Makita DCS430, DCS431, DCS520, DCS520i, DCS540 User Manual

Owner’ s and Safety Manual

for Gasoline Chain Saws (page 2 - 31)

Manuel d’emploi et de sécurité

de tronçonneuses thermiques (page 32 - 61)

DCS 430, 431
DCS 520, 520i
DCS 540
DCS 5200i

WARNING!

Read and understand this Manual. Always follow safety precautions in the Owner’s and Safety Manual.

Improper use can cause serious injury!

The engine exhaust from this product contains chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm. Preserve this Manual carefully!

ATTENTION!

Suivez toujours les conseils de sécurité du présent manuel d’emploi et de sécurité. Une utilisation

incorrecte de la tronçonneuse peut entraîner des blessures graves! Conservez avec soin ce manuel!
Les gaz d’échappement émis par ce produit contiennent des produits chimiques connus par l’Etat de
Californie pour provoquer le cancer, des défauts de naissance ou autres dommages de reproduction.

Lisez et comprenez ce manuel.

1

WARNING !

Careless or improper use of this product can cause serious or even fatal injury.
Before operating a chain saw or other MAKITA products it is important that you read, fully understand and
carefully follow the instructions outlined in this owners manual. Kickback may cause severe or fatal injury and
is one of many potential dangers in operating a chain saw. Kickback and other safety related precautions are
described in detail within this owners manual. Additional owners manuals are available from MAKITA U.S.A.,
INC., 14930-C Northam Street, La Mirada, CA 90638-5753, USA, Telephone: [phone] and MAKITA
CANADA INC.,1950 Forbes Street, Whitby, Ontario, L1N 7B7, Canada, Telephone: [phone].

This product complies with: American National Standard Institute B 175.1-1991 chain saw safety standard.

Canadian Standards Association Z62.1-95 chain saw safety standard.

Z62.3-96 chain saw kickback standard.

Society of Automotive Engineers SAEJ 335-Jun 95 „Multiposition small

engine exhaust system fire ignition
suppression”

With the purchase of this chain saw you have chosen a German quality product. Important instructions for the
assembly and operation of this saw are given in this manual. For your own safety, we ask you to read the accident
prevention instructions very carefully before putting your chain saw into operation, as incorrect handling can,
despite all precautions, lead to accidents. With a little care and attention you will have good service and lasting
satisfaction from this first-rate product. The following industrial property rights apply: US 4465440, US 5411382,
EP 0236858, EP 0560201, GBM 8710075, GBM 8809928, GBM 9203378, GBM 29616652.

DCS 430, DCS 431, DCS 520, DCS 520i, DCS 540, DCS 5200i

Contents Page

Delivery inventory 3
Symbols 3
Safety precautions 4-15
Denomination of components 16
Technical data 17
Approved bar and chain combinations 17
Mounting the guide bar and saw chain 18-19
Chain brake 19
Fuel / Refuelling 20-21
Adjusting the chain lubrication 21
Starting the engine 22
Stopping the engine 22
Checking the chain brake 23
Checking the chain lubrication 23
Adjusting the carburetor 23
Working in winter 24

The MAKITA DCS 430, DCS 431, DCS 520, DCS 520i, DCS 540, DCS 5200i will be delivered in a protective
cardboard box to prevent transport damage. Cardboard is a basic raw material and is consequently reuseable or
suitable for recycling (waste paper recycling).

Contents Page
Sharpening the saw chain 24-25

Cleaning the guide bar 25
Cleaning the brake band and sprocket interior 26
Replacing the saw chain 26
Replacing the suction head 26
Replacing / cleaning the spark arrester screen 26
Cleaning the air filter 27
Replacing the spark plug 27
Replacing the starter cable 28
Replacing the return spring 28
Mounting the fan housing 28
Instructions for daily and periodic maintenance 29
Service, spare parts and guarantee 29-30
Troubleshooting 30
Extract from the spare parts list 31
Adress list 62

RE Y

2

Delivery inventory

STOP

3

4

2

1 Chain saw
2 Saw chain
3 Guide bar
4 Chain protection cover
5 Universal wrench
6 Wrench
7 Screw driver for carburetor adjustment

(only in delivery for model 5200i)

8 Owner’s and Safety Manual (not shown)

5

Symbols

You will notice the following symbols on the chain saw and in the Owner’s and Safety Manual:

Read instruction manual
and follow the warning- and
safety precautions!

7 6

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

Stop engine!

1

Particular care and caution!

Forbidden!

Wear protective helmet, eye

Wear protective gloves!

Chain brake

Caution, kickback!

and ear protection!

No smoking!

No open fire!

On/Off (I/O) switch

2

1

Press starting valve

Fuel and oil mixture

Carburetor adjustment

Chain oil fill/oil pump

Working in winter

Engine - manual start

Choke lever

RE Y

First aid

Recycling

Further
symbols
see page 5.

3

Safety precautions for chain saw operators

Additional safety precautions

While operating the chain saw please observe the
following rules:

a) Contact of the guide bar nose with any object

should be avoided.

b) Tip contact may cause the guide bar to move

suddenly upward and backward, which may
cause serious or fatal injury.

c) Always operate the chain saw with both hands.

