DOLMAR GmbH Service Manual PC-6212 HappyStart PC-6214 HappyStart PC-7312 HappyStart PC-7314 HappyStart 1
DOLMAR GmbH Index Index 2 Special tools page 3 Technical data 4 02 Clutch, clutch drumm 5 04 Ignition 6 - 10 05 Starting system 11 06 Carburetor, intake system 12-13 07 Cover, air filter 14 08 Front handle, rubber mounts 15 09 Fuel filter 16 10 Cylinder, piston 17 11 Crankcase, crankshaft 18 12 Checking operation 19 13 Cutting attachment 20 - 21 Torques 22 Notizen 23
DOLMAR GmbH Special tools 1 2 Puller for Flywheel 957.427.010 Puller for oil seals 944.500.900 Puller for ball bearing Counter support (1) 955.102.015 Inside pulller (2) 955.102.025 Mounting tool for clutch hub 944.500.570 1 1 2 Screw driver Torx (T27) (1) 944.500.860 (2) 944.500.862 2 Set of pistonring tension belt (1) 944.600.001 Piston stop wedge (2) 944.602.
DOLMAR GmbH Technical data PC-6212 3 Displacement cm Bore mm Stroke mm Max. power kW Max. torque Nm Idling speed 1/min Clutch engagement speed 1/min Engine speed limitation 1/min Max.
DOLMAR GmbH 02 Clutch, clutch drum 1 4 5 2 3 02-01 Dismantling the clutch/drum To dismantle the clutch and drum, remove the cutting device (1), strut (2) and V-belt cover (3). 02-01 Dismantling the clutch/drum To remove the cutting device, loosen the fixing screws (4). Remove screw (5) to the point where the end of the screw projects from the cover (arrow).
DOLMAR GmbH 04 Ignition system 02-02 Dismantling the clutch/drum Unscrew the clutch with the special tool (parts no. 944.500.570) and a 19mm wrench. Caution: left-handed thread 02-01 Repairing the clutch The tension springs of the clutch can be removed/ replaced with pointed pliers. If spares are required, the 3 tension springs are only available as individual parts. 02-01 Repairing the clutch The tension springs should only be replaced as a set if replacement is required.
DOLMAR GmbH 04 Ignition system 2 11 STOP 4 102 39 11 0,5 mm 04-01 Checking the spark plug Remove filter hood. Pull spark plug socket (1) off the spark plug and remove spark plug (2). 04-01 Checking the spark plug Connect spark plug (2) with plug socket and hold to earth (3). Pull out starter cable. If no spark is produced, repeat procedure with new spark plug. Note: Switch (4) must be in position “I”.
DOLMAR GmbH 04 Ignition system 1 04-03 Removing the ignition/ short circuit cable Unscrew the starter device that is fixed with 4 screws. 04-03 Removing the ignition/ short circuit cable Unscrew filter hood (07-03). Remove ignition and short circuit cable from the guide (1) of the hood. 2a 2 04-03 Removing the ignition/ short circuit cable Remove hood - to do this, unscrew the 3 screws (2). The screw (2a) is also the fixing for the earth cable.
DOLMAR GmbH 04 Ignition system 04-03 Removing the ignition/ short circuit cable Push throttle control rod towards the cylinder using pointed pliers, pulling upwards out of the guide of the gas grip (arrow). 4 3 04-03 Removing the ignition/ short circuit cable Remove intake elbow with carburetor and choke shaft from the tank housing. 1 2 04-03 Removing the ignition/ short circuit cable Pull short circuit cable (1) from its place in the choke shaft (2).
DOLMAR GmbH 04 Ignition system 1 04-04 Removing the ignition armature Unscrew starting device. Remove the two screws (1) of the ignition armature. Clip off ignition and short circuit cable. 2 3 04-04 Mounting the ignition armature Connect ignition and short circuit cable. Position setting gauge 944.500.890 (arrow) between ignition device and magnet on the flywheel. Press ignition device firmly whilst at the same time tightening the screws evenly.
DOLMAR GmbH 05 Startering system 2 2 1 3 44 05-02 Removing the starter Remove air duct (1). Relieve the tension on the return spring by pulling out the starter cable (2) slightly. Hold cable drum and remove cable from rope drum.Let drum spool back slowly. 821 17 18 6 19 5 1 3 05-02 Removing the return spring To remove the return spring, remove the circlip ring (3), the return spring (4) is in a cartridge which is fixed to the fan housing with three screws (5). Note: Grease new spring (944.360.
