Dolmar Happy start

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Important:

Read this instruction manual carefully before putting the chain saw into operation and strictly observe the

safety regulations! Keep this instruction manual!

http://www.dolmar.com

Instruction ManualOriginal Instruction Manual

109, 109 HappyStart

111

115, 115 H


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EU Conformity Declaration

The undersigned, Tamiro Kishima and Rainer Bergfeld, asauthorized by DOLMAR GmbH, declare that the DOLMARmachines,

Type EU prototype test certicate No.

111 (026) K-EG-2007/4661115 (027) K-EG-2007/4662

manufactured by DOLMAR GmbH, Jenfelder Str. 38, 22045Hamburg, Germany, conforms to the basic safety and healthrequirements of the applicable EU Directives:

EU Machinery Directive 2006/42/EG, EU EMC Directive2004/108/ EG, Outdoor Noise Directive 2000/14/EG.

The most important standards applied to properly meet therequirements of the above EU Directives were: EN 11681-1,CISPR 12, EN 50082-1, DIN VDE 0879 T1.

The conformity assessment procedure 2000/14/EG was perfor-med per Annex V. The measured sound power level (Lwa) is 112dB(A). The guaranteed sound power level (Ld) is 113 dB(A).

The EU Type-Examination Certicate was performed by: Deut-

sche Prf- und Zertizierungsstelle fr Land- und Forsttechnik,Max-Eyth Weg 1, D-64823 Gro-Umstadt.

The technical documentation is on le at DOLMAR GmbH, Ab-teilung FZ, Jenfelder Strasse 38, 22045 Hamburg, Germany.

Hamburg, 29.12.2009 for DOLMAR GmbH

Tamiro Kishima Rainer BergfeldManaging Director Managing Director

Page

Thank you for purchasing a DOLMAR product!Congratulations on choosing a DOLMAR chain saw! We are condentthat you will be satised with this modern piece of equipment.

The DOLMAR-chain saws are light, handy saws with highperformance, a good power-to-weight ratio, and a wide rangeof speeds for top utility.

The long-life "Nikasil"-lined cylinder, tough die-cast magne-sium crankcase with sturdy, easy-to-operate central guide-barmounting and rugged metal spike bar make this saw a reliable,hard-working tool.

The automatic chain lubrication with variable-ow oil pumpand maintenance-free electronic ignition ensure trouble-freeoperation, while the hand-saving anti-vibration system andergonomic grips and controls make work easier, safer, andless tiring for the user.

DOLMAR chain saws are equipped with the latest safety fea-tures and meet all national and international standards. Thesefeatures include: hand guards on both handles, grip throttle leverlock, chain catch, safety saw chain, and chain brake. The chainbrake can be actuated manually, and is also inertia-actuatedautomatically in case of kickback.

The following industrial property rights apply: US 4465440, US

5411382, EP 0236858, EP 0560201, GBM 8710075, GBM8809928, GBM 9203378, GBM 29616652.

In order to ensure the proper functioning and performanceof your new chain saw, and to safeguard your own per-sonal safety, it is imperative that you read this instructionmanual thoroughly before operation. Be especially carefulto observe all safety precautions!Failure to observe theseprecautions can lead to severe injury or death!

Table of contents PageEU conformity declaration.................................................2

Packing................................................................................2

Delivery inventory ..............................................................3

Symbols...............................................................................3

SAFETY PRECAUTIONS ....................................................4

General precautions .......................................................4

Protective equipment ......................................................4

Fuels / Refuelling ............................................................5

Putting into operation ......................................................5 Kickback .........................................................................6

Working behavior/Method of working ...........................6-7

Transport and storage .....................................................8

Maintenance ...................................................................8

First aid ...........................................................................8

Technical data.....................................................................9

Denomination of components...........................................9

PUTTING INTO OPERATION ............................................10

Mounting the guide bar and saw chain ....................10-11

Tightening the saw chain .............................................. 11

Chain brake .................................................................. 11

Fuels / Refuelling .....................................................12-13 Adjusting the chain lubrication ......................................13

Starting the engine ........................................................14

Cold start ......................................................................14

Packing

Your DOLMAR chain saw comes delivered in a protective card-board box to protect against shipping damage.

Cardboard is a basic raw material and is consequently reuseableor suitable for recycling (waste paper recycling).

RE Y

Warm start ....................................................................14

Stopping the engine ......................................................14

Checking the chain brake .............................................15

Checking the chain lubrication ......................................15

Adjusting the carburetor(only for EU-countries)..............15

Adjusting the carburetor(only for not EU-countries)........16

Working in winter .............................................................17

Handle heating ..............................................................17

MAINTENANCE .................................................................17 Sharpening the saw chain .......................................17-18

Cleaning the guide bar ..................................................18

Cleaning the brake band and sprocket interior .............19

Replacing the saw chain ...............................................19

Replacing the suction head ..........................................19

Cleaning the air lter .....................................................20

Replacing the spark plug ..............................................20

Replacing the starter cable ...........................................21

Replacing the return spring ...........................................21

Mounting the fan housing .............................................21

Instructions for periodic maintenance ...........................22

Service, spare parts and guarantee ...........................22-23Trouble shooting ..............................................................23

Extract from spare parts list............................................24

Accessories ..................................................................24


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1

2

3

4

5 6 7

RE Y

1

2

Wear protective gloves!

Chain brake

Caution, kickback!

Fuel and oil mixture

Carburetor adjustment

Chain oil ll/oil pump

Working in winter

Handle heating

First aid

Recycling

CE - Marking

Delivery inventory

1. Chain saw2. Guide bar

3. Saw chain4. Chain protection cover5. Universal wrench

6. Screwdriver for carburetor adjustment

(only in delivery for model 115, 115 H)7. Offset screwdriver8. Instruction manual (not shown)

In case one of the parts listed should not be included in thedelivery inventory, please consult your sales agent.

SymbolsYou will notice the following symbols on the saw and in the Instruction Manual:

Read instruction manual andfollow the warning- and safetyprecautions!

Particular care and caution!

Forbidden!

Wear protective helmet, eye andear protection!

No smoking!

No open re!

On/Off (I/O) switch

Press starting valve

Engine - manual start

Choke lever

Stop engine!


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1

SAFETY PRECAUTIONS

Intended use

Power chain saws

This power chain saw may be used only for sawing wood out of doors.It is intended for the followung uses depending on its class:

- Professional and mid-class: Use on small, medium and largetrees: felling, limb removal, cutting to length, thinning.

- Hobbyklasse: Occasional use on small trees, fruit-tree care,felling, limb removal, cutting to length.

Unauthorised users:

Persons who are not familiar with the Instruction Manual, children,young people, and persons under the inuence of drugs, alcoholor medication must not use this saw.

General precautions

- To ensure correct operation the user has to read this instruc-tion manual to make himself familiar with the characteristicsof the chain saw. Users insufciently informed will endangerthemselves as well as others due to improper handling.

- It is recommended to lend the chain saw only to people whoare experienced in working with chain saws. Always hand over

the instruction manual.

- First users should ask the dealer for basic instructions to becomefamiliarized with the characteristics of engine powered sawingor even attend a recognized course of instruction.

- Children and young persons aged under 18 years must not beallowed to operate the chain saw. Persons over the age of 16years may, however, use the chain saw for the purpose of beingtrained as long as they are under the supervision of a qualiedtrainer.

- Use chain saws always with the utmost care and attention.

- Operate the chain saw only if you are in good physical condition.If you are tired, your attention will be reduced. Be especiallycareful at the end of a working day. Perform all work calmly andcarefully. The user has to accept liability for others.

- Never use the chain saw after having consumed alcohol, drugsor medication.