WARNING!

Read and follow all safety precautions in the owner’s
manual. Failure to follow instructions could result
in serious injury. It is recommended to lend the
chain saw only to people who are experienced in
working with chain saws. Always hand over the
Owner’s and Safety Manual.

WARNING!

This chain saw is capable of severe kickback that
could result in serious injury to the operator. Do not
operate this chain saw unless you have
extraordinary cutting needs and experience in and
special training for dealing with kickback. Chain
saws with significantly reduced kickback potential
are available.

The following additional safety precautions should be
observed by all users of chain saws:

1. Do not operate a chain saw when you are fatigued.

2. Use safety footwear; snug-fitting clothing;
protective gloves; and eye, hearing, and head
protection devices.

3. Use caution when handling fuel. Move the chain
saw at least 10 feet (3 m) from the fueling point
before starting the engine.

4. Do not allow other persons to be near the chain
saw when starting or cutting with the chain saw.
Keep bystanders and animals out of the work
area.

5. Do not start cutting until you have a clear work
area, secure footing, and a planned retreat path
from the falling tree.

6. Keep all parts of your body away from the saw
chain when the engine is running.

7. Before you start the engine, make sure that the
saw chain is not contacting anything.

8. Carry the chain saw with the engine stopped, the
guide bar and saw chain to the rear, and the
muffler away from your body.

WARNING!

Kickback may occur when the nose or tip of the
guide bar touches an object, or when the wood
closes in and pinches the saw chain in the cut. This
contact may abruptly stop the saw chain and in
some cases may cause a lightning fast reverse
reaction, kicking the guide bar up and back towards
the user, or push the guide bar back towards the
operator. Kickback may cause you to lose control
of the saw.

As a chain saw user, you can take several steps to
reduce the risk of a kickback and potential injury.

A. With a basic understanding of kickback, you

can reduce or eliminate the element of surprise.
It is a sudden surprise that contributes to
accidents.

B. Keep a good firm grip on the saw with both

hands, your right hand on the rear grip and
your left hand on the tubular handle, when the
engine is running. Use a firm grip with thumbs
and fingers encircling the chain saw handles.
A firm grip can neutralize kickback and help
you maintain control of the saw. Don’t let go!

C. Make sure that the area in which you are

cutting is free from obstructions. Do not let the
nose of the guide bar contact the log, branch,
or any other obstructions which could be hit

while you are operating the saw.
D. Do not overreach or cut above shoulder height.
E. Follow manufacturer’s sharpening and main-

tenance instructions for the saw chain.
F. Only use replacement bars and chains speci-

fied by the manufacturer or the equivalent.

4

9. Do not operate a chain saw that is damaged, is
improperly adjusted, or is not completely and
securely assembled. Be sure that the saw chain
stops moving when the throttle control trigger is
released.

10. Shut off the engine before setting it down.

11. Use extreme caution when cutting small size
brush and saplings because slender material may
catch the saw chain and be whipped towardyou
or pull you off balance.

12. When cutting a limb that is under tension be alert
for springback so that you will not be struck when
the tension on the wood fibers is released.

13. Keep the handles dry, clean, and free of oil or fuel
mixture.

14. Operate the chain saw only in well-ventilated
areas.

15. Do not operate a chain saw in a tree unless you
have been specifically trained to do so.

16. All chain saw service, other than the items listed in
the owner’s manual maintenance instructions,
should be performed by MAKITA . (For example,
if improper tools are used to remove the flywheel
or if an improper tool is used to hold the flywheel
in order to remove the clutch structural damage to
the flywheel could occur and could subsequently
cause the flywheel to burst.)

17. When transporting your chain saw, use the chain
protection cover.

18. Low kickback bars and low kickback chains are
designed to reduce the risk of kickback injury. Ask
your MAKITA dealer about these devices.

General Safety Precautions

max. CKA 45

O

The use of any chain saw may be hazardous. At full
throttle chain speed can reach 45 mph (20 m/s). It is
important that you read; fully understand and observe
the following safety precautions and warnings. Read
the owner’s manual and the safety instructions
periodically.

max. CKA 40

Maximum Computed Kickback Angle
(CKA)* without using the chain brake when
using the recommended bar and chain
combinations (In this example the CKA is 45°).

O

MaximumComputed Kickback Angle
(CKA)* with using the chain brake when
using the recommended bar and chain
combinations (In this example the CKA is 40°).

WARNING !

Reactive forces, including kickback, can be dan­gerous. Careless or improper use of any chain saw
may cause serious or fatal injury.

Have your MAKITA dealer show you how to operate
your chain saw. Observe all applicable local safety
regulations, standards and ordinances.

1

WARNING!

Minors should never be allowed to use a chain
saw.
Bystanders, especially children and animals should
not be allowed in the area where a chain saw is in
use (fig. 1).
Never let the saw run unattended.
Store it in a locked place away from children. Fill
the fuel tank to 7/8 th full (see storing the saw).
Do not lend your chain saw without this owner’s
manual. Be sure that anyone using your saw un­derstands the information given.

