DCS540 - Chain saw MAKITA - Free user manual and instructions

USER MANUAL DCS540 MAKITA

Owner's and Safety Manual for Gasoline Chain Saws (page 2 - 32)

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!

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

Carburetor and internal parts

Fuel filter, if applicable

Throttle stopper, if applicable

Choke System, if applicable

Ignition System

Spark plugs

Flywheel Magneto

Ignition Coil

Air Induction System

Pre filter, if exist

Air filter, Air cleaner case, Intake manifold

Miscellaneous Items Used in Above Systems

Fuel hoses, clamps and sealing gaskets

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.

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

Canadian Standards Association

B 175.1-1991 chain saw safety standard.

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	Contents	Page
Delivery inventory	4	Sharpening the saw chain	25-26
Symbols	4	Cleaning the guide bar	26
Safety precautions	5-16	Cleaning the brake band and sprocket interior	27
Denomination of components	17	Replacing the saw chain	27
Technical data	18	Replacing the fuel filter	27
Approved bar and chain combinations	18	Replacing / cleaning the spark arrester screen	27
Mounting the guide bar and saw chain	19-20	Cleaning the air filter	28
Chain brake	20	Replacing the spark plug	28
Fuel / Refuelling	21-22	Replacing the starter cable	29
Adjusting the chain lubrication	22	Replacing the return spring	29
Starting the engine	23	Mounting the fan housing	29
Stopping the engine	23	Instructions for daily and periodic maintenance	30
Checking the chain brake	24	Service, spare parts and guarantee	30-31
Checking the chain lubrication	24	Troubleshooting	31
Adjusting the carburetor	24	Extract from the spare parts list	32
Working in winter	25	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 reusable or suitable for recycling (waste paper recycling).

river for carburetor adjustment

delivery for model DCS5200i, DCS5200) and Safety Manual (not shown)

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

ice 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

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.

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

Z62.3-96

Class 1A

Compliance with

CSA -Standards

ANSI B175.1-1991

Compliance with

ANSI -Standards

45M6

Chain Saw listed in accordance with American National Standard Safety 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^ ).

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 diseasesase, 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.

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.

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 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).

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).

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).

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).

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.

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.

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.

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.

always maintainer, in a tree or onthe saw above

a way that your body iswhenever the engine is

when reaching the end cause the bar and rotating kerf, go out of control and other object. If the rotating object a reactive force (see use the chain to strike the

The cut, including kickback

RNING!

may occur during any cut area and pull-in. Reactive forces in any chain saw, the powerful pod can be reversed (and work or).

tion is suddenly stopped by contact object like a log or branch or is reactive forces instantly occur. These may result in loss of control which cause serious or fatal injury. An ing of the causes of these reactive help you avoid loss of control.

Common reactive forces are

ck,
back,
in.

Many factors influence the occurrence 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.

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.

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

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.

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

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.

Begin the felling cut slightly 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.

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.

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.

Plunge-Cut Method

Timber having a diameter more than twice the length of the guide bar requaires 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)

26

27

28

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.

Identification plate

example model DCS5200)

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

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 Throttle stopper
21 Throttle lever
22 Fuel tank cap
23 Fan housing with starting assembly
24 Oil tank cap
25 Decompression valve (only DCS431)

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	TILLLOTSON HU 116	Walbro WT 465	1)
Carburetor (for USA)	Type	Walbro WT 465	TILLLOTSON 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. specified 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~cm^3

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 kick-back requirements of ANSI B 175.1-1991 for the use in the USA
Models DCS430, DCS431
GUIDE BAR length	pitch	part no.	SAW CHAIN 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 length	pitch	part no.	SAW CHAIN part no.
15" (38 cm)	.325"	445 038 631	523 085 664
16" (40 cm)	.325"	445 040 631	523 102 664
18" (45 cm)	.325"	445 045 631	523 102 672
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 kick-back requirements of CSA Z62.3-96 for the use in CANADA
Models DCS430, 431, 520, 520i, 540 and DCS5200, 5200i
GUIDE BAR length	pitch	part no.	SAW CHAIN 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

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:

• 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.

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

• 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!

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!