- A re extinguisher must be available in the immediate vicinitywhen working in easily inammable vegetation or when it hasnot rained for a long time (danger of re).

Protective equipment

- In order to avoid head, eye, hand or foot injuries as well asto protect your hearing the following protective equipmentmust be used during operation of the chain saw:

- The kind of clothing should be appropriate, i. e. it should betight-tting but not be a hindrance. Do not wear jewelleryor clothing which could become entangled with bushes orshrubs. If you have long hair, always wear a hairnet!

- It is necessary to wear a protective helmet whenever workingwith the chain saw. The protective helmet (1) is to be checkedin regular intervals for damage and is to be replaced after 5years at the latest. Use only approved protective helmets.

- The face shield(2) of the protective helmet (or the goggles)protects against sawdust and wood chips. During operation ofthe chain saw always wear a goggle or a face shield to preventeye injuries.

- Wear adequatenoise protection equipment(ear muffs (3),ear plugs, etc.). Octave brand analysis upon request.

- The safety jacket(4) is provided with special signal-colouredshoulder straps and is comfortable and easy to care for.

- The protective brace and bib overall(5) is made of a nylonfabric with 22 layers and protects against cuts. We stronglyrecommend its use.

- Protective gloves (6) made of thick leather are part of the4

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1

2

3

4

5 6

7

prescribed equipment and must always be worn duringoperation of the chain saw.

- During operation of the chain saw safety shoesor safetyboots(7) tted with anti skid sole, steel toe caps and pro-tection for the leg must always to be worn. Safety shoesequipped with a protective layer provide protection against

cuts and ensure a secure footing.


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!"Maintenance !"Stopping work!"Refuelling !"Transport!"Sharpening the chain " !"Putting out of function

3 meters

6

5

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8

Fuels / Refuelling- Stop the engine before refuelling the chain saw.

- Do not smoke or work near open res (5).

- Let the engine cool down before refuelling.- Fuels can contain substances similar to solvents. Eyes and skin

should not come in contact with mineral oil products. Always wearprotective gloves when refuelling. Frequently clean and changeprotective clothes. Do not breathe in fuel vapors. Inhalation offuel vapours can be hazardous to your health.

- Do not spill fuel or chain oil. When you have spilt fuel or oil im-mediately clean the chain saw. Fuel should not come in contact

with clothes. If your clothes have come in contact with fuel,change them ot once.

- Ensure that no fuel or chain oil oozes into the soil (environmentalprotection). Use an appropriate base.

- Refuelling is not allowed in closed rooms. Fuel vapors will ac-cumulate near the oor (explosion hazard).

- Ensure to rmly tighten the screw plugs of the fuel and oiltanks.

- Change the place before starting the engine (at least 3 m fromthe place of refuelling) (6).

- Fuel cannot be stored for an unlimited period of time. Buy onlyas much as will be consumed in the near future.

- Use only approved and marked containers for the transport andstorage of fuel and chain oil. Ensure children have no access to

fuel or chain oil.

Putting into operation- Do not work on your own. Another person must be nearby

in case of emergencies (within shouting distance).

- Ensure that there are no children or other people within theworking area. Pay attention to any animals in the working area,as well (7).

- Before starting work the chain saw must be checked forperfect function and operating safety according to the pre-scriptions.

Check especially the function of the chain brake, the correctmounting of the guide bar, the correct sharpening and tighten-ing of the chain, the rm mounting of the sprocket guard, theeasy motion of the throttle lever and the function of the throttlelever lock, the cleanliness and dryness of the handles, and thefunction of the ON/OFF switch.

- Put the chain saw only into operation if it is completely assembled.Never use the chain saw when it is not completely assembled.

- Before starting the chain saw ensure that you have a safe foot-ing.

- Put the chain saw into operation only as described in this instruc-tion manual (8). Other starting methods are not allowed.

- When starting the chain saw it must be well supported andsecurely held. The guide bar and chain must not be in contactwith any object.

- When working with the chain saw always hold it with bothhands. Take the back handle with the right hand and the tubu-lar handle with the left hand. Hold the handles tightly with your

thumbs facing your ngers.- CAUTION: When releasing the throttle lever the chain will

keep on running for a short period of time (free-wheeling).

- Continuously ensure that you have a safe footing.- Hold the chain saw such that you will not breathe in the exhaust

gas. Do not work in closed rooms (danger of poisoning).- Switch off the chain saw immediately if you observe any

changes in its operating behavior.

- The engine must be switched off before checking the chaintension, tightening the chain, replacing it or clearing mal-functions (9).

- When the sawing device is hit by stones, nails or other hardobjects, switch off the engine immediately and check thesawing device.

- When stopping work or leaving the working place switch off thechain saw (9) and put it down such that nobody is endangered.

- Do not put the overheated power chain saw in dry grass or on anyinammable objects. The mufer is very hot (danger of re).

- CAUTION: Oil dropping from the chain or guide bar after hav-ing stopped the saw chain will pollute the soil. Always use anappropriate base.


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12

11

13

14

Z

Kickback

- When working with the chain saw dangerous kickbacks mayoccur.

- Kickback occurs when the upper part of the end of the guidebar inadvertently touches wood or other hard objects (10).

- This causes the saw to be thrown back toward the user withgreat force and out of control. Risk of injury!

In order to prevent kickback, follow these rules:

- Only specially-trained persons should perform plunge cuts, i.e.,piercing timber or wood with the tip of the saw!

- Never apply the end of the bar when starting to make a cut.

- Always observe the end of the guide bar. Be careful whencontinuing an already started cut.

- When starting to cut the chain must be running.

- Ensure that the chain is always sharpened correctly. Pay specialattention to the height of the depth limiter.

- Never cut several branches at the same time. When cutting abranch ensure that no other branch is touched.

- When crosscutting a trunk be aware of the trunks next to it.

Working behavior/Method of working

- Only use the chain saw during good light and visibility periods.

Be aware of slippery or wet areas, and of ice and snow (risk ofslipping). The risk of slipping is extremely high when workingon recently peeled wood (bark).

- Never work on unstable surfaces. Make sure that there are noobstacles in the working area, risk of stumbling. Always ensurethat you have a safe footing.

- Never saw above your shoulder height (11).

- Never saw while standing on a ladder (11).

- Never climb up into trees to perform sawing with the chainsaw.

- Do not work leaning too far over.

- Guide the chain saw in such a way that no part of your body iswithin the elongated swivelling range of the saw (12).

- Use the chain saw for sawing wood only.

- Avoid touching the ground with the chain saw while it is stillrunning.

- Never use the chain saw for lifting up or removing pieces ofwood or other objects.

- Remove foreign objects such as sand, stones and nails foundwithin the working area. Foreign objects may damage the saw-ing device and can cause dangerous kickback.

- When sawing precut timber use a safe support (sawing jack,13). Do not steady the workpiece with your foot, and do notallow anyone else to hold or steady it.

- Secure round pieces against rotation.

- For cutting down trees or performing crosscuts the spikebar (13, Z)must be applied to the wood to be cut.

- Before performing a crosscutrmly apply the spike bar to thetimber, only then can the timber be cut with the chain running.For this the chain saw is lifted at the back handle and guidedwith the tubular handle. The spike bar serves as a centre ofrotation. Continue by slightly pressing down the tubular handleand simultaneously pulling back the chain saw. Apply the spikebar a little bit deeper and once again lift the back handle.

- When the timber must be pierced for cutting or longitudi-nal cuts are to be performed it is urgently recommendedto have this carried out by specially trained persons only(high risk of kickback).

- Do longitudinal - lengthwise - cutsat the lowest possibleangle (14). Be very careful when doing this type of cut, as thespike bar cannot grip.

