0 0 2 Intermediate flange Carburattor 5 0 0 5 Clutch hub 35 0 0 5 Flywheel 25 0 5 0 Spark plug 25 0 5 0
6. H 04 Ignition system F 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 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 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 8 DOLMAR 255505 04 01 Checking the spark plug Clean or renew contaminated or defective spark plugs 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 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 DOLMAR 2
7. Service Manual 2 93 DOLMAR 109 DOLMAR 110i DOLMAR 111 DOLMAR 111i DOLMAR 115i DOLMAR 222 DOLMAR GmbH Postfach 70 04 20 e D 2000 Hamburg 70 Germany DOLMAR GmbH DOLMAR 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 DOLMAR 55555 Technical data EE Rating kw Allowed max engine speed with bar and chain 1 min Hoi 12500 13200 12500 13000 with speed limitation High tension wire length 180 180 3 3 180 BPMR 7A WSR 6F 3 3 CHAMPION Gap Flywheel Coil 0 2 0 3 0 2 0 3 0 2 0 3 0 2 0 3 Spark plug NGK BPMR 7A BPMR 7A 0 5 0 56 0 28 1 1 1 8 3 5 980 Elektrode gap mm 0 5 m Oil tank capacity Ltr 0 28 0 28 Carb adjustment L H Si 1 1 1 1 Starter rope length mm 3 5 980 3 5 980 3 5 980 Normal profil Low profil Normal profil Fuel tank capacity BOSCH WSR 6F WSR 6F WSR 6F Saw chain Model Low profil Cutter type Chisel Semi chisel Semi chisel 3 8 3 8 3 8 9 52 8 2 9 52 9 52 emm S Filing Angie sl ls sl
8. e brake band 8 and a damaged or defective tension spring must be replaced without delay 6 Caution Safety components 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 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 04 Fitting the hand guard When fitting the hand guard ensure that the compression spring 16 is installed correctly DOLMAR GmbH 02 Clutch drum 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 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 Checking the clutch drum sprocket of models 109 111 Worn sprockets or clutch drums arrows must be replaced DOLMAR 255505 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 03 Checking the clutch drum sproc
9. ew tool 1 no 944 500 900 into the sealing ring 2 and withdraw it from the crankcase by means of the spindle 3 11 03 Removing the crankcase After removing the attachment screws separate the crankcase using a plastic hammer DOLMAR 2 22 11 03 Dismantling the crankcase For dismantling the crankcase and oil reservoir remove the seven attachment screws 11 03 Crankcase is divided into a magnet side MS 4 including the oil reservoir 4a and tank closing mechanism 11 03 Crankcase is divided into a clutch side KS 5 including the oil reservoir and the intake pipe 5a Note Housings supplied as spare parts are already fitted with needle bearings and radial sealing rings 11 03 Assembling the crankcase halves Start by inserting the crankshaft 6 into the KS half Place the seal 7 and press both halves together DOLMAR GmbH DOLMAR 12 Checking operations i D d y B 4 pa i gt i i 1 d 12 02 Checking the ignition system 12 03 Checking the carburettor Use tester no 956 010 300 for checking the For in situ checking of the carburettor sepa ignition system spark plug rate the fuel pipe from the connection nipple Fit pressure tester no 965 004 000 to the connection nipple 12 03 Checking carburettor and crankcase 12 04 Use a torque wrench for tightening Pressure testing of the carburettor or screwed connections crankcase Is
10. ghtly 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 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 03 Replacing the starter ratchets Using a punch remove the locating pin of the starter ratchet from the flywheel 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 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 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 DOLMAR GmbH O6 Carburettor DOLMAR 2 22 06 01 Adjusting the carburettor To perform the basic adjustment carefully screw in screws L and H against the stop Then back off idling jet L 1 turn max 1 4 compensation jet 1 turn max 1 4
11. ket 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 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 DOLMAR GmbH 03 Oil pump 03 02 Adjusting the oil pump delivery Turn the screw clockwise for less chain oil anti clockwise for more chain oil 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 DOLMAR 2 22 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 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 DOLMAR Gmb
12. oving the intermediate flange Unscrew attachment screw 9 and remove The intermediate flange 12 can be taken out the valve assembly 10 from the carburettor after the carburettor has been removed body Use new valve if the needle tip 11 is worn DOLMAR GmbH DOLMAR 2 22 07 Cover system air filter 07 01 Removing the cover For cleaning the air filter remove cover 1 In case of model 109 cover assembly 2 must For cleaning the auxiliary filter remove cover be removed to clean the air filter For this 4 purpose remove lever attachment screw 12 and the three cover attachment screws 3 Remove auxiliary filter 5 and unscrew the To clean the main filter separate the upper 7 main filter 6 and the lower part 8 07 06 Removing the bottom part Following the removal of the carburettor the bottom 11 can be removed Integrated into the bottom are plug 9 for the winter heating system ventilation bore seal 10 for the carburettor control side DOLMAR GmbH DOLMAR 25550505 08 Vibration damping system handle 08 01 Removing and fitting the handle 08 02 Replacing the vibration damper KS For the removal of the handle unscrew Unscrew screws 5 3 4 Always use 1 2 x tank screws lateral special tool no 944 500 621 when removing 2 2 x tank screws bottom or fitting vibration dampers 6 3 1 x vibration damper 4 catching band 08 02 Replacing the vibration
13. vidual part 09 05 Removing the throttle lever and the starting throttle locking system Remove the half throttle and compression spring 12 from the housing DOLMAR GmbH 10 Cylinder and piston 10 01 Removing the cylinder To remove the cylinder unscrew the four cylinder attachment screws 1 Lift off the cylinder from the housing and piston 10 01 Removing the cylinder Remove the gudgeon pin retaining ring and press out the gudgeon pin 6 Remove the piston from piston rod 7 with bearing 8 10 01 Cylinder and piston marking In case of Henkel duct cylinders piston and cylinder are precision machined to form a single assembly The identification A B or C can be found on the top part 16 DOLMAR 255505 10 01 Replacing the piston rings Spread the piston rings 3 at the ring cap 4 and carefully remove the piston 5 Note When assembling ensure that the arrow points to the silencer 10 01 Different cylinder design Die cast cylinder 9 for models 109 111 and piston with one piston ring Henkel cylinder 10 for models110 115 and two piston rings 10 01 Installing the cylinder Place the fork 11 no 944 600 001 on the crankcase align the piston rings 3 and compress them using the tension band 12 Pass the cylinder over the piston while sliding the tension band downwards DOLMAR GmbH 11 Crankcase crankshaft 11 01 Replacing the radial sealing rings Tightly scr
Download Pdf Manuals
Related Search