Makita DCS520i, DCS5200i, DCS540, DCS430, DCS5200 User Manual

...
4.3 (3)

Owner’s and Safety Manual

for Gasoline Chain Saws (page 2 - 32)

Manuel d’emploi et de sécurité

de tronçonneuses thermiques (page 33 - 63)

DCS430, DCS431

DCS520, DCS520i

DCS540

DCS5200, DCS5200i

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

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE

MAKITA U.S.A, Inc warrant to the initial retail purchaser and each subsequent owner, that this utility equipment was designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.

Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period.

For the components listed under PARTS COVERED, the service dealer authorized by MAKITA will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations.

EMISSION COMPONENT DEFECT WARRANTY PERIOD

The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years.

PARTS COVERED

Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part.

Fuel Metering System

Ignition System

Carburetor and internal parts

Spark plugs

Fuel filter, if applicable

Flywheel Magneto

Throttle stopper, if applicable

Ignition Coil

Choke System, if applicable

 

Air Induction System

Miscellaneous Items Used in Above Systems

Pre filter, if exist

Fuel hoses, clamps and sealing gaskets

Air filter, Air cleaner case, Intake manifold

 

OBTAINING WARRANTY SERVICE

To obtain warranty service, take your engine to the nearest MAKITA Factory Service Center or service Center authorized by MAKITA. Bring your sales receipts indicating date of purchase for this engine. The dealer of service authorized by MAKITA will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of MAKITA.

WHAT IS NOT COVERED

Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by MAKITA during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required maintenance services.

The replacement parts used for required maintenance services.

Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.

Diagnosis and inspection charges that do not result in warranty-eligible service being performed.

Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts.

OWNER’S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. MAKITA recommends that you retain all receipts covering maintenance on your engine, but MAKITA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should however be aware that MAKITA may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your engine to the nearest service dealer authorized by MAKITA when a problem exists.

If you have any questions regarding your warranty rights and responsibilities, you should contact the MAKITA Warranty service Department at 1-888-OPE-PART for the information.

THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY:

MAINTENANCE AND REPAIRS

You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. MAKITA reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY MAKITA. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by MAKITA are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by MAKITA in their performance and durability.

HOW TO MAKE A CLAIM

All repair qualifying under this limited warranty must be performed by a service dealer authorized by MAKITA. In the event that any emission-related part is found to be defective during the warranty period, you shall notify MAKITA Warranty service Department at 1-888-OPE-PART and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed.

2

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: (714) 522 80 88 and MAKITA CANADA INC.,1950 Forbes Street, Whitby, Ontario, L1N 7B7, Canada, Telephone: (905) 571 22 00.

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.

DCS430, DCS431, DCS520, DCS520i, DCS540, DCS5200, DCS5200i

Contents

Page

Delivery inventory

4

Symbols

4

Safety precautions

5-16

Denomination of components

17

Technical data

18

Approved bar and chain combinations

18

Mounting the guide bar and saw chain

19-20

Chain brake

20

Fuel / Refuelling

21-22

Adjusting the chain lubrication

22

Starting the engine

23

Stopping the engine

23

Checking the chain brake

24

Checking the chain lubrication

24

Adjusting the carburetor

24

Working in winter

25

Contents

Page

Sharpening the saw chain

25-26

Cleaning the guide bar

26

Cleaning the brake band and sprocket interior

27

Replacing the saw chain

27

Replacing the fuel filter

27

Replacing / cleaning the spark arrester screen

27

Cleaning the air filter

28

Replacing the spark plug

28

Replacing the starter cable

29

Replacing the return spring

29

Mounting the fan housing

29

Instructions for daily and periodic maintenance 30

Service, spare parts and guarantee

30-31

Troubleshooting

31

Extract from the spare parts list

32

Adress list

64

The MAKITA DCS430, DCS431, DCS520, DCS520i, DCS540, DCS5200, DCS5200i 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).

REY

3

Delivery inventory

 

3

4

 

2

1

1 Chain saw

2 Saw chain

3 Guide bar 5 7 6

4 Chain protection cover

5 Universal wrench

6 Wrench

7Screw driver for carburetor adjustment

(only in delivery for model DCS5200i, DCS5200)

8 Owner’s and Safety Manual (not shown)

Symbols

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

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

Stop engine!

Wear protective gloves!

Chain brake

Caution, kickback!

Fuel and oil mixture

Carburetor adjustment

Chain oil fill/oil pump

Working in winter

First aid

Recycling

4

Safety precautions for chain saw operators

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.

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 maintenance instructions for the saw chain.

F.Only use replacement bars and chains specified by the manufacturer or the equivalent.

Additional safety precautions

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.

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 toward you 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.