- The saw must be running whenever you remove the chain sawfrom the wood.

- When performing several cuts the throttle lever must be releasedin between.


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= cutting down area

16

17

18

19

45o

2 1/2

45o

15

- Be careful when cutting splintery wood. Cut pieces of woodmay be pulled along (risk of injuries).

- When cutting with the upper edge of the guide bar, the chainsaw may be pushed in the direction of the user if the chaingets clamped. For this reason use the lower edge of the barwhenever possible. The chain saw will then be pushed awayfrom you (15).

- If the timber is under tension (16), rst cut the pressure side(A). Then the crosscut can be performed on the tension side(B). Thus clamping of the guide bar can be avoided.

CAUTION:

People felling trees or cutting of branches must be speciallytrained. High risk of injuries!

- When cutting of branches, the chain saw should be supportedon the trunk. Do not use the end of the bar for cutting (risk ofkickback).

- Be aware of branches under tension. Do not cut free branchesfrom below.

- Never perform detensioning cuts while standing on the trunk.

- Before cutting down a tree ensure that

a) only those people are within the working area which areactually involved in cutting down the tree.

b) every worker involved can withdraw without stumbling (thepeople should withdraw backwards in a diagonal line, i. e.at a degree of 45).

c) the bottom part of the trunk is free from foreign objects,underbrush and branches. Make sure to have a safe footing(risk of stumbling).

d) the next working place is at least 2 1/2 tree lengths away(17). Before cutting down the tree check the direction of falland make sure that there are neither people nor objectswithin a distance of 2 1/2 tree lengths.

- Judging the tree:

Direction of hanging - loose or dry branches - height of the tree- natural overhang - is the tree rotten?

- Take into account the direction and speed of the wind. If stronggusts are occurring, do not do any felling.

- Cutting the roots:

Start with the strongest root. First do the vertical and then thehorizontal cut.

- Notching the trunk (18, A):

The notch determines the direction of fall and guides the tree.The trunk is notched perpendicular to the direction of fall andpenetrates 1/3 -1/5 of the trunk diameter. Perform the cut nearthe ground.

- When correcting the cut, always do so over the whole width ofthe notch.

- Cut downthe tree (19, B) above the bottom edge of the notch(D). The cut must be exactly horizontal. The distance betweenboth cuts must be approx. 1/10 of the trunk diameter.

- The material between both cuts(C) serves as a hinge. Nevercut it through, otherwise the tree will fall without any control.Insert felling wedges in time.

- Secure the cut only with wedges made of plastic or aluminium.Do not use iron wedges. If the saw hits an iron wedge the chaincan be seriously damaged or torn.

- When cutting down a tree always stay sidewards of the fallingtree.

- When withdrawing after having performed the cut, be alert forfalling branches.

- When working on sloping ground the user of the chain sawmust stay above or sidewards of the trunk to be cut or the treealready cut down.

- Be alert for trunks which may roll towards you.


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SERVICE

20

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22

Transport and storage

- When changing your location during work switch off the chainsaw and actuate the chain brake in order to prevent an inad-vertent start of the chain.

- Never carry or transport the chain saw with the chain running.

- When transporting the chain saw over long distances the guidebar protection cover (delivered with the chain saw) must beapplied.

- Carry the chain saw with the tubular handle. The guide barpoints backwards (20). Avoid coming in contact with the mufer(danger of burns).

- Ensure safe positioning of the chain saw during car trans-portation to avoid fuel or chain oil leakage.

- Store the chain saw safely in a dry place. It must not be storedoutdoors. Keep the chain saw away from children.

- Before storing the chain saw over a long period of time or ship-ping it the fuel and oil tanks must be completely emptied.

Maintenance

- Before performing maintenance work switch off the chainsaw (21)and pull out the plug cap.

- Before starting work always check the operating safety of thechain saw, in particular the function of the chain brake. Makesure that the chain is always sharpened and tightened cor-rectly (22).

- Operate the chain saw only at a low noise and emission level.For this ensure the carburetor is adjusted correctly.

- Regularly clean the chain saw.

- Regularly check the tank cap for tightness.

Observe the accident prevention instructions issued bytrade associations and insurance companies. Do notperform any modications on the chain saw. You will putyour safety at risk.

Perform only the maintenance and repair works described inthe instruction manual. All other work must be carried out byDOLMAR Service.

Use only original DOLMAR spare parts and accessories.

Using spare parts other than original DOLMAR parts or ac-cesories and guide bar/chain combinations or lengths whichare not approved bring a high risk of accidents. We cannotaccept any responsibility for accidents and damage resultingfrom using sawing devices or accesories which have not beenapproved.

First aid

For the event of a possible accident, please make sure that arst aid kit is always immediately available close by. Immediatelyreplace any items used from the rst aid box.

When calling for help, give the following information:

- Place of the accident

- What happened

- Number of injured people

- Kind of injuries

- Your name!

NOTE

Individuals with poor circulation who are exposed to excessivevibration may experience injury to blood vessels or the nervoussystem.

Vibration may cause the following symptoms to occur in the n-gers, hands or wrists: Falling asleep (numbness), tingling, pain,stabbing sensation, alteration of skin colour or of the skin. If anyof these symptoms occur, see a physician!


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Stroke volume cm3 43 52 52

Bore mm 40 44 44

Stroke mm 34 34 34

Max. power at speed kW / RPM 2.0 / 9,000 2.4 / 9,000 2.7 / 9,000

Max. torque at speed Nm / RPM 2.4 / 6,000 2.9 / 6,000 3.1 / 6,000

Idling speed / max. engine speed with bar and chain RPM 2,500 / 12,500 2,500 / 12,500 2,500 / 13,000

Clutch engagement speed RPM 3,600 3,600 3,600

Sound pressure level (at the workplace)LpA, eqper ISO 22868 1) 3) dB(A) 101 / KpA= 2,5 101 / KpA= 2,5 101 / KpA= 2,5

Sound power level LWA, eqper ISO 22868 1) 3) dB(A) 110 / KWA= 2,5 110 / KWA= 2,5 110 / KWA= 2,5Vibration acceleration ahv, eqper ISO 22867 1) 3)

- Tubular handle m/s2 5,9 / K=2 5,9 / K=2 5,9 / K=2- Rear handle m/s2 5,2 / K=2 5,2 / K=2 5,2 / K=2

Carburetor (diaphragm carburetor) Type Walbro WT-76 C Walbro WT-76 C Walbro WT-76 C

Ignition system Type electronic electronic electronic

Spark plug Type BOSCH WSR 6F BOSCH WSR 6F BOSCH WSR 6F

Electrode gap mm 0.5 0.5 0.5

or spark plug Type NGK BPMR 7A NGK BPMR 7A NGK BPMR 7A

Fuel consumption at max. load per ISO 7293 kg/h 0.90 1.08 1.21

Specic consumption at max. load per ISO 7293 g/kWh 450 450 450

Fuel tank capacity l 0.56 0.56 0.56

Chain oil tank capacity I 0.28 0.28 0.28

Mixture ratio (fuel/two-stroke oil)- when using DOLMAR oil 50:1

- when using Aspen Alkylat (two-stroke fuel) 50 : 1 (2%) - when using DOLMAR HP 100 oil 100:1 - when using other oils 50 : 1(quality grade: JASO FC or ISO EGD)

Chain brake engages manually or in case of kickback

Chain speed 2) m/s 19.7 19.9

Sprocket pitch inch 3/8 .325

Number of teeth Z 7 8

Chain type (see the Extract from the spare-parts list)

Pitch / gauge inch 3/8 - .325 / .058

Guide bar, length of a cut cm 33, 38, 45

Guide-bar type (see the Extract from the spare-parts list)

Weight (fuel tank empty, without chain and guide bar) kg 5,1

1)Figures derived in equal part from idling, full-load and racing speed.2)At max. power. 3) Uncertainty (K=).