• Unscrew retaining nuts (B/3).
  Pull off the sprocket guard (B/4).
• Remove the plastic transport cover (B/5) and dispose of properly.

• 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.

• 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.

• 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.

Tightening the saw chain

• Slightly lift the end of the guide bar and turn the chain adjusting screw (1/6) 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

• Replace the sprocket guard (H/4).
• Manually tighten the retaining nuts (H/3).

Checking the chain tension

• 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.

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.

Gasoline	40:1 other oil	50:1 MAKITA oil	100:1 MAKITA oil
HP 100 Takita
1.0 Us-gal. (3.7 l) 2.5 Us-gal. (9.4 l) 5.0 Us-gal. (18.9 l)	3.2 floz.(94 cm3) 8.0 floz.(236 cm3) 16.0 floz.(473 cm3)	2.5 floz.(75 cm3) 6.4 floz.(189 cm3) 12.8 floz.(378 cm3)	1.3 floz.(38 cm3) 3.2 floz.(94 cm3) 6.4 floz.(189 cm3)

Fuel mixture

The engine of the chain saw is a high-efficiency two-stroke engine. It runs on a mixture of gasoline and two-stroke engine oil.

The engine is designed for unleaded regular gasoline with a min. octane value of 91 ROZ. In case no such fuel is available, you can use fuel with a higher octane value. This will not affect the engine. In order to obtain an optimum engine output and to protect your health and the environment use unleaded fuel only. Gasoline which contens alcohol should not used in MAKITA products.

For lubricating the engine use a high-performance two-stroke engine oil (quality grade JASO FC or ISO EGD specifications), which is added to the fuel. The engine has been designed for use of MAKITA HP 100 high-performance two-stroke engine oil and a mixture ratio of only 100:1 to protect the environment. In addition, a long service life and reliable operation with a minimum emission of exhaust gases are ensured.

MAKITA HP 100 high-performance two-stroke engine oil is available in the following sizes:

0.5 I order number 980 008 609

MAKITA high-performance two-stroke engine oil is available in the following sizes to suit your individual requirements:

1 order number 980 008 607

100 ml order number 980 008 606

In case MAKITA high-performance two-stroke engine oil is not available, it is urgently recommended to use a mixture ratio of 40:1 with other two-stroke engine oils, as otherwise optimum operation of the engine cannot be guaranteed.

The correct mixture ratio:

50:1 when using MAKITA high-performance two-stroke engine oil, i. e. mix 50 parts gasoline with 1 part oil.
100:1 when using MAKITA HP 100 high-performance two-stroke engine oil, i. e. mix 100 parts gasoline with 1 part oil.
40:1 when using other two-stroke engine oils, i. e. mix 40 parts gasoline with 1 part oil.

Handling and storage

Utmost care is required when handling with fuel. Fuel can contain substances which have a behavior similar to that of solvents. Fill the tank only outside or ventilated rooms. Do not inhale vapors, avoid any fuel contact with your skin. For preparing the fuel-oil mixture first mix the entire oil quantity with half of the fuel required, then add the remaining fuel. Thoroughly shake the mixture before filling it into the chain saw tank.

It is not wise to add more engine oil than specified to ensure safe operation. This will only result in a higher production of combustion residues which will pollute the environment and clog the exhaust channel in the cylinder as well as the muffler. In addition, fuel consumption will rise and performance will decrease.

Fuel cannot be stored for an unlimited period of time. Buy only as much as will be consumed in 4 weeks. Use only approved and marked containers for transport and storage.

Chain oil

Use an oil with adhesive additive for lubricating the chain and guide bar. The adhesive additive prevents the oil from being flung off the chain too quickly.

We recommend the use of chain oil which is bio-degradable in order to protect the environment. The use of bio-degradable oil may even be required by local regulations.

The chain oil BIOTOP sold by MAKITA is made of special vegetable oils and is 100% bio-degradable. BIOTOP has been granted the "blue angel" (Blauer Umweltschutz-Engel) for being particularly environment-friendly (RAL UZ 48).

BIOTOP chain oil is available in the following sizes:

1 order number 980 008 610
5 order number 980 008 611

Bio-degradable oil is stable only for a limited period of time. It should be used within 2 years from the date of manufacture (printed on the container).