DOLMAR GmbH 06 Carburetor L S 06-01 Setting the carburetor "L" For the basic setting, turn in the idling nozzle “L” carefully as far as it will go. Then back off “L” nozzle = 11/8. For fine tuning, the “L” nozzle only needs to be changed by max. +/- 1/8 of a turn. 06-01 Setting the carburetor "S" When during idling the engine speed is too high (moving of cutting disc) or too low (engine stalls), correct the the setting of idling screw "S" (speed) accordingly.
DOLMAR GmbH 06 Carburetor 1 2 5 6 4 7 3 06-03 Carburetor - dismantling the control side Unscrew cover (1). Carefully remove the seal (2) and diaphragm (3) from the control lever (4). Remove control lever, spring (5) and inlet needle (6) from the carburetor. 06-03 Carburetor - testing the control membrane After removing the control diaphragm, it must remain flat. The rim around the stiffening plate (7) must be even. Faulty diaphragm must be replaced immediately.
DOLMAR GmbH 07 Hood system / Air filter / Winter operation 3 5 1 2 4 07-03 Removing the air filter Remover filter hood (5), unscrew cover hood (4). Filter system consists of the pre-filter (1), the paper cartridge (2) and the inside filter (3). 07-04 Cleaning the filter - pre-filter Clean the pre-filter in luke-warm soapy water using normal washing-up liquid. Dry before replacing. Note: under extrem dusty conditions, the pre-filter may need to be oiled slightly.
DOLMAR GmbH 08 Front handle with stand / vibration damping system 1 2 08-01 Removing and replacing the bracket handle To dismantle the front handle, the strut (1) with 3 screws and the foot (2) with 2 screws must be unscrewed. 08-03 Replacing the vibration absorber The system consists of 4 vibration absorbers, 3 of which are on the clutch side. To dismantle them, the front handle, filter system and tank must be removed.
DOLMAR GmbH 09 Fuel tank B C 2-3mm (.080”-0.12”) 09-02 Removing the ventilation valve Push the ventilation valve with a pin into the tank (arrow) and remove with pointed pliers through the filler opening. 2 1 6 16 ;; ;; 7 5 4 09-02 Inserting the ventilation valve Press the new ventilation valve with a pin into the housing until the white sinter plastic project about 2-3 mm beyond the tank.
DOLMAR GmbH 10 Cylinder / piston / decompression valve 1 1 10-01 Dismantling the cylinder To dismantle the cylinder, unscrew the 4 screws (1) from the cylinder foot. Pull cylinder off crankcase and piston. 2 10-01 Dismantling the cylinder - piston Remove piston pin securing ring (2) from the annular slot in the piston using pointed pliers. Push piston pin out. Note: During assembly, make sure the securing ring clicks completely into the groove.
DOLMAR GmbH 11 Crankcase / Crankshaft 1 2 4 3 11-03 Complete crankcase The complete crankcase is divided into the crankcase magnet side (2) "MS", and the crankcase clutch side (1) "KS". 11-03 Removing the crankcase "MS" To dismantle the magnet side (MS), unscrew the 4 fixing screws (3) and the left lower screw (4). 5 18 11-03 Dismantling the crankcase After removing the 5 fixing screws, separate the crankcase carefully by tapping with a plastic hammer.
DOLMAR GmbH 12 Testing 12-02 Testing the ignition system To test the ignition system / spark plug, use test device no. 965 010 030. 12-03 Testing the carburetor To test the carburetor in the installed state, pull fuel line out off the fuel tank. Pull off the fuel filter and attach pressure test device no. 965 004 000 to fuel line by using a connecting nipple. 12-03 Testing the carburetor Test carburetor at 0.5 bar.
DOLMAR GmbH 13 Cutting attachment 4 2 1 5 3 13-01 Replacing the pressure disc Undo screw (1) and remove pressure disc. Note: With the 25.4 mm (1") axle, the inner flange is located behind the recess of the axle (2). Remove axle and flange together. 13-02 Replacing the V-belt pulley Block the V-belt pulley (3). To do this, push a pin through the hole (4) in the V-belt pulley into the housing. Remove screw (5).
DOLMAR GmbH 13 Cutting attachment 3 1 2 13-06 Replacing the guard stop Knock the shaft (1) with a pin out of the handle (2). In assembly, push the new handle onto the shaft until the shaft is flush with the outside edge of the handle. 13-07 Replacing the fixing screws Push the screws (3) out of the housing. Before inserting, wet the stop area (arrow) on the screws with glue 980.009.000.
DOLMAR GmbH Torques Assy.
DOLMAR GmbH Notice 23
DOLMAR GmbH DOLMAR GmbH Postfach 70 04 20 D-22004 Hamburg Germany 24 Specifications subject to change without notice Form: 995.716.