Contact of the guide bar tip with
any object should be avoided!
Tip contact may cause the guide
bar to move suddenly upward
and backward, which may cause
serious injury!

Always use two hands when
operating the chain saw!

Reduced Kickback Bar and
Chain combination that has been

XXX.YYY.ZZZ

evaluated with the power head
to achieve kickback protection

XXX.YYY.ZZZ

(according to ANSI and CSA
standards).

* The Computed Kickback Angle is a calculated value
from energies measured on a test bench.It is not the
angle of the guide bar moved upward in case of a
KICKBACK.

The operator

Physical Condition

You must be in good physical condition and mental
health and not under the influence of any substance
(drugs, alcohol), which might impair vision, dexterity
or judgment.

2

Proper use of a chain saw involves

1. the operator

2. the saw

3. the use of the saw.

Discription of symbols used on chain
saws:

Z 62.1-95 and
Z 62.3-96
Class 1A

ANSI B175.1-1991

Chain Saw listed in accordance with

®

45M6

American National Standard Safety
Specifications for Gasoline Powered
Chain Saws (ANSI B 175.1-1991).

Compliance with
CSA -Standards

Compliance with
ANSI -Standards

WARNING !

Prolonged use of chain saws exposing the operator
to vibrations may produce Whitefinger disease
(Raynaud’s phenomenon). This phenomenon
reduces the hand’s ability to feel and regulate
temperature, produces numbness and burning
sensations and may cause nerve and circulation
damage and tissue necrosis.

All MAKITA saws are therefore provided with an
antivibration system which is essential for those
using chain saws on a regular or sustained basis.
Antivibration systems do not guarantee that you will
not sustain Whitefinger disesase, however, they
reduce this danger considerably. Nevertheless,
continual and regular users should observe their
hands and fingers and in case of any abnormal
symptoms, seek medical advice immediately.

5

Proper clothing

The saw

Clothing must be sturdy and snug-fitting, but allow
complete freedom of movement. Avoid loose-fitting
jackets, scarfs, neckties, jewelry, flared or cuffed pants,
or anything that could become entangled with the saw
or brush. Wear overalls or jeans with a reinforced
cutting resistant insert (fig. 3).

Protect your hands with gloves when handling saw
and saw chain. Heavy-duty, nonslip gloves improve
your grip and protect your hands.

Parts of the chain saw: illustrations and description of
parts see page 16.

WARNING !

Never modify a chain saw in any way. Only
attachments supplied by MAKITA or expressly
approved by MAKITA for use with the specific saw
are authorized.

WARNING !

Bow guide bars substantially increase the potential
for kickback and severe or fatal injury due to the
greater kickback zone of the bow design. Bow
guide bars are not recommended for use on
MAKITA chain saws nor are they approved by the
ANSI B 175.1-1991 chain saw safety standard.

The use of the saw

Transporting the chain saw

3

Good footing is most important in chain saw work.
Wear sturdy boots with nonslip soles. Steel-toed safety
boots are recommended.

Proper eye protection is a must. Non-fogging, vented
goggles and a face screen is recommended. Their
use reduces the risk of eye and facial injury.

Wear an approved safety hard hat to protect your
head. Chain saw noise may damage your hearing.
Always wear noise protection equipment (ear plugs
or ear muffs) to protect your hearing.

Continual and regular users should have their
hearing checked regularly.

WARNING!

Always stop the engine before putting a chain saw
down or carrying it. Carrying a chain saw with the
en- gine running is extremely dangerous. Accidental
acceleration of the engine can cause the chain to
rotate.
Avoid touching the hot muffler.

4

By hand: When carrying your saw by hand, the
engine must be stopped and the saw must be in the
proper position.
The chain protection cover should be over the
chain and the guide bar must point backwards.
When carrying your saw the bar should be behind
you (fig. 4).

Wear protective helmet,
eye and ear protection

6

By vehicle: When transporting in a vehicle, keep
chain and bar covered with the chain guard. Properly
secure your saw to prevent turnover, fuel spillage
and damage to the saw. Make sure the saw in not
exposed to heat or sparks.

Chain saw operating instructions

For assembly follow the procedure in the appropriate
section "Mounting Guide Bar and Chain" of this manual.
MAKITA chain, guide bar and sprocket must match
each other (see the appropriate section in this manual).

WARNING!

Proper tension of the chain is extremely important.
In order to avoid false setting the tensioning
procedure must be followed as described in this
manual. Always make sure the hexagonal nut(s)
for the sprocket guard is (are) tightened securely
after tensioning the chain. Check chain tension
once more after having tightened the nuts and
thereafter at regular intervals (always before starting
to work). If the chain becomes loose while cutting,
shut off the engine and then tighten. Never try to
tighten the chain while the engine is running!

Fueling

Your MAKITA saw uses on oil-gasoline mixture for fuel
(see chapter "Fuel" of this manual).

Wipe off any spilled fuel before starting your saw and
check for leakage.

Check for fuel leakage while refueling and during
operation. If fuel or oil leakage is found, do not start or
run the engine until leak is fixed and spilled fuel has
been wiped away. Clothing with fuel on it has to be
changed immediately (this is a danger to your life!).
Avoid skin contact with fuel. Never loosen or remove
the cap of the fuel tank while the engine is running.