Important note on bio-degradable chain oils:

If you are not planning to use the saw again for an extended period of time (longer than the expiration date of the chain oil), empty the oil tank and put in a small amount of regular engine oil (SAE 30), and then run the saw for a time. This is necessary to flush out all remaining bio-degradable oil from the oil tank, oil-feed system, chain and guide bar, as many such oils tend to leave sticky residues over time, which can cause damage to the oil pump or other parts.

The next time you use the saw, fill the tank with BIOTOP chain oil again.

NEVER USE WASTE OIL

Waste oil is very dangerous for the environment.

Waste oil contains high amounts of carcinogenic substances.

Residues in waste oil result in a high degree of wear and tear at the oil pump and the sawing device.

In case of damage caused by using waste oil or inappropriate chain oil the product guarantee will be null and void.

Your salesman will inform you about the use of chain oil.

Refuelling

FOLLOW THE SAFETY PRECAUTIONS ON PAGE 7!

Be careful and cautious when handling fuels.

The engine must be switched off!

• Thoroughly clean the area around the caps, to prevent dirt from getting into the fuel or oil tank.
• Unscrew the cap and fill the tank with fuel (fuel/oil mixture) or chain oil as the case may be. Fill up to the bottom edge of the filler neck. Be careful not to spill fuel or chain oil!
  Tightly screw on the cap.

After refuelling, clean screw cap, tank and check for leukages.

Adjusting the chain lubrication

The engine must be switched off.

You can adjust the oil pump feed rate with the adjusting screw (F/1). The adjusting screw is located in the housing underneath the sprocket guard (F/2). It is accessible from below.

The oil pump comes factory-set to a medium feed rate.

Note: To set from minimum to maximum oil supply, turn the adjusting screw (F/1 with adjustment markings) max. a 1/4-turn.

Mineral oil products degrease your skin. If your skin comes in contact with these substances repeatedly and for an extended period of time, it will desiccate. Various skin deseases may result. In addition, allergic reactions are known to occur.

Eyes can be irritated by contact with oil. If oil comes into your eyes, immediately wash them with clear water.

If your eyes are still irritated, see a doctor immediately!

Lubricating the chain

During operation there must always be sufficient chain oil in the chain-oil tank to provide good chain lubrication. One filling is sufficient for about one half-hour of continuous operation. While working make sure there is enough chain oil in the tank. If necessary, add oil. The engine must be switched off!

To ensure troublefree operation of the oil pump the oil guide groove at the crank case (G/3) and the oil inlet bore in the guide bar (G/4) must be cleaned regularly.

To change the feed quantity use the universal wrench and adjust the adjusting screw (F/1) in the following way:

• Turn to the right to reduce the feed rate.
• Turn to the left to increase the feed rate.

Note: After the saw has been turned off it is normal for residual chain oil to drip from the oil feed system, the guide bar and the chain for a time. This does not constitute a defect!

Place the saw on a suitable surface.

Cold-starting the DCS430, 431, 520, 540, 5200:

The carburetors of these saws have a choke valve for cold starting (mixture enrichment).

To make it easier to start, the chain saw DCS431 is equipped with a semi-automatic decompression valve (B/5). Pushing this valve in reduces the amount of compression effort needed, so that it is easier to bring the engine up to starting speed when pulling the starter cable. The high pressure increase in the combustion chamber that results from the first ignitions will automatically close the decompression valve (button pops back out).

Model DCS430, DCS520 and DCS5200 do not have a decompression valve. Starting and carburetor adjustment are as for model DCS 431 except without the instruction "Push the decompression valve".

Put the short-circuit ignition switch in the "I" position (B/1).
Pull out the choke (B/2).
- Depress the half-throttle lock button (B/3) half-way and hold.
- Depress the throttle (B/4) and half-throttle lock button (B/3) all the way. Release the throttle - it will now be held at half-throttle by the lock button.
- Push the decompression valve (B/5) (only DCS431).
- Slowly pull out the starter cable until you notice resistance (the piston is positioned before the top dead center).
- Now pull the starter cable with a fast and forceful movement until you hear the first ignition.