Technical data

Identication plate (11)Indicate when ordering spare parts

Serial numberYear of manufacture

2010

Denomination of components

1 Handle

2 Choke

3 Filter cover 4 Tubular handle 5 Mufer 6 Retaining nuts 7 Spike bar 8 Chain catche 9 Adjusting screw for oil pump (bottom side)10 Sprocket guard11 Identication plate12 Hand guard13 Guide bar14 Chain15 Hand guard (release for chain brake)16 Starter grip

17 Adjusting screws "S-L-H" for carburetor18 I/STOP-switch19 Safety locking button20 Throttle lever21 Fuel tank cap22 Fan housing with starting assembly23 Oil tank cap24 Starting valve (only 109 HappyStart)

111 115, 115 H109, 109 HappyStart

2023

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16

3 42

12

22 21

24

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11

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10 9 8

14 15

1319

18


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CAUTION: Before doing any work on the guide bar or chain,always switch off the engine and pull the plugcap off the spark plug (see "Replacing the sparkplug"). Always wear protective gloves!

CAUTION: Start the chain saw only after having assembled

it completely and inspected.

PUTTING INTO OPERATION

- Always release the chain brake before removing or replacingthe sprocket guard (B/4). To do so, pull the hand guard (A/1)towards the tubular handle (A/2) until you feel it catch.

C D

- Position the guide bar (D/8). Make sure that the pin (D/9)of the chain tightener is in the hole (circled) on the guidebar.

8

E F

- Turn the chain adjusting screw (C/6) to the left (counter-clockwise) until the pin (C/7) is at the left stop.

10 8

11

- Lift the chain (E/10) over the clutch drum and onto thesprocket (E/11). Using your right hand, guide the chain intothe top guide groove on the guide bar (E/8). Note that thecutting edges along the top of the chain must point in thedirection of the arrow!

- Lead the chain (F/10) around the sprocket nose (F/12) ofthe guide bar.

NOTE:The chain should be easy to pull in the direction of thearrow. The clutch drum (E/11) should turn with the chain (thesprocket engages the chain).

10 12

Mounting the guide bar and saw chain

Use the universal wrench delivered with the chain saw for thefollowing work.

Put the chain saw on a stable surface and carry out the following

steps for mounting the guide bar and saw chain:

A B

1

2

- Unscrew retaining nuts (B/3).

- Pull off the sprocket guard (B/4).

- Remove the plastic transport cover (B/5) and dispose ofproperly.

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- Turn the chain tightener (G/6) to the right (clockwise)until the chain engages the guide groove of the bottomside of the bar (see circle). Press the guide bar against thehousing with your left hand.

- Replace the sprocket guard (H/4).

- Manually tighten the retaining nuts (H/3).

Chain brake

J

Tightening the saw chain

- Slightly lift the end of the guide bar and turn the chain adjust-ing screw (I/6) to the right (clockwise) until the chain restsagainst the bottom side of the guide bar.

- While still holding up the tip of the guide bar, tighten theretaining nuts (H/3) with the universal wrench.

G H

6

K

L

I

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12

3

4 3

Checking the chain tension

- The tension of the chain is correct if the chain rests againstthe bottom side of the guide bar and can still be easily turnedby hand.

- While doing so the chain brake must be released.

- Check the chain tension frequently - new chains tend to getlonger during use!

- When checking the chain tension the engine must be switchedoff.

NOTE:

It is recommended to use 2-3 chains alternatively.

In order to guarantee uniform wear of the guide bar the barshould be turned over whenever replacing the chain.

Engaging the chain brake(braking)

If the kickback is strong enough the sudden acceleration of the

guide bar combined with the inertia of the hand guard (L/3) willautomaticallyactuate the chain brake.

To engage the chain brake manually, simply push the hand guard(L/3) forward (towards the tip of the saw) with your left hand (arrow 1).

Releasing the chain brake

Pull the hand guard (L/3) towards you (arrow 2) until you feelit catch. The brake is now released.

The DOLMAR models comes with an inertia chain brake asstandard equipment. If kickback occurs due to contact of theguide-bar tip with wood (see SAFETY PRECAUTIONS, page6), the chain brake will stop the chain through inertia if thekickback is sufciently strong. The chain will stop within a frac-tion of a second.

The chain brake is installed to block the saw chain beforestarting it and to stop it immediately in case of an emer-gency. MPORTANT: NEVER run the saw with the chain brakeactivated(except for testing, see Testing chain brake)! Doingso can very quickly cause extensive engine damage!

ALWAYS release the chain brake before startingthe work!


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B

Chain oil

Use an oil with adhesive additive for lubricating the chain andguide bar. The adhesive additive prevents the oil from beingung off the chain too quickly.

We recommend the use of chain oil which is bio-degradable in

order to protect the environment. The use of bio-degradable oilmay even be required by local regulations.

The chain oil BIOTOP sold by DOLMAR is made of specialvegetable oils and is 100% bio-degradable. BIOTOP has beengranted the "blue angel" (Blauer Umweltschutz-Engel) for beingparticularly environment-friendly (RAL UZ 48).

BIOTOP chain oil is available in the following sizes:

1 l order number 980 008 210 5 l order number 980 008 21120 l order number 980 008 213

Bio-degradable oil is stable only for a limited period of time. Itshould be used within 2 years from the date of manufacture(printed on the container).

Important note on bio-degradable chain oils:

If you are not planning to use the saw again for an extendedperiod of time, empty the oil tank and put in a small amount ofregular engine oil(SAE 30), and then run the saw for a time.This is necessary to ush out all remaining bio-degradable oilfrom the oil tank, oil-feed system, chain and guide bar, as manysuch oils tend to leave sticky residues over time, which cancause damage to the oil pump or other parts.

The next time you use the saw, ll the tank with BIOTOP chainoil again.

C

NEVER USE WASTE OIL

Waste oil is very dangerous for the environment.

Waste oil contains high amounts of carcinogenic substances.

Residues in waste oil result in a high degree of wear and tearat the oil pump and the sawing device.

In case of damage caused by using waste oil or unappropriatechain oil the product guarantee will be null and void.

Your salesman will inform you about the use of chain oil.

waste oil

Fuel / Refuelling

1000 cm3 (1 litre) 20 cm3 20 cm3 10 cm3

5000 cm3 (5 litres) 100 cm3 100 cm3 50 cm3

10000 cm3 (10 litres) 200 cm3 200 cm3 100 cm3

100:1

+

A

Gasoline 50:1 50:1

OIL

Fuel mixture

This tool is powered by a high-performance air-cooled two-stroke engine. It runs on a mixture of gasoline and two-strokeengine oil.The engine is designed for unleaded regular gasoline with a min.octane value of 91 ROZ. In case no such fuel is available, you canuse fuel with a higher octane value. This will not affect the engine.In order to obtain an optimum engine output and to protect yourhealth and the environment use unleaded fuel only.

To lubricate the engine, use a synthetic oil for two-stroke air-cooled engines (quality grade JASO FC or ISO EGD), which hasto be added to the fuel. The engine has been designed for use ofDOLMAR HP 100 high-performance two-stroke engine oil and amixture ratio of only 100:1 to protect the environment. In addition, along service life and reliable operation with a minimum emission ofexhaust gases are ensured.