5

General Safety Precautions

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.

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.

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

Compliance with

Z 62.3-96

CSA -Standards

Class 1A

 

 

 

ANSI B175.1-1991

Compliance with

ANSI -Standards

Chain Saw listed in accordance with American National Standard Safety 45M6 Specifications for Gasoline Powered

Chain Saws (ANSI B 175.1-1991).

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

XXX.YYY.ZZZ

XXX.YYY.ZZZ

Always use two hands when operating the chain saw!

Reduced Kickback Bar and Chain combination that has been evaluated with the power head to achieve kickback protection (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

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.

6

Proper clothing

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.

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.

Wear protective helmet, eye and ear protection!

The saw

Parts of the chain saw: illustrations and description of parts see page 17.

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

WARNING!

Always stop the engine before putting a chain saw down or carrying it. Carrying a chain saw with the engine 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).

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.

7

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).

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).

10 feet

5a

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).

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.

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.

8

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

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.

7

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 10 to 12) and may lose control of the saw.

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.

9

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 11 to 13 ) 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.

10

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.

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.

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.

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 14) 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.

11

12

Makita DCS520i, DCS5200i, DCS540, DCS430, DCS5200 User Manual

45°

2 1 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:

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.

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

Felling cut

1/10

 

 

Hinge

11/2" (4cm)

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.

13

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.

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.

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

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)

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

2

3

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.

26

27

28

14

29

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.

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.

30

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.

Bucking

Bucking is cutting a log into sections.

15

16

Denomination of components

1

2

3

4

11

12

10

9

8

Identification plate

(example model DCS5200)

 

DCS5200

 

Serial no.

21" (530mm)

0405 123456

 

 

Year of manufacture

 

 

 

 

 

 

 

 

 

523.102.672

 

 

 

 

 

443.053.661

22045 Hamburg,Germany

027.100. 653

Indicate when ordering spare parts!

5

7

6

14 15

16

17

19

13

20

25

24 23 22 18 21

1

Handle

13

Guide bar

2

Choke

14

Chain

3

Filter cover

15

Hand guard (release for chain brake)

4

Tubular handle

16

Starter grip

5

Muffler

17

Adjusting screws "S-L-H" for carburetor

6

Retaining nuts

18

I/STOP-switch

7

Spike bar

19

Stop knob for halfway throttle

 

(toothed stop for holding saw steady against wood)

20

Throttle stopper

8

Chain catch

21

Throttle lever

9

Adjusting screw for oil pump (bottom side)

22

Fuel tank cap

10 Sprocket guard

23

Fan housing with starting assembly

11 Identification plate

24

Oil tank cap

12 Hand guard

25

Decompression valve (only DCS431)

 

 

17

 

Technical data

 

 

 

 

 

 

 

 

 

DCS430 / 431

 

DCS520 / 520i

DCS540

 

DCS5200 / 5200i

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

db(A)

75

 

75

75

 

75

 

Carburetor (for CANADA)

Type

Walbro WT 465

 

TILLOTSON HU 116

Walbro WT 465

 

1)

 

 

 

 

 

Carburetor (for USA)

Type

Walbro WT 465

 

TILLOTSON HU 116

Walbro WT 465

 

1)

 

 

 

 

 

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.

 

 

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

10 lbs

 

10 lbs

10 lbs 2 oz

 

10 lbs 2 oz

 

 

 

 

 

 

 

 

 

1) DCS5200 = Walbro WT 465 / DCS5200i = 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 DCS430, DCS431

 

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 DCS520, DCS520i, DCS540, DCS5200, DCS5200i

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

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

CANADA

Models DCS430, 431, 520, 520i, 540 and DCS5200, 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

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

18

PUTTING INTO OPERATION

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:

STOP

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 assembled it completely and inspected!

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.

4

5

B3

-Unscrew retaining nuts (B/3).

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

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

8

6

9

 

C

7

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

- Turn the chain adjusting screw (C/6) to the left (counter-

- Position the guide bar (D/8). Make sure that the pin (D/9)

 

clockwise) until the pin (C/7) is at the left stop.

 

of the chain tightener is in the hole (circled) on the guide

 

 

 

 

 

bar.

10 8

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!

10 12

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.

19

6

 

 

 

 

 

4

3

 

G

 

 

H

 

 

 

 

 

 

 

 

 

 

 

- Turn the chain tightener (G/6) to the right (clockwise)

-

Replace the sprocket guard (H/4).

 

until the chain engages the guide groove of the bottom side

-

Manually tighten the retaining nuts (H/3).

 

of the bar (see circle). Press the guide bar against the

 

 

 

 

housing with your left hand.

Checking the chain tension

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

K

STOP

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.

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.

20

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