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Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
Introduction
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
A chainsaw is a portable power tool specifically designed for cutting wood. When used and
maintained correctly it is very efficient. However, in the hands of inexperienced or careless
operators, serious injuries and fatalities can occur.
Injuries to chainsaw operators have commonly resulted from a lack of saw control or from failing
to follow safe work practices. Operator fatalities have occurred as a result of being struck by rolling
logs, falling trees or dislodged tree limbs.
While improved technology and safety features on chainsaws, and the correct fitting of personal
protective equipment, can help to reduce injuries, these offer little protection if the operator is not
properly trained or does not follow safe operating techniques.
The major market for chainsaws now includes farming, local government, emergency services and
recreational users who may not receive formal training. While this manual is designed primarily for
all timber workers who use chainsaws in the course of their work, it will also provide guidance on
safe chainsaw operation to the wider community.
This edition of the Chainsaw Operator’s Manual includes updated information and additional
material on chainsaw safety equipment and safe operating techniques.
A major change is the reorganisation of the manual into two separate books, reflecting the division
of the content into basic chainsaw operations and manual tree felling operations.
Compliance with licensing, regulatory or certification requirements may be required in some states
and jurisdictions. Please contact the relevant state authority listed at the back of this manual for
current requirements.
Chainsaw Operator’s Manual | 1
3. Chainsaw safety
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
Operating a chainsaw can be a high risk activity. There are two Australian Standards that cover
safety in chainsaw operations and that the operator should be familiar with:
AS 2726 Chainsaw Safety Requirements
AS 2727 Chainsaws – Guide for Safe Working Practices.
Develop a professional attitude
It is essential that a chainsaw operator develops a professional attitude towards all aspects of
chainsaw use. Personal attributes that help to make a safe and competent operator include:
• forward planning and risk assessment
• putting safety first
• maintaining a steady work pace
• concentrating at all times
• using sound, low risk techniques
• understanding and taking care of your equipment
• caring about the environment.
Risk management
Using a chainsaw brings with it risks that the operator must be aware of, in order to take steps to
minimise the possibility of accidents or injury. It is vital that you think before you act, and carry out
a risk assessment of the work you are about to do.
Risk management is a process of identifying hazards in a workplace and eliminating or reducing as
far as possible the risks associated with those hazards. There are four basic steps to risk
management:
Table 2 : Risk management strategy.
Step 1
Identify hazard
Step 2
Assess risk
Step 3
Control risk
Step 4
Check risk controls
Find out what hazards are present in the workplace.
Example: Hanging limbs in trees overhanging the work area.
Assess the risk – what could happen and why.
Example: The hanging limbs could dislodge and fall on operator s.
Evaluate and select options for minimising the risk.
Example: 1. Prohibit work in the hazardous area
2. Use mechanical equipment to remove the hanging limbs
Make sure the risk controls are working.
Example: Ensure the area is cordoned off and operators kept out until hanging limbs are removed.
Chainsaw Operator’s Manual | 7
Some of the things you need to consider before using a chainsaw include:
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
The operator
• Are you properly equipped and capable of doing the work?
• Do you have the necessary training and physical capabilities to do the work?
• Do you need assistance from other people, or special equipment?
• Are you tired, fatigued or under the influence of alcohol or medication?
• Do you have an adequate supply of drinking water?
The equipment
• Is your chainsaw sharp, properly maintained and suitable for the task at hand?
• Is it full of fuel and bar oil, so you don’t need to stop the cutting sequence to refuel?
• Do you have other equipment such as an axe, wedges and hammer and first aid kit close at
hand? Are they all in good condition?
The work environment
• What are the current and predicted weather conditions?
Extreme temperatures, heavy rain, lightning or strong winds can make chainsaw operations very
risky.
• What is the fire danger?
Work should cease in the case of extreme fire danger. In summer months, keep fire fighting
equipment handy.
• Are there any physical ground hazards that might hinder your movements?
Look for rocks, undergrowth, stumps, holes, etc.
• Are there any unsafe trees nearby?
Look for stags, hang-ups or burnt out trees. Look up ! Are there any hanging dead or broken
limbs overhead? (Known as ‘widow makers’ for obvious reasons.)
• Who else is in the area?
Be aware of other public activity, traffic or machinery movements.
• What are your workmates doing?
Is there sufficient separation distance between the saw operator and other personnel? Do not
work alone, and maintain regular contact with other workers.
• Is there tree felling activity in the work area?
Do not work within at least two tree lengths (minimum) of any tree felling activity.
At least two tree heights area shall be clear
8 | Chainsaw Operator’s Manual
Figure 5: Area to be isolated during falling activity.