Starting

Do not drop start. This method is very dangerous be­cause you may lose control of the saw (fig. 6).

5

WARNING!

Gasoline is an extremely flammable fuel. Use
extreme caution when handling gasoline or fuel
mix. Do not smoke or bring any sparks or flame
near the fuel (fig. 5).

Fueling instructions

Fuel your chain saw in well ventilated areas or out­doors. Always shut off the engine and allow it to cool
before refueling. Select bare ground for fueling and
move the chain saw at least 10 feet (3 m) from fueling
spot before starting the engine (fig. 5a).

6

6a

Place the chain saw on firm ground or other solid
surface in an open area. Maintain a good balance and
secure footing. Place your right foot through the rear
handle opening and firmly grasp the front handle with
your left hand (fig. 6a).

Be absolutely sure that guide bar and chain are clear
of you or all other obstructions and objects, including
the ground, because when the engine starts in semi­throttle position, engine speed will be fast enough for
the clutch to engage the sprocket and turn the chain
which may cause a kickback.
Never attempt to start the saw when the guide bar is in
a cut or kerf.

10 feet

When you pull the starter grip, don’t wrap the starter
rope around your hands. Do not allow the grip to snap
back, but guide the starter rope slowly back to permit
the rope to rewind properly. Failure to follow this
procedure may result in injury to hand or fingers and
may damage the starter mechanism.

5a

7

Important adjustments

WARNING!

At correct idle speed, chain should not turn. For di­rections to adjust idle speed, see the appropriate
section of this instruction manual.

Do not use a saw with incorrect idle speed adjust­ment. Adjust the idle speed yourself according to
the appropriate section of this manual.

Have your MAKITA dealer check your saw and
make proper adjustments or repairs.

Check the saw chain tension frequently, especially
just after installing a new chain. New chains may
stretch more during their initial use. A properly ad­justed saw chain can be pulled freely around the
guide bar by hand without sagging. Always stop
the engine and wear gloves when checking or
adjusting the chain tension.

Working conditions

Wrap your fingers tightly around the handles, keeping
the handles cradled between your thumb and forefinger
(fig. 7). With your hands in this position, you can best
oppose and absorb the push, pull and kickback forces
of your saw without having it slip out of your grip (see
section of reactive forces). Make sure your chain saw
handle and grip are in good condition and free of
moisture, pitch, oil or grease.

Always start a cut with the chain running at full speed
and the spike bar in contact with the wood.

WARNING!

Never use the saw with one hand. You cannot
control reactive forces (see pages 9 to 11) and
may lose control of the saw.

Operate your chain saw only outdoors. Operate the
saw under good visibility and daylight conditions only.

WARNING!

Take extreme care in wet and freezing weather
(rain, snow, ice). Put off the work when the weather
is windy, stormy or rainfall is heavy. Clear the area
where you are working.

WARNING!

Avoid stumbling on obstacles such as stumps,
roots or rocks and watch out for holes or ditches.
Be extremely cautious when working on slopes or
uneven ground. There is increased danger of slip­ping on freshly debarked logs.

Cutting instructions

Always hold the saw firmly with both hands when the
engine is running. Place your left hand on the tubular
handle and your right hand on grip and throttle lever.
Left-handers should follow these instructions too.

8

WARNING!

Do not operate your chain saw in semi-throttle
position. Cutting in this position does not permit
the operator proper control of the saw or chain
speed.

WARNING!

Never come too close to a rotating chain with your
hands or body.

WARNING!

Do not cut any material other than wood or
wooden objects.

Use your chain saw for cutting only. It is not
designed for prying or shoveling away limbs, roots
or other objects.

When sawing, make sure that the saw chain does
not touch any foreign materials such as rocks,
nails and the like (fig. 8). Such objects may be flung
off, damage the saw chain or cause the saw to
kickback.

7

8

9

In order to keep control of your saw, always maintain a
firm foothold. Never work on a ladder, in a tree or on any
other insecure support. Never use the saw above
shoulder height (fig. 9).

10

Position the chain saw in such a way that your body is
clear of the cutting attachment whenever the engine is
running (fig. 10).

Don’t put pressure on the saw when reaching the end
of a cut. The pressure may cause the bar and rotating
chain to pop out of the cut or kerf, go out of control and
strike the operator or some other object. If the rotating
chain strikes some other object a reactive force (see
pages 10 to 12 ) may cause the chain to strike the
operator.

Reactive forces during the cut, including kickback

WARNING!

Reactive forces, that may occur during any cut are
kickback, pushback and pull-in. Reactive forces
can be dangerous! In any chain saw, the powerful
force used to cut wood can be reversed (and work
against the operator).

If the rotating chain is suddenly stopped by contact
with any solid object like a log or branch or is
pinched, the reactive forces instantly occur. These
reactive forces may result in loss of control which
may, in turn, cause serious or fatal injury. An
understanding of the causes of these reactive
forces may help you avoid loss of control.

The most common reactive forces are

- kickback,

- pushback,

- pull-in.