CAUTION: Do not pull out the starter cable more than approx. 50 cm, and lead it back by hand.

• When you hear the first ignition, push the choke (B/2) in. Push the decompression valve again (only DCS431) and pull the starter cable. As soon as the engine is running, press the throttle (B/4) to release the half-throttle lock (B/3), allowing the engine to idle.

CAUTION: As soon as the engine is started it must be put in idle to prevent the chain brake from being damaged.

• Now release the chain brake.

• Move at least 10 feet (3 m) away from the place where you fuelled the saw.
  Make sure you have a good footing, and place the saw on the ground in such a way that the chain is not touching anything.
• Engage the chain brake (lock).
• Hold the tubular handle tightly with one hand and press the chain saw to the ground.
• Steady the rear handle by standing in the hand guard.

Cold-starting the DCS520i and DCS5200i:

The carburetors of these saws have a fuel-injection system (injection carburetor) for cold starting (mixture enrichment). These two cold-starting systems work differently.

• Put the short-circuit ignition switch in the "I" position (B/1).
• Pull out the choke (B/2) (opens the injection valve).
• Depress the half-throttle lock button (B/3) half-way and hold.
• Depress the throttle (B/4) and half-throttle lock button (B/3) all the way. Release the throttle - it will now be held at half-throttle by the lock button.

Note: If the temperature is below -15°C (5° F) start at full throttle.

• Slowly pull out the starter cable until you notice resistance (the piston is positioned before the top dead center).
• Now pull the starter cable with a fast and forceful movement until you hear the first ignition.

CAUTION: Do not pull out the starter cable more than approx. 50 cm, and lead it back by hand.

• Push in the choke (B/2) when the engine starts, or after the first audible ignitions.
• If the engine has not yet started, keep pulling the starter cable until it does.
• As soon as the engine is running, press the throttle (B/4) to release the half-throttle lock (B/3), allowing the engine to idle.

CAUTION: As soon as the engine is started it must be put in idle to prevent the chain brake from being damaged.

• Now release the chain brake.

Warm starting (all models):

• As described above for cold starting, but without using the choke (B/2). Keep the choke in.

Starting under special conditions

(MAKITA DCS520i and DCS5200i only):

In conditions of high ambient temperature and when the engine has been stopped for only a short period following full-load operation, if a fuel with a low boiling point is used (winter fuel), and at high altitudes especially, the heat could prevent the engine from starting immediately. If this happens, proceed as follows:

• Pull out the choke (B/2) and start the engine at half-throttle, as described for cold starting.
• When the engine has started, release the chain brake immediately and gun the engine all the way several times until it runs smoothly.
  Now push in the choke (B/2).

If the engine won't start:

If the engine refuses to start even after a number of tries, check the spark plug (see the section on "Replacing the spark plug").

Stopping the engine

Put the short-circuiting switch (B/1) in position "O" (STOP).

Do not work with the chain saw without first checking the chain brake!

• Start the engine as described (make sure you have a good footing, and place the chain saw on the ground in such a way that the guide bar is free of contact).
• Grasp the tubular handle firmly with one hand and hold the grip with the other.
• With the engine running at moderate speed, press the hand guard (C/1) in the direction of the arrow with the back of your hand until the chain brake engages. The chain should stop immediately.
• Immediately release the throttle and release the chain brake.

IMPORTANT: If the chain does not stop immediately when you test the chain brake, do NOT use the chain saw. Take the chain saw to a MAKITA service center for repair.

Adjusting the carburetor

Workin

ter

In orderfature cooperatire heatedAt tempfed failureto the

carburetor icing in conditions of low temper- th high humidity, and in order to get up to a ture faster in subfreezing temperatures, taken from the cylinder.

above freezing the carburetor must NOT be

N these instructions can lead to damage and piston!

• /e the filter cover and air filter (see "Cleaning the air

F

• The sharpening angle must be identical for all cutters! Different angles result in a roughly, irregularly running chain, increase wear and tear and cause chain breakage.
• The front rake of the cutter results from the cut depth of the round file. If the proper file is used in the right manner, the correct front rake will be obtained automatically.