Personal protection equipment
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
The Australian Standard AS 2727 Chainsaws – Guide for Safe Working Practices lists the items of
personal protection equipment (PPE) that a chainsaw operator must use. Remember that PPE is at
the lower end of the scale of risk control, and will not guarantee your safety. Proper risk
assessment and safe work practices must always be followed.
The items below are recommended when working in a forest environment. Refer to the list of
technical standards at the back of this manual for more detailed specifications.
• Safety helmet (AS/NZS 1801)
Must be replaced if cracked, damaged or past expiry date. Avoid damage caused by attaching
stickers, storing in direct sunlight and contact with solvents. A legionnaire-style flap can be
attached to protect the back of the neck.
• Eye protection (AS/NZS 1336 and 1337)
Preferably non-scratch and non-fogging. Can be either clear or mesh visors or goggles. Safety
glasses should also provide an acceptable level of protection.
• Steel-capped safety boots (AS/NZS 2210)
Boots should also have non-slip tread
and lace-up for better ankle support.
• Cut resistant trousers or chaps
(AS/NZS 4453)
The cut resistant layers cannot be
repaired and the garment should be
replaced if it has been cut. The
effectiveness of the cut resistant layers
may be reduced over time by the
absorption of oil when used regularly.
• High-visibility vest/shirt (AS/NZS
4602)
Long sleeves are preferable for sun
protection. Some vests are also
reinforced with cut resistant fabric for
added protection.
• Safety gloves
Should be snug fitting and of a hard
wearing, protective fabric. Some gloves
have gel cushioning to protect against
vibration. Protective wrist bands and
forearm guards are also available.
• Hearing protection (AS/NZS 1270)
May be either ear plugs or ear muffs.
Be aware that ear plugs and some
cheap ear muffs may not provide
sufficient protection when using larger
saws. Check with your dealer for
correct level of protection required for
your chainsaw.
Safety helmet
Hearing protection
Eye and face
protection
High visibility
vest or shirt
Cut resistant
gloves
Cut resistant
leg protection
Steel-capped
safety boots
Figure 6: Personal protective clothing and equipment.
Chainsaw Operator’s Manual | 9
4. Chainsaw maintenance
U
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
Regular maintenance of the chainsaw, in accordance with the manufacturer’s advice, is essential for
safe, reliable and trouble-free operation. Chainsaw breakdowns are costly both in repair expenses
and lost production. A professional attitude to maintenance means paying attention to:
• the recommended frequency of servicing
• careful inspection of all components
• cleanliness of the saw and related equipment
• reporting of problems and faults promptly
• arranging for specialist repairs when required.
Do not operate the saw if any components become defective, par ticularly any safety devices.
F
A
N
C
A
T
M
R
E
F
E
Powerhead and guide bar maintenance
R
R
e
c
o
Daily service (or frequent service as required)
The maintenance schedules are based on a regular daily engine operating time of 6 to 8 hours.
However, when working in par ticularly dirty or dusty conditions, or when cutting dry timber, the
service intervals may need to be shortened. The tasks below should be carried out daily according
to manufacturer’s specifications:
U
R
E
R
S
s
n
o
i
t
m
a
m
d
e
n
Cleaning
• Thoroughly clean saw body, air intake vents and cooling fins.
• Use plastic or wooden scrapers, not metal screwdrivers which can damage paintwork, leading
to corrosion.
Air filter
• Before removing filter, apply the choke to close off the carburettor throat to prevent the entry
of foreign matter. Remove and check the filter for damage and penetration of foreign material.
Clean as per manufacturer’s recommendations. Replace filter if damaged.
• A spare filter is useful to have as a replacement as required.
Figure 16: Checking the air f ilter.
Chainsaw Operator’s Manual | 13
Chain brake
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
• Thoroughly clean, par ticularly around brake band and
operating mechanism.
• Frequent operation of the brake throughout the day
will keep the brake’s internal components free from
an accumulation of dir t and saw dust.
• Ensure correct operation.
Saw chain and guide bar
• Remove side cover, clean and inspect.
• Remove saw chain and visually inspect chain and bar
for wear and cracks.
• Clean out groove, working from the nose backwards. Remove any burrs.
• Clean oil holes.
• Sprocket nose:
− clean out debris
− ensure sprocket rotates and check for broken teeth
− grease, if appropriate.
Figure 17: Cleaning the chain brake.
Figure 18: Cleaning and greasing the sprocket nose.
• Reverse the guide (cutter) bar to equalise wear.
• Install chain and sharpen, or fit spare chain. It may be necessary to change or sharpen the chain
several times during the day.
• Tension chain correctly.
Loose screws/nuts
• Check screws/nuts for tightness. Do not over-tighten.
Safety features
• Check all safety devices are operational.