DOLMAR HP 100 high-performance two-stroke engine oil is avail-able in the following sizes:

0,5 l order number 980 008 109

DOLMAR high-performance two-stroke engine oil is available in thefollowing sizes to suit your individual requirements:

1 l order number 980 008 107

100 ml order number 980 008 106

In case DOLMAR high-performance two-stroke engine oil is notavailable, it is urgently recommended to use a mixture ratio of 50:1with other two-stroke engine oils, as otherwise optimum operationof the engine cannot be guaranteed.

Caution: Do not use ready-mixed fuel from petrol stati-ons.

The correct mixture ratio:

50:1 when using DOLMAR high-performance two-stroke engineoil, i. e. mix 50 parts gasoline with 1 part oil.

100:1 when using DOLMAR HP 100 high-performance two-stroke

engine oil, i. e. mix 50 parts gasoline with 1 part oil.50:1 when using other synthetic two-stroke engine oils

(quality grade JASO FC or ISO EGD), i. e. mix 50 partsgasoline with 1 part oil.

NOTE:For preparing the fuel-oil mixturerst mix the entire oil quantitywith half of the fuel required, then add the remaining fuel. Thoroughlyshake the mixture before lling it into the chain saw tank.

It is not wise to add more engine oil than specied to ensuresafe operation. This will only result in a higher production ofcombus-tion residues which will pollute the environment andclog the exhaust channel in the cylinder as well as the mufer.In addition, fuel consumption will rise and performance willdecrease.

The Storage of Fuel

Fuels have a limited storage life. Fuel and fuel mixtures age throughevaporation, especially at high temperatures. Aged fuel and fuelmixtures can cause starting problems and damage the engine.Purchase only that amount of fuel, which will be consumed overthe next few months. At high temperatures, once fuel has beenmixed it should be used up in 6-8 weeks.Store fuel only in proper containers, in dry, cool, securelocations!


13/2813

AVOID SKIN AND EYE CONTACT

D

Mineral oil products degrease your skin. If your skin comes incontact with these substances repeatedly and for an extendedperiod of time, it will desiccate. Various skin deseases may result.In addition, allergic reactions are known to occur.

Eyes can be irritated by contact with oil. If oil comes into youreyes, immediately wash them with clear water.

If your eyes are still irritated, see a doctor immediately!

Refuelling

FOLLOW THE SAFETY PRECAUTIONS!

Be careful and cautious when handling fuels.

The engine must be switched off!

- Thoroughly clean the area around the caps, to preventdirt from getting into the fuel or oil tank.

- Unscrew the cap and ll the tank with fuel (fuel/oil mixture)or chain oil as the case may be. Fill up to the bottom edgeof the ller neck. Be careful not to spill fuel or chain oil!

- Tightly screw on the cap.

After refuelling, clean the tank cap and surroundings andmake sure the cap is sealed!

E chain oil

Adjusting the chain lubrication

G

The engine must be switched off.

You can adjust the oil pump feed rate with the adjusting screw(F/1). The adjusting screw is located in the housing underneaththe sprocket guard (F/2). It is accessible from below.

The oil pump comes factory-set to a medium feed rate.

Note: To set from minimum to maximum oil supply, turn the ad-

justing screw (F/1with adjustment markings) max. a 1/4-turn.

Note:After the saw has been turned off it is normal for residualchain oil to drip from the oil feed system, the guide bar and thechain for a time. This does not constitute a defect!

Place the saw on a suitable surface.

To ensure troublefree operation of the oil pump the oil guidegroove at the crank case (G/3) and the oil inlet bore in the guidebar (G/4) must be cleaned regularly.

To change the feed quantity use the universal wrench and adjustthe adjusting screw (F/1) in the following way:

- Turn to the right to reduce the feed rate.

- Turn to the left to increase the feed rate.

F

2

1

3

4

fuel/oil mixture

Lubricating the chain

During operation there must always be sufcient chain oil inthe chain-oil tank to provide good chain lubrication. One lling

is sufcient for about one half-hour of continuous operation.While working make sure there is enough chain oil in the tank.

If necessary, add oil. The engine must be switched off!


14/2814

Starting the engine

- Move at least 3m away from the place where you fuelledthe saw.

- Make sure you have a good footing, and place the sawon the ground in such a way that the chain is not touching

anything.- Engage the chain brake (lock).

- Hold the tubular handle tightly with one hand and press thechain saw to the ground.

- Steady the rear handle by standing in the hand guard.A

1

2

109 HappyStart

Cold-starting

The carburetors of these saws have a choke valve for coldstarting (mixture enrichment).

To make it easier to start, the chain saw 109 HappyStart isequipped with a semi-automatic starting valve (B/5). Pushing this

valve in reduces the amount of compression effort needed, so thatit is easier to bring the engine up to starting speed when pullingthe starter cable. The high pressure increase in the combustionchamber that results from the rst ignitions will automaticallyclose the starting valve (button pops back out).

Models 109, 111, 115 and 115 H do not have a startingvalve. Starting and carburetor adjustment are as for model109 HappyStart except without the instruction "Push thestarting valve".

Pull the choke (B/1) out until it audibly clicks. This simulta-neously actuates the half-throttle lock.

Put the short-circuiting switch (B/2) in position "I" (START).

Slowly pull out the starter cable (B/3) until you notice resistance(the piston is positioned before the top dead centre).

Push the starting valve (B/5) (only 109 HappyStart).

Now pull the starter cable with a fast and forceful movementuntil you hear the rst ignition.

CAUTION:Do not pull out the starter cable more than approx.50 cm, and lead it back by hand.

When you hear the rst ignition, push the choke (B/1) in.Push the starting valve again (only 109 HappyStart) and pullthe starter cable.

As soon as the engine is running, grasp the rear handle (thisactuates the grip safety (B/6)) and tap the throttle (B/4). This will

release the half-throttle lock and the engine will run in idle.CAUTION:As soon as the engine is started it must be putin idle to prevent the chain brake from being damaged.

Now release the chain brake.

Warm starting

As described for cold starting, except before starting pull thechoke (B/1) all the way out and back in one time, in order toactivate the half-throttle lock.

If the engine doesnt start after 2 or 3 pulls, repeat the entire

starting procedure as described for cold starting.

Stopping the engine

Put the short-circuiting switch (B/2) in position "O" (STOP).

B

5

1

2

42

1

63


15/2815

Do not work with the chain saw without rst checkingthe chain brake!

- Start the engine as described (make sure you have a goodfooting, and place the chain saw on the ground in such away that the guide bar is free of contact).

- Grasp the tubular handle rmly with one hand and hold thegrip with the other.

- With the engine running at moderate speed, press the handguard (C/1) in the direction of the arrow with the back ofyour hand until the chain brake engages. The chain shouldstop immediately.

- Immediately release the throttle and release the chainbrake.

IMPORTANT: If the chain does not stop immediatelywhen you test the chain brake, do NOT use the chainsaw. Take the chain saw to a DOLMAR service center.

Checking the chain brake

DC

1

Never work with the chain saw withoute sufcient chain lubri-cation. Otherwise the service life of the chain and guide barwill be reduced. Before starting work check the oil level in thetank and the oil feed.Check the oil feed rate as described below:- Start the chain saw.- Hold the running chain saw approx. 15 cm above a trunk

or the ground (use an appropriate base).If the lubrication is sufcient, you will see a light oil trace be-

cause oil will be ung off the sawing device. Pay attention to thedirection the wind is blowing and avoid unnecessary exposureto the oil spray!

Checking the chain lubrication

E

Adjusting the carburetor(only for EU-countries)

Carburetor adjustment must only be done with the enginewarm, a clean airlter and the saw chain properly tensionedand mounted. Always have a DOLMAR service centre docarburetor adjustment, since incorrect adjustment cancause considerable damage to the engine.