Cleaning the guide bar

CAUTION:

Protective gloves must be worn.

Regularly inspect the bearing surfaces of the guide bar for damage, and clean them with a suitable tool.

Cleaning the brake band and sprocket interior

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!

• Remove the sprocket guard (A/1) (See "PUTTING INTO OPERATION" figs. A and B).
• Turn the chain tightener screw (A/2) to the left (counterclockwise) until you feel resistance.
• Remove the chain (A/3) and guide bar (A/4).
• Clean the interior with a brush, in particular the brake-band area (A/5).

NOTE:

Make sure that no residue or contaminants remain in the oil guide groove (A/6) and the chain tightener (A/7).

• For replacing the guide bar, chain, and sprocket see "PUTTING INTO OPERATION".

NOTE:

The chain brake is a very important safety device and like any other component subject to normal wear and tear.

Regular inspection and maintenance are important for your own safety and must be done by a MAKITA service center.

Replacing the fuel filter

The felt filter (D/1) of the fuel filter can become clogged. It is recommended to replace the fuel filter once every three months in order to ensure unimpeded fuel flow to the carburetor.

To remove the fuel filter for replacement, pull it out through the tank filler neck using a piece of wire bent at one end to form a hook.

Replacing the saw chain

CAUTION:

Use only chains and guide bars designed for this saw (see the Extract from the spare-parts list and page 18)!

Check the sprocket (B/1) before mounting a new chain.

The sprocket is located underneath the clutch drum (B/2).

CAUTION:

Worn out sprockets (C) may damage the new chain and must therefore be replaced. If the wear marks on the teeth are very pronounced (about 0,5mm / 0.02 deep), the sprocket should be replaced.

Do not attempt to replace the sprocket yourself. Sprocket replacement requires special training and tools and must be done at a MAKITA service center.

Replacing/cleaning the spark arrester screen

The spark arrester screen should be checked and cleaned regularly.

• Loosen the 3 screws (E/1) and remove the spark arrester screen (E/2).
• Reassembly the spark arrester screen and tighten the screws. The two long screws must be tigthed with a torque of 6,3 ft. lb.(8,5 Nm).

CAUTION:

Do not use sharp or pointed objects for screen cleaning.

Damaged or misformed screen wires may result.

Cleaning the air filter

• Remove the filter cover (F/1) (2 screws).
• Loosen the screws on the air filter (F/2) and remove from intake manifold.
• Loosen the screw on the prefilter cover (F/3) and remove.
• Remove prefilter (F/4).

IMPORTANT:

Cover the intake opening with a clean cloth to prevent dirt particles from getting into the carburetor.

• Pry apart the top and bottom of the air filter as shown in Figure G.

CAUTION:

To prevent injury to the eyes, do NOT blow out dirt particles!

Do not use fuel to clean the air filter and prefilter.

Replacing the spark plug

CAUTION:

Do not touch the spark plug or plug cap if the engine is running (high voltage).

Switch off the engine before starting any maintenance work.

A hot engine can cause burns. Wear protective gloves!

The spark plug must be replaced in case of damage to the insulator, electrode erosion (burn) or if the electrodes are very dirty or oily.

• Remove the filter cover (see "Cleaning the air filter").

• Pull the plug cap (H/1) off the spark plug. Use only the combination wrench supplied with the saw to remove the spark plug.

CAUTION: Use only the following spark plugs:

BOSCH WSR 6F or NGK BPMR 7A.

• Clean the air filter and prefilter with a soft brush.
• If the filter is very dirty, clean it in lukewarm water with dishwashing detergent.
• Let the air filter dry completely.
  Put the top and bottom sections back together.
• Before reinstalling the air filter, check the intake opening and remove any dirt particles. If there are any, remove them with a brush.

Clean frequently (several times a day) when working in very dusty or dirty conditions. Full engine power is possible only with a clean air filter and prefilter!

CAUTION: If the air filter or prefilter becomes damaged, replace immediately!

Pieces of cloth or large dirt particles can destroy the engine!

Electrode gap

The electrode gap must be .020" (0.5 mm).