11

Kickback:

Kickback occurs when the upper quadrant of the bar
nose contacts a solid object in the wood or is pinched
(fig. 11). The reaction of the cutting force of the chain
causes a rotational force of the chain saw in the direc tion
opposite to the chain movement, mainly in the plane of
the bar. This may fling the bar in an uncontrolled arc
towards the operator.

12

This reaction can occur in a fraction of a second and
under some circumstances, cause the guide bar and
chain to strike the operator with enough force to cause
severe or fatal injury. It may also occur during limbing.
It also occurs when the nose of the guide bar is pinched
unexpectedly, unintentionally contacts solid material
in the wood (fig.12) or is incorrectly used to begin a
plunge or boring cut.

The greater the force of the kickback reaction, the more
difficult it becomes for the operator to control the saw.

9

Many factors influence the occurence and force of
the kickback reaction. The type of bar and saw chain
you use is a factor in the force of the kickback reaction.

The speed of contact at which the cutter contacts
the object.

Kickback force increase with the rate of impact.

The contact angle between the nose of the bar
and the foreign object (fig. 11).

Kickback is most pronounced in the upper quadrant
of the bar nose.

MAKITA chain types are designed to reduce kickback
forces.

The depth gauges:

Improper lowering of the depth gauges also increases
the risk of a kickback.

13

To avoid kickback

The best protection from personal-injury that may
result from kickback is to avoid kickback situations:

1. Hold the chain saw firmly with both hands and
maintain a secure grip.

Saw chain cutter sharpness:

WARNING!

A dull improperly sharpened chain may increase
the risk of kickback. Always cut with a properly
sharpened chain.

Devices for reducing the risk of kickback injury

MAKITA have developed a special chain brake to
reduce the risk of kickbacks.

This chain brake increases the safety factor on the
job, e.g. when the saw suddenly bucks upwards the
chain stops rotating within a fraction of a second. A
deflection guard on the disengaging lever of the chain
brake and a scoop rear handle ensure that the opera­tor’s hands are fully protected at all times.

Kickback tendency increases as the radius or size of
the guide bar nose increases. MAKITA have devel­oped guide bars with small nose radius, to reduce the
kickback tendency.

WARNING!

No chain brake prevents kickback.
These brakes are designed only to stop the chain,
if activated.
To ensure a proper operation of the chain brake, it
must be properly maintained. Furthermore, there
must be a sufficient distance between the operator
and the bar to ensure that the chain brake has
sufficient time to activate and stop the chain before
potential contact with the operator.

2. Be aware of the location of the guide bar nose at
all times.

3. Never bring the nose of the guide bar in contact
with any object. Do not cut limbs with the nose of
the guide bar. Be especially careful with small,
tough limbs, small size brush and saplings which
may easily catch the chain.

4. Don’t overreach.

5. Don’t cut above shoulder height.

6. Begin cutting and continue at full throttle.

7. Cut only one log at a time.

8. Use extreme caution when re-entering a previous

cut.

9. Do not attempt plunge cuts (see page 13) if you
are not experienced with these cutting techniques.

10. Be alert for shifting of the log or other forces that
may cause the cut to close and pinch the chain.

11. Maintain saw chain properly. Cut with a correctly
sharpened, properly tensioned chain at all times.

12. Stand to the side of the cutting path of the chain
saw.

10

Pushback:

To avoid pull-in

Pushback occurs when the chain on the top of the bar
is suddenly stopped when it is pinched, caught or
encounters a foreign object in the wood. The reaction
of the chain drives the saw straight back toward the
operator causing loss of saw control. Pushback fre­quently occurs when the top of the bar is used for
cutting (fig. 14).

14

To avoid pushback

1. Be alert to forces or situations that may cause
material to pinch the top of the chain.

2. Do not cut more than one log at a time.

3. Do not twist the saw when withdrawing the bar
from a plunge cut or under buck cut (figures 25 to
27 and 33, pages 13 and 15), because the chain
can pinch.

Pull-in:

Pull-in occurs when the chain on the bottom of the bar
is suddenly stopped. The chain on the bottom of the
bar stops when it is pinched, caught or encounters a
foreign object in the wood (see fig. 15). The reaction of
the chain pulls the saw forward, causing the operator
to lose control.

1. Always start a cut with the chain rotating at full
speed and the spike bar in contact with the wood.

2. Pull-in may also be prevented by using plastic
wedges to open the kerf or cut.

Cutting techniques

Felling

Felling is cutting down a tree.
Before felling a tree, consider carefully all conditions

which may affect the direction of fall, including:
The intended direction of the fall.

The neutral lean of the tree.
Any unusually heavy limb structure.
Surrounding trees and obstacles.
The wind direction and speed.

WARNING!

Always observe the general condition of the tree.
Look for decay and rot in the trunk. If it is rotted
inside, it could snap and fall toward the operator
while being cut.
Also look for broken or dead branches which could
vibrate loose and fall on the operator. When felling
on a slope, the operator should stand on the up-hill
side.

Pull-in frequently occurs when the spike bar of the
saw is not held securely against the tree or limb and
when the chain is not rotating at full speed before it
contacts the wood.