Due to new emissions regulations, the adjustment range ofscrews (H) and (L) has been limited. This adjustment rangelimitation (to about 180 degrees) prevents over-rich settings.

This ensures compliance with emissions regulations, optimumengine performance and economical fuel consumption.

Factory setting of adjustment screws (H) and (L):Screwed out almost all the way (counter-clockwise).

For proper adjustment, proceed as follows:

Checking adjustment screw (H)

Before starting, make sure that adjustment screw (H) is un-screwed all the way (until you feel a stop). Limitations do notprotect against too lean running (insufcient fuel)!

1. Start engine and let it warm up (3-5 minutes)

2. Set idle

3. Check acceleration

4. Set highest permissible speed.

5. Check idle speed

2. Set idle

Set the idle speed per the technical specications.

Turning the adjusting screw (S) in (clockwise) increases theidle speed. Turning it out (counter-clockwise) lowers the idlespeed. The chain or blade must not move in idle!


When the throttle is pressed, the engine should go smoothlyfrom idle to high speed.

Unscrew adjustment screw (L) counter-clockwise in smallsteps until acceleration is good.

4. Set the top speed

Set the top speed with a minimal adjustment to screw (H)in accordance with the technical data.

Screwing in adjustment screw (H) clockwise increasesengine speed. Never exceed the top speed under anycircumstances!

5. Checking the idle speed

After setting the maximum permissible speed, check the idlespeed (the saw chain or cutting tool must not turn in idle).

Repeat the adjustment procedure starting with step 2 aboveuntil idle speed, acceleration, and speed are all good.


16/2816

Carburetor adjustment is necessary for optimum engineperformance, for safer and more economical operation. Theengine should be warm, the air lter clean, and the chainproperly tensioned. Have carburetor adjustment done byan authorised DOLMAR service centre.

The carburetor is factory-adjusted for the air pressure at sealevel. At other elevations or under other conditions of weather,

temperature, or humidity, or when breaking in a new engine, it maybe necessary to make slight adjustments to the carburetor.

You will need a tachometer (1, part No. 950 233 210) foroptimum adjustment.

Do not go below the specied setting of the main nozzle(H). Doing so may cause engine damage due to overheatingand insufcient lubrication!

Use the supplied carburetor screwdriver (2) for carburetor adju-stment. It has a moulded-on projection that aids in adjusting.

Before undertaking the adjustment, run the engine for 3-5 mi-nutes to warm it up, but not at high speed!

For proper adjustment, proceed as follows:

1. Basic setting (engine off)

Start engine and warm up.

2. Set idle


4. Check top speed

5. Check idle speed

Repeat steps 2-5 until you get the right idle speed, goodacceleration and maximum permissible

1. Basic setting

Carefully turn the adjusting screws for the main nozzle (H)and idle nozzle (L) clockwise until you feel a stop.

Turn adjusting screws (H) 11/2 and (L) 11/2counter-clockwise.

2. Set idle

Set the idle speed per the technical specications.

Turning the adjusting screw (S) in (clockwise) increases theidle speed. Turning it out (counter-clockwise) lowers the idlespeed. In no case should the chain move.


When the throttle is pressed, the engine should go smoothlyfrom idle to high speed. If this is too slow, turn the adjustingscrew (L) in small (max. 1/8turns) increments counter-clo-ckwise.

4. Check top speed

The basic setting H=11/2and L=11/2gives a maximum speedof about 13,500 rpm.

For higher speed (electronically limited ), turn the adjustingscrew (H) a maximum1/4 turn clockwise.The top speedin the governor can be clearly heard from the ignition mis-ses.

Note: Since there is an electronic speed governor (limiter)at 13,500 rpm that cuts off the ignition current, the top speedcannot be read from the tachometer.

Important: To prevent engine damage, never go belowsetting (H) 11/4turns.

5. Check idle speed

Check the idle speed after setting the top speed (the chainmust not move).

Repeat the adjustment procedure starting at Step 2, until theengine runs with the correct idle speed, good acceleration,and top speed.

E

1

2

Adjusting the carburetor(only for not EU-countries)


17/2817

- Remove the lter cover and air lter (see "Cleaning theair lter").

- To enable hot-air induction from the cylinder, remove theplug (A/1) using the universal wrench.

NOTE:

Keep the plug in the saws tool kit. You must put the plug backin at temperatures above 0 C / 32 F.

- Reinstall the air lter and lter cover.

- The snow lter (B/1, see Accessories) prevents the induc-tion of powder snow. It is placed under the prelter (B/2).

NOTE:

Remove the snow lter before working at temperatures above0 C (32 F)!

When not in use, store the snow lter in the assembly toolpouch.

Handle heating(electric, special equipment for model 110i H and 115i H)

The electrically heated handles are activated by pushing theswitch (B/3).

Switch up - ON

Switch down - OFF

The chain needs sharpening when:

- The sawdust produced when sawing damp wood lookslike wood our.

- The chain penetrates the wood only under great pressure.

- The cutting edge is visibly damaged.

- The saw is pulled to the left or right when sawing. This iscaused by uneven sharpening of the chain.

Important: Sharpen frequently, but without removing toomuch metal!

Generally, 2 or 3 strokes of the le will be enough.

Have the chain resharpened at a service centre when youhave already sharpened it yourself several times.

D

Proper sharpening:

CAUTION:

Use only chains and guide bars designed for this saw (seethe Extract from the spare-parts list)!

- All cutters must be of the same length (dimension a). Cutterswith different lengths result in rough running of the chain andcan cause cracks in the chain.

- The minimum cutter length: 0.11" (3 mm). Do not resharpenthe chain when the minimum cutter length has been reached;at this point, the chain must be replaced (see the Extractfrom the spare-parts list and "Replacing the saw chain").

- The depth of the cut is determined by the difference in heightbetween the depth limiter (round nose) and the cutting

edge.- The best results are obtained with a depth-limiter depth of

.025" (0.64 mm).

CAUTION:

Excessive depth increasesthe risk of kickback!

MAINTENANCESharpening the saw chain

CAUTION:Before doing any work on the guide bar or chain, alwaysswitch off the engine and pull the plug cap off the sparkplug(see "Replacing the spark plug"). Always wear protec-tive gloves!

C

B3

2

1

.025"(0,64 mm) .025"(0,64 mm)

Working in winter

In order to prevent carburetor icing in conditions of low tem-perature combined with high humidity, and in order to get upto operating temperature faster in subfreezing temperatures,heated air can be taken from the cylinder.

At temperatures above freezing the carburetor must NOT befed heated air.

Failure to follow these instructions can lead to damageto the cylinder and piston!

A

1


18/2818

F

- The sharpening angle ()must be identical for all cutters!Different angles result in a roughly, irregularly running chain,increase wear and tear and cause chain beakage.

- The front rake ()of the cutter results from the cut depth ofthe round le. If the proper le is used in the right manner,the correct front rake will be obtained automatically.

Files and how to work with them

- Sharpen using a special le holder with a saw chain round le:

- 086 (.325") chain: File the rst cutter half with a 4.8 mm dia.round saw-chain le, then switch to a 4.5 mm dia. le.

- 093 (3/8") and 099 (3/8") chain: File the rst cutter halfwith a 5.5 mm dia. round saw-chain le, then switch to a4.8 mm dia. le.

Normal round les are not appropriate for this work. See"Accessories" for the order number.

- The le should cut only when pushed forwards (arrow). Liftthe le when leading it backwards.

- First sharpen the shortest cutter. The length of this cutter isthen the standerd for all other cutters of the chain.

- Always guide the le as in Fig. F shown (chain 086 (.325"),099 (3/8") = 10 and 093 (3/8") = 90).