Checking the ignition spark

• Press the loosened spark plug with the ignition cable firmly connected against the cylinder using insulated pliers (not near the spark plug opening).
• ON/OFF switch in the "I" (ON) position.
  Pull the starter cable hard.

If the function is correct, an ignition spark must be visible near the electrodes.

• Unscrew the four screws (A/1) holding down the fan housing (A/2). Lift the housing slightly, pull in the direction of the arrow, and remove.
• Remove all pieces of cable.

Replacing the return spring

Mounting the fan housing

• Thread in a new cable (4 mm/.16" dia. x 1000 mm/39" long) as shown in Figure B and tie the ends as shown.
  Pull knot (B/1) into the cable pulley (B/3).
  Pull knot (B/2) into the cable grip (B/4).
• Wind the cable around the pulley in the direction shown by the arrow. Pull the cable out from the pulley by the grip, then hold the pulley firmly and wrap the cable around it another three times.

CAUTION: Danger of injury! Secure the cable grip when pulled out! It will whip back if the cable pulley is released by accident.

NOTE: With the cable pulled all the way out, it must still be possible to turn the pulley another 1/4 turn against the return spring.

• Remove the fan housing (see above under "Replacing the starter cable").
  Take off the circlip (C/1) and washer (C/2) (circlip pliers, see "Accessories").
• Remove the cable pulley (C/3).
• Unscrew screws (C/4) and carefully remove spring housing (C/5) with spring.

CAUTION: Danger of injury! If the spring is broken it may pop out!

NOTE:

The old spring and spring housing should be recycled.

Replacement springs come already installed in a new spring housing. Before installing, grease the spring lightly with multi-purpose grease, order No. 944 360 000.

• Assemble in reverse order. When putting the cable pulley back on, turn it slightly until you feel it catch.

• Wind on the starter cable as described above under "Replacing the starter cable."

• Push the tab (D/1) extending out from the edge of the fan housing (D/3) under the hood (D/2).

• Position the screw holes.
• Push the fan housing (D/3) gently and pull the starter grip until the starter catches.
• Screw in the four fastening screws tightly.

Instructions for daily and periodic maintenance

To ensure long life, prevent damage and ensure the full functioning of the safety features the following maintenance must be performed regularly. Guarantee claims can be recognized only if this work is performed regularly and properly. Failure to perform the prescribed maintenance work can lead to accidents!

Perform the following servicing work daily after use. Make a habit of it, it does not require much time and your saw will always function properly.

Possibly hidden faults can be detected in this manner before causing expensive and annoying interruptions of your work. In case you should detect a fault in the safety equipment when performing daily servicing, the saw must not be used before elimination of the fault. The user of the chain saw must not perform maintenance work which is not described in the instruction manual. All such work must be carried out by a MAKITA service center.

Page

General	Chain saw Saw chain Chain brake Guide bar	Clean exterior, check for damage. In case of damage, have repaired by a qualified service center immediately Sharpen regulatory, replace in good time Have inspected regularly at an authorized service center Turn over to ensure even wear of bearing surfaces Replace in good time	25-26 20
Before each start	Saw chain Guide bar Chain lubrication Chain brake Chain catch OFF switch, Throttle stopper, Throttle lever Fuel/oil tank cap	Inspect for damage and sharpness Check chain tension Check for damage Functional check Functional check Check for damage Functional check Check for tightness and lekages	25 20 24 20 23-24
Dayli servicing	Air filter, prefilter Chain brake Guide bar Guide bar support Idle speed	Clean (more often if necessary) Clean, check for visible damage or cracks Clean, in particular the oil guide groove Check for damage, clean oil intake bore Check that a sufficient difference is existing between idlind speed and engaging speed, to ensure that the chain is in standstill while the engine is idling.	28 27 22 22, 27 24
Every week	Fan housing Starter cable Carburetor interior Chain brake Spark plug Muffler Chain guide	Clean to ensure proper air cooling Check for damage Clean (remove filter cover for access) Clean the brake band (sawdust, oil) Check and replace if necessary Check tightness of mounting, clean spark arrester screen Check	29 29 28 27 28 27 26
Every 3 months	Fuel filter Fuel, oil tanks	Replace Clean	27 22
Annually	Chain saw	Check at an authorized service center
Storage	Chain saw Guide bar/chain Fuel, oil tanks Carburetor	Clean exterior, check for damage. In case of damage, have repaired by a qualified service center immediately Demount, clean and oil slightly Clean the guide groove Empty and clean Run empty	26

Service, spare parts and guarantee

Maintenance and repair

The maintenance and repair of modern engines as well as all safety devices require qualified technical training and a special workshop equipped with special tools and testing devices.