15

WARNING!

Use extreme caution when cutting small size brush
and saplings which may easily catch the chain and
pull you off balance.

16

When felling in the vicinity of roads, railways and
power lines, etc., take extra precautions (see fig.

16). Inform the police, utility company or railway
authority before beginning to cut.

11

45°

1

2

2

45°

= cutting down area

17

When felling, maintain a distance of at least 2 1/2 tree
lengths from the nearest person (see fig. 17)

.

Note:

The noise of your engine may drown any warning call.

Felling instructions:

First cut

Second cut

20

If the tree has large buttress roots, cut into the largest
buttresses vertically first (horizontally next) and re­move (fig. 20).

Direction of fall

21

18

First clear the tree base and work area from inter­fering limbs and brush and clean its lower portion an
axe (see fig. 18).

45°

19

Then, establish a path of escape and remove all
obstacles. This path should be opposite to the planned
direction of the fall of the tree and at a 45° angle (fig.

19). An alternate path must also be selected. Place all
tools and equipment a safe distance away from the
tree, but not on the escape path.

Felling cut

1

"

/

(4cm)

1

2

1/10∅

Hinge
Felling notch

1/5∅

22

Felling notch

Hinge

23

Then, determine the placement of the felling notch
(fig. 21). The felling notch when properly placed de­termines the direction in which the tree will fall. It is
made perpendicular to the line of fall and should be as
close to the ground as possible. Cut the felling notch
to a depth of about one-fifth to one-fourth of the trunk
diameter (fig. 22). It should be in no case higher than
it is deep. Make the felling notch very carefully.

12

Begin the felling cut slighty higher than the felling
notch and on the opposite side of the tree (fig. 22).
Then cut horizontally through towards the felling notch.
Apply the chain saw with its spikes directly behind the
uncut portion of wood and cut toward the notch (fig.

23). Leave approximately 1/10 of the tree diameter
uncut! This is the hinge (fig. 23). Do not cut through the
hinge because you could lose control of the direction
of the fall. Drive wedges into the felling cut where
necessary to control the direction of the fall. Wedges
should be of wood, light alloy or plastic - never of steel,
which can cause kickback and damage to the chain.

Always keep to the side of the falling tree. When the
tree starts to fall, shut off the engine, withdraw the bar
and walk away on the pre-planned escape path.
Watch out for falling limbs.

WARNING!

Be extremely careful with partially fallen trees which
are poorly supported.

Plunge-Cut Method

Timber having a diameter more than twice the length
of the guide bar reauires the use of the plunge-cut
method before making the felling cut.
First, cut a large, wide notch. Make a plunge cut in the
center of the notch.
The plunge cut is made with the guide bar nose. Begin
the plunge cut by applying the lower portion of the
guide bar nose to the tree at an angle (fig. 25). Cut until
depth of the kerf is about the same as the width of the
guide bar (fig. 26). Next, align the saw in the direction

When the tree hangs or for some other reason does
not fall completely, set the saw aside and pull the
tree down with a cable winch, block and tackle or
tractor. If you try to cut it down with your saw, you
may be injured.

Sectioning Method

WARNING!

Felling a tree that has a diameter greater than the
length of the guide bar requires use of either the
sectioning or plunge-cut method. These methods
are extremely dangerous because they involve the
use of the nose of the guide bar and can result in
kickback. Only properly trained professionals
should attempt these techniques.

1

25

in which the recess is to be cut. With the saw at full
throttle, insert the guide bar in the trunk (fig. 27).

Enlarge the plunge cut as shown in illustration (fig. 28)

26

23

24

For the sectioning method (fig. 24) make the first cut
with the guide bar fanning in toward the hinge. Then,
using the bumper spike as a pivot, reposition the saw
for the next cut. Avoid repositioning the saw more than
necessary. When repositioning for the next cut, keep
the guide bar fully engaged in the kerf to keep the
felling cut straight. If the saw begins to pinch, insert a
wedge to open the cut. On the last cut, do not cut
the hinge.

27

28

13

3

2

Bucking

Bucking is cutting a log into sections.

1

WARNING!

There is an extreme danger of kickback at this
point. Extra caution must be taken to maintain
control of the saw. To make the felling cut, follow
the sectioning method described previously (fig.

29). If you are inexperienced with a chain saw
plunge-cutting should not be attempted. Seek the
help of a professional.

29

Limbing

Limbing is removing the branches from a fallen tree.

WARNING!

There is an extreme danger of kickback during the
limbing operation. Do not work with the nose of the
bar. Be extremely cautious and avoid contacting
the log or other limbs with the nose of the guide bar.
Do not stand on a log while limbing it - you may slip
or the log may roll.

31

WARNING!

1. When bucking, do not stand on the log. Make
sure the log will not roll down-hill. If on a slope,
stand on the up-hill side of the log (see fig. 31).
Watch out for rolling logs.

WARNING!

2. Cut only one log at a time.

WARNING!

3. Shattered wood should be cut very carefully.
Sharp slivers of wood may be caught and flung
in the direction of the operator of the saw.

