Makita DCS 431, DCS 520, DCS 520i, DCS 540, DCS 5200i Owner's Manual

...
Owner’s
and
Safety Manual
for
Gasoline Chain Saws
(page
2
31)
Manuel
d’emploi
et
de
securite
de
tronGonneuses
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. Presepe this Manual carefully!
AlTENTlONl
Suivez toujours les conseils de skurite du present manuel d’emploi et de securite. Une utilisation
incorrecte de la tronqonneuse peut entrainer des blessures graves! Conservez avec soin ce manuel!
Les
gaz
d’echappement emis par ce produit contiennent des produits chimiques connus par I’Etat de
Californie pour provoquer le cancer, des defauts de naissance ou autres dommages de reproduction.
Lisez et comprenez ce manuel.
WARNING
I
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., 149304 Northam Street,
La
Mirada, CA 90638-5753, USA, Telephone: (714) 522 80 88 and MAKITA
CANADA INC.,1950 Forbes Street, Whitby, Ontario,
L1
N 787, Canada, Telephone: (905) 571 22
00.
4'1
.
This product complies
with:
American National Standard Institute B 175.1-1991 chain saw safety standard. Canadian Standards Association
Society of Automotive Engineers
262.1 -95 chain saw safety standard.
262.3-96 chain saw kickback standard. SAEJ 335-Jun 95 ,Multiposition small
engine exhaust system fire ignition suppression"
1,
.
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
541 1382,
EP 0236858, EP 0560201, GBM 8710075, GBM 8809928, GBM 9203378, GEM 29616652.
DCS
430,
DCS
431,
DCS
520,
DCS
5201,
DCS
540,
DCS
5200i
Contents
Delivery inventory
Symbols
Safety precautions Denomination of components Technical data Approved bar and chain combinations Mounting the guide bar and saw chain
Chain brake Fuel
I
Refuelling Adjusting the chain lubrication Starting the engine Stopping the engine
Checking the chain brake Checking the chain lubrication Adjusting the carburetor Working in winter
Page
3
3
4-1
5
16 17 17
18-1
9
19
20-21
21 22 22
23 23 23 24
Contents
Page
.
Sharpening the saw chain
24-25
c
Cleaning the guide bar 25
Cleaning the brake band and sprocket interior 26
Replacing the saw chain 26 Replacing the suction head 26 Replacing
I
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
Troubleshooting 30
Extract from the spare parts !ist 31 Adress list 62
Service, spare parts and guarantee
29-30
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).
.
,'
1
2
Delivery inventory
4
I
2-
I
6
I
-
’I
1
Chainsaw
2
Sawchain
3
Guidebar
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)
57
In case one of the parts listed should not be included in the delivery inventory, please consult your sales agent.
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!
Particular care and caution!
Forbidden!
Wear protective helmet, eye and ear protection!
No
smoking!
No
open fire!
OnlOff
(UO) switch
Press starting valve
Engine
-
manual start
Choke lever
Stop engine!
Wear protective gloves!
Chain brake
Caution, kickback!
Fuel and oil mixture
Carburetor adjustment
Chain oil filUoil pump
Working
in
winter
First aid
(Further
symbols
see
page
5.
@
Recycling
3
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.
Always operate the chain saw with both hands.
c)
manual. Failure
to
follow instructions could result
in
serious injury.
It
is recommended
to
lend the
chain saw only
to
people who are experlenced in
working with chain saws. Always hand over the
Owner‘s and Safety Manual.
WARNING!
Tbis chain saw
k
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 significantlv reduced kickback wtential are available.
Kickback may
occur
when the no
guide bar touches an object,
or
w
closes in and pinchesthe saw
chain
ntact
may
abruptly
stop
th
me
cases
may
cause a
lii
ction,WkingtheguIdebar
user,
or
push the guide b
reduce the risk
of
a kckbadc and potential injury.
With
a-basic understandina
of
kickback. vou
C.
D.
E. F.
can reduceor eliminatethe
e7ementot
surpise.
It
is
a sudden surprise that contributes
to
acciden Keep
a
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! 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.
Do not overreach or cut above shoulder height.
Follow manufacturer‘s sharpening and main-
tenance instructionsforthe saw chain. Only use replacement bars and chains speci-
fied by the manufacturer or the equivalent.
Additional safety precautions
The following additional safety precautions should be
.
observed by all users of chain saws:
1.
2.
3.
4.
5.
6.
7.
8.
Do
not operate a chain saw when you are fatigued.
Use safety footwear; snug-fitting clothing; protective gloves: and eye, hearing, and head protection devices.
Use caution when handling fuel. Move the chain saw at least 10 feet
(3
m) from the fueling point
before starting the engine.
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.
*
Do
not start cutting until you have a clear work area, secure footing, and a planned retreat path from the falling tree.
Keep all parts of your body away from the saw chain when the engine is running.
Before you start the engine, make sure that the saw chain is not contacting anything.
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 sizec 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.
14.
15.