We therefore recommend that you consult a MAKITA service center for all work not described in this instruction manual.

The MAKITA service centers have all the necessary equipment and skilled and experienced personnel, who can work out cost-effective solutions and advise you in all matters.

Please contact the general agent or importer indicated on the back cover of this Instruction Manual, who will gladly provide you with the address of your nearest MAKITA service center.

Spare parts

Reliable long-term operation, as well as the safety of your chain saw, depend among other things on the quality of the spare parts used. Use only original MAKITA parts, marked

Only original spare parts and accessories guarantee the highest quality in material, dimensions, function and safety.

Original spare parts and accessories can be obtained from your local dealer. He will also have the spare part lists to determine the required spare part numbers, and will be constantly informed about the latest improvements and spare part innovations.

Please bear in mind that if parts other than original MAKITA spare parts are used, this will automatically invalidate the MAKITA product guarantee.

Guarantee

MAKITA guarantees the highest quality and will therefore reimburse all costs for repair by replacement of damaged parts resulting from material or production faults occurring within the guarantee period after purchase. Please note that in some countries particular guarantee conditions may exist. If you have any questions, please contact your salesman, who is responsible for the guarantee of the product.

Please note that we cannot accept any responsibility for damage caused by:

• Disregard of the instruction manual.
  Non-performance of the required maintenance and cleaning.
  Incorrect carburetor adjustment.
  Normal wear and tear.
• Obvious overloading due to permanent exceeding of the upper performance limits.
  Use of guide bars and chains which have not been approved.
  Use of guide bar and chain lengths which have not been approved.
  Use of force, improper use, misuse or accidents.
• Damage from overheating due to dirt on the fan housing.
  Work on the chain saw by unskilled persons or inappropriate repairs.
  Use of unsuitable spare parts or parts which are not original MAKITA parts, insofar as they have caused the damage.
  Use of unsuitable or old oil.
• Damage related to conditions arising from lease or rent contracts.

Cleaning, servicing and adjustment work is not covered by the guarantee. All repairs covered by the guarantee must be performed by a MAKITA service center.

Troubleshooting

Malfunction	System	Observation	Cause
Chain does not run	Chain brake	Engine runs	Chain brake actuated.
Engine does not start or only with difficulty	Ignition system	Ignition spark	Malfunction in fuel supply system, compression system, mechanical malfunction. Switch on STOP, fault or short-circuit in the wiring, plug cap or spark plug defective.
	Fuel supply	No ignition spark
	Compression system	Fuel tank is filled	Choke in wrong position, carburetor defective, fuel filter dirty, fuel line bent or interrupted.
		Inside	Cylinder base packing ring defective, radial shaft packings defective, cylinder or piston rings defective
	Mechanical malfunction	Outside	Spark plug does not seal.
		Starter does not engage	Spring in starter broken, broken parts inside the engine.
Warm start difficulties	Carburetor	Fuel tank is filled Ignition spark	Wrong carburetor adjustment.
Engine starts, but dies immediately	Fuel supply	Fuel tank is filled	Wrong idling adjustment, fuel filter or carburetor dirty. Tank venting defective, fuel line interrupted, cable defective, STOP switch defective. Decompression valve dirty (DCS431).
Insufficient power	Several systems may be involved simultaneously	Engine is idling	Air filter or prefilter dirty, wrong carburetor adjustment, muffler clogged, exhaust channel in cylin- der clogged, spark arrester screen clogged.
No chain lubrication	Oil tank/pump	No oil on the chain	Oil tank empty. Oil guide groove dirty. Oilpump adjusting screw incorrectly adjusted.

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EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE

18" (45 cm) 3/8" 443045661 523102664

21" (53 cm) 3/8" 443 053 661 523 102 672