Start limbing by leaving the lower limbs to support
the log off the ground (fig. 30). Always cut from the
top of the limb. Do not underbuck freely hanging
limbs. A pinch may result or the limb may fall,
causing loss of control. If a pinch occurs, stop the
engine and remove the saw, by lifting the limb.

WARNING!

Be extremely cautious when cutting limbs under
tension. The limbs could spring back toward the
operator and cause loss of control of the saw or
injury to the operator.

14

30

32

WARNING!

4. When cutting small logs, use a sawhorse (fig. 32).

Never permit another person to hold the log.
Never hold the log with your leg or foot.

1. Relieving cut

2. Cross cut

2. Cross cut

Tension side

Pressure side

1. Relieving cut

Pressure side
Tension side

33

Maintenance and Repair

Never operate a chain saw that is damaged, improp­erly adjusted or not completely or securely assembled.
Follow the maintenance and repair instructions in the
appropriate section of this manual.

WARNING !

Always stop the engine and make sure that the
chain is stopped before commencing any mainte­nance or repair work or cleaning the saw. Do not
attempt any maintenance or repair work not de­scribed in this manual. Have such work performed
by your MAKITA service shop only.

Maintaining and storing the saw

Keep the chain, bar and sprocket clean and lubricated;
replace worn sprockets or chains.

34

WARNING!

5. Logs under strain require special attention to
prevent the saw from pinching. The first cut is
made on the compression side to relieve the
stress on the log (see fig. 33, 34). The bucking
cut is then made as shown. If the saw pinches,
stop the engine and remove it from the log.

Keep the chain sharp. You can spot a dull chain when
easy-to-cut wood becomes hard to cut and burn marks
appear on the wood.

Keep the chain at proper tension. Tighten all nuts,
bolts and screws except the carburetor adjustment
screws after each use.

Keep spark plug and wire connection tight and clean.
Store saws in a high or locked place, away from

children.

35

WARNING!

6. Only properly trained professionals should work
in an area where the logs, limbs and roots are
tangled (i. e. a blowdown area, fig. 35). Work­ing in blowdown areas is extremely hazard­ous.

WARNING!

7. Drag the logs into a clear area before cutting.
Pull out exposed and cleared logs first.

15

Denomination of components

1

32

11

12

Identification plate

(example model DCS 5200i)

21" (530mm)

DCS 5200i

9910 123456

523.102.672

443.053.661

22045 Hamburg,Germany

4

10

Serial no.
Year of manufacture

9

5
7

6

8

14

15

16
17

19

13

20

25

027.100. 653

Indicate when ordering spare parts!

1 Handle
2 Choke
3 Filter cover
4 Tubular handle
5 Muffler
6 Retaining nuts
7 Spike bar

(toothed stop for holding saw steady against wood)

8 Chain catcher

9 Adjusting screw for oil pump (bottom side)
10 Sprocket guard
11 Identification plate
12 Hand guard

24

13 Guide bar
14 Chain
15 Hand guard (release for chain brake)
16 Starter grip
17 Adjusting screws "S-L-H" for carburetor
18 I/STOP-switch
19 Stop knob for halfway throttle
20 Safety locking button
21 Throttle lever
22 Fuel tank cap
23 Fan housing with starting assembly
24 Oil tank cap
25 Starting valve (only DCS 431)

2223

18

21

16

Technical data

Stroke volume cu. in 2.7 (43 cm3) 3.2 (52 cm3) 3.3 (54 cm3) 3.2 (52 cm3)
Bore inch 1.57 (40 mm) 1.73 (44 mm) 1.77 (45 mm) 1.73 (44 mm)
Stroke inch 1.34 (34 mm) 1.34 (34 mm) 1.34 (34 mm) 1.34 (34 mm)
Max. power at speed kW / rpm 2.0 / 9,000 2.4 / 9,000 2.2 / 9,000 2.7 / 9,000
Max. torque at speed Nm / rpm 2.4 / 6,000 2.9 / 6,000 3.0 / 6,000 3.1 / 6,000
Idling speed rpm 2,500 2,500 2,500 2,500
Coupling speed rpm 3,600 3,600 3,600 3,600
Sound Pressure Level at the operator’s ear
at full load according to ANSI B 175.1 db(A) 102 102 102 102
Sound Pressure Level at the bystander’s position
(50ft/15 m distance) according to ANSI B 175.1
Carburetor (for CANADA) Type Walbro WT 465
Carburetor (for USA) Type Walbro WT 465
Ignition system Type electronic electronic electronic electronic
Spark plug Type BOSCH WSR 6F BOSCH WSR 6F BOSCH WSR 6F BOSCH WSR 6F
Electrode gap inch .020 .020 .020 .020
or spark plug Type NGK BPMR 7A NGK BPMR 7A NGK BPMR 7A NGK BPMR 7A
Fuel consumption at max. load kg/h 0.90 1.08 1.30 1.21
Specific consumption at max. load g/kWh 450 450 590 450
Fuel tank capacity oz 18.6 18.6 18.6 18.6
Chain oil tank capacity oz 9.3 9.3 9.3 9.3
Mixture ratio (fuel/two-stroke oil) see chapter "Fuel"
Chain brake Engages manually or in case of kickback.