16.
17
18.
Keep the handles dry, clean, and free of oil
or
fuel
mixture. Operate the chain saw only in well-ventilated
areas.
Do
not operate a chain saw in a tree unless you
have been specifically trained
to
do
so,
All
chain saw service, other than the items listed in the owner’s manual maintenance instructions, should be performed by MAKlTA
.
(For example,
if
improper
tools
are used
to
remove the flywheel
or
if
an improper tool is used to hold the flywheel
in orderto remove the clutch structural damage
to
the flywheel could occur and could subsequently cause the flywheel
to
burst.)
When transporting your chain saw, use the chain protection cover.
Low kickback bars and low kickback chains are designed
to
reduce the risk of kickback injury. Ask
your MAKITA dealer about these devices.
4
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.
gerous. Careless or improper use of any chain saw
may cause serious or
f
Have your MAKlTA dealer
show
you
how
to operate
your chain saw. Observe
all
applicable
local
safety
regulations,
standards
and ordinances.
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").
Maximumcomputed Kickback Angle
(CKA)' with using the chain brake when using the recommended bar and chain combinations (In
this
example
me
CKA
is
40").
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
fuel tank to
7/8
th
full
(see
storing the
saw).
not lend your chain
saw
without
this owner's
nual. Be sure that
anyone
usinn your
saw
un-
Proper use of a chain
1.
the operator
2
the saw
3.
the use of the
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 list.ed in accordance with
45M6
Amencan,National Standard Safety S
ecifications for Gasoline Powered
rain
saws (ANSI B 175.1-1991).
@
Chain combination that has been
c-2
evaluated with the power head to achieve kickback Drotection
@X.~~-~
(according to ANSI 'and CSA standards).
The Computed Kickback Angle is a calculated value
from eneraies measured on a test bench.lt is
mt
the angle of tbe guide bar moved upward in caseof 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.
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 buming sensations and may cause nerve and circulation damage
and
tissue necrosis.
Alt MANTA
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 Whiefinger disesase, however, they
reduce this danger considerably. Nevertheless, continual and regular
users
should observe their
hands
and fingers
and
in
case
af
any abnormal
symptoms,
seek
medii
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.
0
Good footing is most important in chain saw worl 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
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
own
or
carrying
it.
Carrying a chain saw with the own
or
carrying
it.
Carrying a chain saw with the
en-gine
Nnningisextremelydangerws.Accidental
By
hand: When carrying your saw by hand, the engine must be stopped and thesaw 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
chainandbarcoveredwiththechainguard. 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.
6
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!
Propertension
of
the chain is extremely important.
In
order
to
avoid false setting the tensioning
pr0CedUre
must
be followed
as
described
in
this
manual. Always make sure
the
hexagonal nut@)
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 (alwaysbeforestarting
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
extreme
caution
when handling gasoline
or
fuel
mix. Do-not smoke or
bring
any sparks or flame
Fueling instructions
630
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).
I I
5a
a
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 be-
cause you may lose control
of
the saw (fig. 6).
L
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. sa).
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.
7
Important adjustments
WARNING1
At correct idle speed, chain should not tum. For di-
rections 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 ad-
justed 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.
(rain, snow,
ice).
Put
off
the workwhen the weather
is
windy, stormy or rainfall
is
heavy. Clear the area
ks
&d
watch
out
for holes or ditches.
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.
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.
p
,
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.
,
.
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, nailsand the like (fig.
8).
Such objects may be flung
off,
damage the saw chain or cause the saw to
kickback.
J
I
In order to keep control of your saw, always maintain a
firmfoothold.Neverworkonaladder,inatreeoronany
other insecure support. Never use the saw above shoulder height (fig.
9).
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 rota!ing chain to pop out of the cut or kerf, goout 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
kickback, pushback and pull-in. Reactive
forces
can
be dangerous1 In any chain saw,
the
powerful
force used
to
cut
wood
can
be
reve
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 instantlyoccur.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.
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 direction
opposite tothe chain movement, mainly in the plane
of the bar. This may fling the bar in an uncontrolled arc towards the operator.
12
\-Y-w--
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. Thegreatertheforceof the kickbackreaction, the more
difficult it becomesforthe 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 theobject.
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 properfy
sharpened chain.
-1
*
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 devel-
oped guide bars with small nose radius, to reduce the kickback tendency.
No
chain brake prevents
ki
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
asufficient 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.
I
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.
c"
_.
.
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 onti one
tog
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:
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 fre-
quently 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 cauE 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.
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
To
avoid
pull-in
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
U
rotfed
vibrate loose
and
fall
on
the
operator. When
fellina
._
on
aslope, the operator should
stand
on the up-hi
When felling in the vicinity of roads, railways
and
power lines, etc., take
extra
precautions (see fig.
16).
Inform the police,
utili
company or railway
authority before beginning to cut.
WARNING!
Use extreme caution when cutting small size brush and saplings which may easily catch the chain and pull you
off
balance.
11
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