E

Chain 086 (.325") 093 (3/8") 099 (3/8")

Sharpening angle 30 35 25

Front rake 85 85 60

Chain: 093 (3/8") 099 (3/8"), 086 (.325")

1 2H

- After having sharpened the chain, the height of the depthlimiter must be checked by means of a chain gauge. See"Accessories" for the order number.

- Correct even the smallest excess height with a special atle (1). See "Accessories" for the order number.

- Round off the front of the depth limiter (2).

I

G

- The le holder makes le guidance easier. It is marked forthe correctsharpening angle (keep the marks parallel withthe chain whenling, see illustration) and limits the cut depthto the correct 4/5 of the le diameter. See "Accessories" forthe order number.

4/5

Cleaning the guide barCAUTION:

Protective gloves must be worn!

Regularly inspect the bearing surfaces of the guide bar fordamage, and clean them with a suitable tool.

J


19/2819

The felt lter (D/1) of the suction head can become clogged.It is recommended to replace the suction head once everythree months in order to ensure unimpeded fuel ow to thecarburetor.

To remove the suction head for replacement, pull it out throughthe tank ller neck using a piece of wire bent at one end toform a hook.

Replacing the saw chain

CAUTION:Use only chains and guide bars designed for this saw (seethe Extract from the spare-parts list)!

Check the sprocket (B/1) before mounting a new chain.

The sprocket is located underneath the clutch drum (B/2).

CAUTION:

Worn out sprockets (C) may damage the new chain and musttherefore be replaced.

Do not attempt to replace the sprocket yourself. Sprocket re-placement requires special training and tools and must be doneat a DOLMAR service centre.

Cleaning the brake band and sprocket interior

A

- Remove the sprocket guard (A/1) (See "PUTTING INTOOPERATION" gs. A and B).

- Turn the chain tightener screw (A/2) to the left (counter-clockwise) until you feel resistance.

- Remove the chain (A/3) and guide bar (A/4).

- Clean the interior with a brush, in particular the brake-band

area (A/5).

NOTE:

Make sure that no residue or contaminants remain in the oilguide groove (A/6) and the chain tightener (A/7).

- For replacing the guide bar, chain, and sprocket see"PUTTING INTO OPERATION".

CAUTION: Before doing any work on the guide bar orchain, always switch off the engine and pull theplug cap off the spark plug (see "Replacing thespark plug"). Always wear protective gloves!

CAUTION: Start the chain saw only after having assembledit completely and inspected.

B C

6

7

2

4

3

1

5

1 2

NOTE:

The chain brake is a very important safety device and likeany other component subject to normal wear and tear.

Regular inspection and maintenance are important foryour own safety and must be done by a DOLMAR servicecentre.

D

SERVICE

1

Replacing the suction head


20/2820

Electrode gap

The electrode gap must be 0.5 mm.

Checking the ignition spark

- Press the loosened spark plug with the ignition cable rmlyconnected against the cylinder using insulated pliers (notnear the spark plug opening).

- ON/OFF switch in the "I" (ON) position.

- Pull the starter cable hard.

If the function is correct, an ignition spark must be visible nearthe electrodes.

CAUTION:

Do not touch the spark plug or plug cap if the engine isrunning (high voltage).

Switch off the engine before starting any maintenance work.

A hot engine can cause burns. Wear protective gloves!

The spark plug must be replaced in case of damage to theinsulator, electrode erosion (burn) or if the electrodes are verydirty or oily.

- Remove thelter cover (see "Cleaning the air

lter").

- Pull the plug cap (G/1) off the spark plug. Use only thecombination wrench supplied with the saw to remove thespark plug.

CAUTION: Use only the following spark plugs:

BOSCH WSR 6F or NGK BPMR 7A.

Replacing the spark plug

Cleaning the air lter

F

G

1

- Remove the lter cover (E/1) (2 screws).

- Loosen the screws on the air lter (E/2) and remove fromintake manifold.

- Loosen the screw on the prelter cover (E/3) and remove.

- Remove prelter (E/4).

IMPORTANT:

Cover the intake opening with a clean cloth to prevent dirtparticles from getting into the carburetor.

- Pry apart the top and bottom of the air lter as shown inFigure F.

CAUTION:

To prevent injury to the eyes, do NOT blow out dirt particles!

Do not use fuel to clean the air lter and prelter.

E

2

4

1

3

- Clean the air lter and prelter with a soft brush.

- If the lter is very dirty, clean it in lukewarm water with dish-washing detergent.

- Let the air lter dry completely.

- Put the top and bottom sections back together.

- Before reinstalling the air lter, check the intake opening andremove any dirt particles. If there are any, remove them with

a brush.Clean frequently (several times a day) when working in verydusty or dirty conditions. Full engine power is possible only witha clean air lter and prelter!

Important:For sawing dry wood and working on dusty groundwe recommend using a Robkook air lter(available as anaccessory). The Robkook lter keeps out even the smallestdust particles.

CAUTION: If the air lter or prelter becomes damaged,replace immediately!

Pieces of cloth or large dirt particles can destroy the en-gine!

H

0,5 mm


21/2821

Replacing the starter cable

- Thread in a new cable (4 mm/.16" dia. x 1000 mm/39" long)as shown in Figure B and tie the ends as shown.

- Pull knot (B/1) into the cable pulley (B/3).

- Pull knot (B/2) into the cable grip (B/4).

- Wind the cable around the pulley in the direction shown bythe arrow. Pull the cable out from the pulley by the grip, thenhold the pulley rmly and wrap the cable around it anotherthree times.

CAUTION: Danger of injury! Secure the cable grip whenpulled out! It will whip back if the cable pulley is releasedby accident.

NOTE:With the cable pulled all the way out, it must still bepossible to turn the pulley another 1/4 turn against the returnspring.

Replacing the return spring

- Remove the fan housing (see above under "Replacing thestarter cable").

- Take off the circlip (C/1) and washer (C/2) (circlip pliers,see "Accessories").

- Remove the cable pulley (C/3).

- Unscrew screws (C/4) and carefully remove spring housing(C/5) with spring.

CAUTION: Danger of injury! If the spring is broken it maypop out!

NOTE:

The old spring and spring housing should be recycled.

Replacement springs come already installed in a new springhousing. Before installing, grease the spring lightly with mul-

ti-purpose grease, order No. 944 360 000.- Assemble in reverse order. When putting the cable pulley

back on, turn it slightly until you feel it catch.

- Wind on the starter cable as described above under "Re-placing the starter cable."

Mounting the fan housing

- Push the tab (D/1) extending out from the edge of the fanhousing (D/3) under the hood (D/2).

- Position the screw holes.

- Push the fan housing (D/3) gently and pull the starter gripuntil the starter catches.

- Screw in the four fastening screws tightly.

- Unscrew the four screws (A/1) holding down the fan hous-ing (A/2). Lift the housing slightly, pull in the direction of thearrow, and remove.

- Remove all pieces of cable.

A B

1

2

C

D

345

2

1

2

1

3

4

3

12

RE Y


22/2822

Service, spare parts and guarantee

Maintenance and repair

The maintenance and repair of modern engines as well as all safety devices require qualied technical training and a special work-

shop equipped with special tools and testing devices.We therefore recommend that you consult a DOLMAR service centre for all work not described in this instruction manual.

The DOLMAR service centres have all the necessary equipment and skilled and experienced personnel, who can work out cost-effective solutions and advise you in all matters.To nd your local distributor, please visit www.dolmar.com

Instructions for periodic maintenance

To ensure long life, prevent damage and ensure the full functioning of the safety features the following maintenance must be per-formed regularly. Guarantee claims can be recognized only if this work is performed regularly and properly. Failure to perform theprescribed maintenance work can lead to accidents!