(fuel tank empty, without chain and guide bar)

Weight

db(A) 75 75 75 75

DCS 430 / 431

10 lbs 10 lbs 10 lbs 2 oz 10 lbs 2 oz

DCS 520 / 520i DCS 540 DCS 5200i

TILLOTSON HU 116
TILLOTSON HU 116

Walbro WT 465
Walbro WT 465

TILLOTSON HU 116
TILLOTSON HU 116

Approved bar and chain combinations

"Low-kickback saw chain is a chain which has met the kickback performance requirements of ANSI B 175.1-1991
(American National Standard for Power Tools-Gasoline-Powered Chain Saws-Safety Requirements) when tested on the
representative sample of chain saws below 3.8 c.i.d. specifed in ANSI B 175.1-1991". The approved bar and chain
combinations are low kickback chains according to ANSI B 175.1-1991 and also meet the kickback requirements of
CSA Z62.3-96 for chains saws below 80 cm3.

WARNING

Do not use other replacement bars and chains unless they have been designated as meeting the ANSI B 175.1-1991
(for USA) and CSA Z62.3-96 (for Canada) kickback performance requirements on that specific powerhead, or has
been designated as "low kickback" saw chain in accordance with the ANSI B 175.1-1991 (for USA) and CSA
Z62.3-96 (for Canada) standard.

Guide bar and saw chain combinations meeting kick­back requirements of ANSI B 175.1-1991 for the use

in the USA
Models DCS 430, DCS 431

GUIDE BAR SAW CHAIN
length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664
16" (40 cm) .325" 445 040 631 523 085 666
18" (45 cm) .325" 445 045 631 523 085 672

Drive link gauge: .058", Chain sprocket: 8 teeth

Guide bar and saw chain combinations meeting kick­back requirements of CSA Z62.3-96 for the use in

CANADA

Models DCS 430, 431, 520, 520i, 540 and DCS 5200i
GUIDE BAR SAW CHAIN

length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664
16" (40 cm) .325" 445 040 631 523 085 666
18" (45 cm) .325" 445 045 631 523 085 672

Drive link gauge: .058", Chain sprocket: 8 teeth

Models DCS 520, DCS 520i, DCS 540, DCS 5200i
GUIDE BAR SAW CHAIN

length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664
16" (40 cm) .325" 445 040 631 523 085 666
18" (45 cm) .325" 445 045 631 523 085 672

Drive link gauge: .058", Chain sprocket: 8 teeth

18" (45 cm) 3/8" 443 045 661 523 102 664
21" (53 cm) 3/8" 443 053 661 523 102 672

Drive link gauge: .050", Chain sprocket: 7 teeth

15" (38 cm) 3/8" 443 038 651 522 094 656
18" (45 cm) 3/8" 443 045 651 522 094 664
21" (53 cm) 3/8" 443 053 651 522 094 672

Drive link gauge: .058", Chain sprocket: 7 teeth

17

PUTTING INTO OPERATION

STOP

Mounting the guide bar and saw chain

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

Put the chain saw on a stable surface and carry out the
following steps for mounting the guide bar and chain:

2

1

A

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

CAUTION: Before doing any work on the guide bar or

chain, always switch off the engine and pull
the plug cap off the spark plug (see "Replacing
the spark plug"). Always wear protective gloves!

CAUTION: Start the chain saw only after having assem-

bled it completely and inspected!

4

5

B

3

- Unscrew retaining nuts (B/3).

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

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

6

C D

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

7

10

8

8

9

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

10

12

11

E

- Lift the chain (E/10) over the clutch drum and onto the
sprocket (E/11). Using your right hand, guide the chain into
the top guide groove on the guide bar (E/8).

NOTE: The cutting edges along the top of the chain must
point in the direction of the arrow!

18

F

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

NOTE: The chain should be easy to pull in the direction of the
arrow.

6

G

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

6

I

Tightening the saw chain

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

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

Chain brake

H

- Replace the sprocket guard (H/4).

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

Checking the chain tension

J

- The tension of the chain is correct if the chain rests against
the bottom side of the guide bar and can still be easily
turned by hand. While doing so the chain brake must be
released.

- Every new chain has to be broken in for about 2 to 3
minutes. Ample chain lubrication is essential during this
period. After breaking in, check chain tension and adjust, if
necessary.

- When checking the chain tension the engine must be
switched off.

NOTE: Check the chain tension frequently - chains tend to
get longer during use! If this is not done, there is a risk of the
chain jumping off the bar. It is recommended to use 2-3
chains alternatively.
In order to guarantee uniform wear of the guide bar the bar
should be turned over whenever replacing the chain.

4

3

STOP

K

The MAKITA models comes with an inertia chain brake as
standard equipment. If kickback occurs due to contact of the
guide-bar tip with wood (see SAFETY PRECAUTIONS), the
chain brake will stop the chain through inertia if the kickback is
sufficiently strong. The chain will stop within a fraction of a
second.

The chain brake is installed to block the saw chain before
starting it and to stop it immediately in case of an emergency.

2

1

3

L

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) will
automatically actuate 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 feel
it catch. The brake is now released.

19