Fill fuel and chain oil tanks
• Filling the tanks at the end of the day will minimise condensation of water in the tanks during
storage.
14 | Chainsaw Operator’s Manual
Saw chain sharpening
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
It is essential that the saw chain is kept sharp. Signs that a saw needs sharpening include:
• you have to apply pressure to make the saw cut
• the cut material is coming out as fine dust rather than ‘chip’
• the saw ‘dishes’ or runs off instead of cutting straight
• damage is present on the chrome surface of top plate or side plate.
Preparation for sharpening
• Don’t attempt to sharpen an oily or wet chain. Cut some dry wood to clean the chain.
• File a little bit often, rather than a lot at once.
The art of sharpening is to ‘hone’ rather than to remove a lot of metal.
• Make sure the saw is firmly positioned and the bar guide is secured. A stump vice can be used if
working in the bush.
• Position the guide bar in the vice so that your wrists are not over the chain. Generally it is best
to secure the guide bar near the tip, but without force on the sprocket nose.
• Match file diameter to file guide and pitch of chain (refer to Table 4 below).
Figure 38: Using a stump vice.
Round file diameter
Always use the correct diameter file for the particular chain. File diameter is governed by the
chain’s pitch. Generally the larger diameter file is used until the cutter is half worn, then the smaller
diameter file is used.
Table 4 : File diameter and chain pitch.
Chain pitch File diameter (round file) Gauge
1/4” 5/32” (4.0 mm) 0.65 mm
0.325” 5/32” (4.0 mm) to 3/16” (4.8 mm) 0.65 mm
3/8” Low Profile 3/16” (4.8 mm) 0.65 mm
3/8” Standard 13/64” (5.2 mm) to 7/32” (5.5 mm) 0.65 mm
0.404” Standard 7/32” (5.5 mm) 0.80 mm
Chainsaw Operator’s Manual | 25
Points to remember when filing cutters:
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
• Use a file guide recommended by the chain manufacturer.
1 = Sighting edges for side plate
angles
2 = Sighting edges for top plate
filing angles
3 = Cut out for depth gauge
setting
4 = Bar groove cleaner and
scale for bar groove
depth (mm)
Figure 39: Roller file guide.
• Ensure the file guide rests both on the top plate
and depth gauge.
• First sharpen the cutter with the shor test top
length, then sharpen all other cutters to match.
File until all damage is removed from top plate and
side plate, i.e. back to unworn plating or chrome
surface.
• File from inside to outside using a full length
stroke. Since the file will only work when used in
the forward direction, hold the file clear of the
cutter and do not apply pressure on the return
stroke.
• File all the cutters on one side of the chain first,
then file the cutters facing the opposite direction.
• File each cutter to maintain the profile of the side
plate.
• Try to keep cutters equal in length and angles.
Failure to do so will cause chain to cut to one side
and excessive vibration.
• Finish each cutter with a crisp leading edge, with
no gap between the file and leading edge of the
cutter.
• After sharpening the cutters, check each depth
gauge for correct clearance.
Figure 40: Multifunction gauge.
File
Top
plate
File guide
Figure 41: Positioning the guide.
A A = B B
Figure 42: Keep cutters equal.
Depth
gauge
26 | Chainsaw Operator’s Manual
Kickback reaction when contact with the tip or upper quadrant of the guide bar nose results in
Chainsaw Operator's Manual:
Chainsaw Safety, Maintenance and Cross-cutting Techniques,
by ForestWorks
Published by CSIRO Publishing, 2009, 64pp
©ForestWorks 2009
http://www.publish.csiro.au
the chainsaw being thrust upwards and backwards in an uncontrolled arc. Kickback reaction
generally takes only a fraction of a second to occur.
Figure 55: Chainsaw kickback reaction.
When cutting with the chainsaw guide bar in the ver tical position, kickback reaction normally
results in the chainsaw being violently flung back in the direction of the operator.
In the horizontal position, the reaction will result in the chainsaw ‘kicking out’ sideways which could
be potentially dangerous for bystanders.
Kickback is one of the most common causes of chainsaw accidents. You can help reduce kickback
by:
• maintaining a firm grip and balanced stance. The saw must not be in line with your face, but
should be slightly to the right of the body.
• cutting at peak revs
• being aware of where the nose of the bar is at all times
• using correct cutting techniques
• making sure the chain is sharp and correctly tensioned
• ensuring correct depth gauge setting
• selecting a narrow profile sprocket tipped bar. This decreases the risk of kickback by reducing
the size of danger area in the upper quadrant of the nose. There are also less cutters in the
danger area at any one time.
36 | Chainsaw Operator’s Manual
Kickback zone
Figure 56: Kickback reaction zone.
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