The user of the chain saw must not perform maintenance work which is not described in the instruction manual. All such work mustbe carried out by a DOLMAR service centre.

Page

General Chain saw Clean exterior, check for damage. In case of damage,have repaired by a qualied service centre immediately

Saw chain Sharpen regulary, replace in good time 17-18

Chain brake Have inspected regularly at an authorized service centre

Guide bar Turn over to ensure even wear of bearing surfacesReplace in good time 11

Before each start Saw chain Inspect for damage and sharpness 17Check chain tension 11

Guide bar Check for damage

Chain lubrication Functional check 15

Chain brake Functional check 15

OFF switch,Safety locking button,Throttle lever Functional check 14

Fuel/oil tankcap Check for tightness

Every day Air lter, prelter Clean 20

Guide bar Check for damage, clean oil intake bore 13

Guide bar support Clean, in particular the oil guide groove 13, 19

Idle speed Check (chain must not run) 15

Every week Fan housing Clean to ensure proper air cooling 9, 21

Starter cable Check for damage 21

Carburetor interior Clean (remove lter cover for access) 20

Chain brake Clean the brake band (sawdust, oil) 19

Spark plug Check and replace if necessary

20

Mufer Check tightness of mounting 9

Chain guide Check 9Screws and nuts Check their condition and that they are rmly secured.

Every 3 months Suction head Replace 19

Fuel, oil tanks Clean

Annually Chain saw Check at an authorized service centre

Storage Chain saw Clean exterior, check for damage. In case of damage,have repaired by a qualied service centre immediately

Guide bar/chain Demount, clean and oil slightly

Clean the guide groove of the guide bar 18

Fuel, oil tanks Empty and clean Carburetor Run empty


23/2823

Malfunction System Observation Cause

Chain does not run Chain brake Engine runs Chain brake actuated.

Engine does not start or Ignition system Ignition spark Malfunction in fuel supply system, com-only with difculty pression system, mechanical malfunction.

No ignition spark Switch on STOP, fault or short-circuit in thewiring, plug cap or spark plug defective.

Fuel supply Fuel tank is lled Choke in wrong position, carburetor defective,suction head dirty, fuel line bent or interrupted.

Compression Inside Cylinder base packing ring defective, radial

system shaft packings defective, cylinder or piston ringsdefective

Outside Spark plug does not seal.

Mechanical Starter does not engage Spring in starter broken, broken partsmalfunction inside the engine.

Warm start difculties Carburetor Fuel tank is lled Wrong carburetor adjustment.Ignition spark

Engine starts, but Fuel supply Fuel tank is lled Wrong idling adjustment, suction head ordies immediately carburetor dirty. Tank venting defective, fuel line

interrupted, cable defective, STOP switchdefective. Starting valve dirty (109 HappyStart).

Insufcient power Several systems Engine is idling Air lter or prelter dirty, wrong carburetor adjust-may be involved ment, mufer clogged, exhaust channel in cylin-simultaneously der clogged.

No chain lubrication Oil tank/pump No oil on the chain Oil tank empty.Oil guide groove dirty.Oil-pump adjusting screw incorrectly adjusted.

Spare parts

Reliable long-term operation, as well as the safety of your chain saw, depend among other things on the quality of the spare partsused. Use only original DOLMAR parts, marked

Only original spare parts and accessories guarantee the highest quality in material, dimensions, function and safety.

Original spare parts and accessories can be obtained from your local dealer. He will also have the spare part lists to determine therequired spare part numbers, and will be constantly informed about the latest improvements and spare part innovations.

Please bear in mind that if parts other than original DOLMAR spare parts are used, this will automatically invalidate the DOLMARproduct guarantee.

Guarantee

DOLMAR guarantees the highest quality and will therefore reimburse all costs for repair by replacement of damaged parts resultingfrom material or production faults occurring within the guarantee period after purchase. Please note that in some countries particularguarantee conditions may exist. If you have any questions, please contact your salesman, who is responsible for the guarantee ofthe product.

Please note that we cannot accept any responsibility for damage caused by:

Disregard of the instruction manual.

Non-performance of the required maintenance and cleaning.

Incorrect carburetor adjustment.

Normal wear and tear.

Obvious overloading due to permanent exceeding of the upper performance limits.

Use of guide bars and chains which have not been approved. Use of guide bar and chain lengths which have not been approved.

Use of force, improper use, misuse or accidents.

Damage from overheating due to dirt on the fan housing.

Work on the chain saw by unskilled persons or inappropriate repairs.

Use of unsuitable spare parts or parts which are not original DOLMAR parts, insofar as they have caused the damage.

Use of unsuitable or old oil.

Damage related to conditions arising from lease or rent contracts.

Damages caused by disregarding loose outer bolted connections.

Cleaning, servicing and adjustment work is not covered by the guarantee. All repairs covered by the guarantee must be performedby a DOLMAR service centre.

Trouble shooting


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Extract from the spare parts listUse only original DOLMAR parts. For repairs andreplacement of other parts, see your DOLMAR service centre.

Pos. DOLMAR-No. Qty. Denomination

1 415 033 631 1 Sprocket nose bar .325", 13" (33 cm)

415 038 631 1 Sprocket nose bar .325", 15" (38 cm)

415 045 631 1 Sprocket nose bar .325", 18" (45 cm)

1 411 907 650 1 Sprocket nose bar 3/8", 15" 411 909 650 1 Sprocket nose bar 3/8", 18"

2 528 086 056 1 Saw chain .325" for 13"

528 086 064 1 Saw chain .325" for 15"

528 086 072 1 Saw chain .325" for 18"

2 523 093 056 1 Saw chain 3/8" for 15"

523 093 064 1 Saw chain 3/8" for 18"

2 528 099 056 1 Saw chain 3/8" for 15"

528 099 064 1 Saw chain 3/8" for 18"

3 952 010 130 1 Chain protection for 13"-15"

952 020 140 1 Chain protection for 18"

4 027 213 571 1 Sprocket guard, cpl.

5 923 208 004 2 Hexagonal nut M8

6 941 719 131 1 Universal wrench SW 13/19 7 963 601 121 1 Suction head

8 965 603 021 1 Spark plug

9 020 173 202 1 Air lter

10 965 451 901 1 Fuel tank cap, cpl.

11 963 232 045 1 O-Ring 31x4,5 mm

12 010 114 032 1 Oil tank plug, cpl.

13 963 100 051 1 Gasket

14 944 340 001 1 Carburetor screwdriver(only in delivery for model 115, 115 H)

15 940 827 000 1 Offset screwdriver

16 108 164 020 1 Starter cable

17 020 163 031 1 Return spring with housing

18 020 173 011 1 Prelter

19 965 404 230 1 Plug

Accessories(not delivered with the chain saw)

20 953 100 090 1 Chain gauge

21 953 004 010 1 File handle

22 953 003 100 1 Round le, dia. 4,5 mm

953 003 070 1 Round le, dia. 4,8 mm

953 003 040 1 Round le, dia. 5,5 mm

23 953 003 060 1 Flat le

24 953 030 030 1 File holder 3/8"

953 030 020 1 File holder .325"25 950 233 210 1 Tachometer

27 020 173 061 1 Snow lter

28 946 101 010 1 Circlip pliers

- 020 173 300 1 Air lter (Robkook)

- 949 000 035 1 Combined can

(for 5l fuel, 2.5l chain oil)

109, 109 HappyStart

111, 115, 115 H


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Specications subject to change without noticeDOLMAR GmbH

To nd your local distributor,please visit www.dolmar.com

Dolmar Happy start

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