Makita DCS540 Manuel utilisateur

1

Owner’s and Safety Manual

for Gasoline Chain Saws (page 2 - 32)

Manuel d’emploi et de sécurité

de tronçonneuses thermiques (page 33 - 63)

WARNING!

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

Improper use can cause serious injury!

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

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

ATTENTION!

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

incorrecte de la tronçonneuse peut entraîner des blessures graves! Conservez avec soin ce manuel!

Les gaz d’échappement émis par ce produit contiennent des produits chimiques connus par l’Etat de

Californie pour provoquer le cancer, des défauts de naissance ou autres dommages de reproduction.

Lisez et comprenez ce manuel.

DCS430, DCS431

DCS520, DCS520i

DCS540

DCS5200, DCS5200i

2

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE

MAKITA U.S.A, Inc warrant to the initial retail purchaser and each subsequent owner, that this utility equipment was designed, built,

and equipped to conform at the time of initial sale to all applicable regulations of the U.S.

Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause

this engine to fail to conform with EPA regulations during its warranty period.

For the components listed under PARTS COVERED, the service dealer authorized by MAKITA will, at no cost to you, make the

necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations.

EMISSION COMPONENT DEFECT WARRANTY PERIOD

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

PARTS COVERED

Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require

scheduled maintenance and are warranted up to the first scheduled replacement point for that part.

Fuel Metering System Ignition System

Carburetor and internal parts Spark plugs

Fuel filter, if applicable Flywheel Magneto

Throttle stopper, if applicable Ignition Coil

Choke System, if applicable

Air Induction System Miscellaneous Items Used in Above Systems

Pre filter, if exist Fuel hoses, clamps and sealing gaskets

Air filter, Air cleaner case, Intake manifold

OBTAINING WARRANTY SERVICE

To obtain warranty service, take your engine to the nearest MAKITA Factory Service Center or service Center authorized by

MAKITA. Bring your sales receipts indicating date of purchase for this engine. The dealer of service authorized by MAKITA will

perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order.

All parts and accessories replaced under this warranty become the property of MAKITA.

WHAT IS NOT COVERED

• Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by

MAKITA during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required

maintenance services.

• The replacement parts used for required maintenance services.

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

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

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

OWNER’S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.

MAKITA recommends that you retain all receipts covering maintenance on your engine, but MAKITA cannot deny warranty solely

for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should

however be aware that MAKITA may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper

maintenance or unapproved modifications.

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

If you have any questions regarding your warranty rights and responsibilities, you should contact the MAKITA Warranty service

Department at 1-888-OPE-PART for the information.

THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY:

MAINTENANCE AND REPAIRS

You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the

performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred

to each subsequent owner of the engine. MAKITA reserves the right to deny warranty coverage if the engine has not been properly

maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep

maintenance records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY

ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE

DEALER AUTHORIZED BY MAKITA. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY

TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A

BEARING ON THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by MAKITA are used for maintenance replacements or for the repair of components affecting

emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts

authorized by MAKITA in their performance and durability.

HOW TO MAKE A CLAIM

All repair qualifying under this limited warranty must be performed by a service dealer authorized by MAKITA. In the event that any

emission-related part is found to be defective during the warranty period, you shall notify MAKITA Warranty service Department at

1-888-OPE-PART and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair

can be performed.

3

The MAKITA DCS430, DCS431, DCS520, DCS520i, DCS540, DCS5200, DCS5200i will be delivered in a

protective cardboard box to prevent transport damage. Cardboard is a basic raw material and is consequently

reuseable or suitable for recycling (waste paper recycling).

WARNING !

Careless or improper use of this product can cause serious or even fatal injury.

Before operating a chain saw or other MAKITA products it is important that you read, fully understand and

carefully follow the instructions outlined in this owners manual. Kickback may cause severe or fatal injury and

is one of many potential dangers in operating a chain saw. Kickback and other safety related precautions are

described in detail within this owners manual. Additional owners manuals are available from MAKITA U.S.A.,

INC., 14930-C Northam Street, La Mirada, CA 90638-5753, USA, Telephone: (714) 522 80 88 and MAKITA

CANADA INC.,1950 Forbes Street, Whitby, Ontario, L1N 7B7, Canada, Telephone: (905) 571 22 00.

RE Y

Contents Page

Delivery inventory 4

Symbols 4

Safety precautions 5-16

Denomination of components 17

Technical data 18

Approved bar and chain combinations 18

Mounting the guide bar and saw chain 19-20

Chain brake 20

Fuel / Refuelling 21-22

Adjusting the chain lubrication 22

Starting the engine 23

Stopping the engine 23

Checking the chain brake 24

Checking the chain lubrication 24

Adjusting the carburetor 24

Working in winter 25

Contents Page

Sharpening the saw chain 25-26

Cleaning the guide bar 26

Cleaning the brake band and sprocket interior 27

Replacing the saw chain 27

Replacing the fuel filter 27

Replacing / cleaning the spark arrester screen 27

Cleaning the air filter 28

Replacing the spark plug 28

Replacing the starter cable 29

Replacing the return spring 29

Mounting the fan housing 29

Instructions for daily and periodic maintenance 30

Service, spare parts and guarantee 30-31

Troubleshooting 31

Extract from the spare parts list 32

Adress list 64

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

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

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

Z62.3-96 chain saw kickback standard.

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

engine exhaust system fire ignition

suppression”

With the purchase of this chain saw you have chosen a German quality product. Important instructions for the

assembly and operation of this saw are given in this manual. For your own safety, we ask you to read the accident

prevention instructions very carefully before putting your chain saw into operation, as incorrect handling can,

despite all precautions, lead to accidents. With a little care and attention you will have good service and lasting

satisfaction from this first-rate product. The following industrial property rights apply: US 4465440, US 5411382,

EP 0236858, EP 0560201, GBM 8710075, GBM 8809928, GBM 9203378, GBM 29616652.

4

Delivery inventory

Symbols

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

In case one of the parts listed should not be included in the

delivery inventory, please consult your sales agent.

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

1

3

2

4

5

7 6

1 Chain saw

2 Saw chain

3 Guide bar

4 Chain protection cover

5 Universal wrench

6 Wrench

7 Screw driver for carburetor adjustment

(only in delivery for model DCS5200i, DCS5200)

8 Owner’s and Safety Manual (not shown)

5

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 main-

tenance instructions for the saw chain.

F. 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. 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.

6

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 dan-

gerous. 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 un-

derstands the information given.

Proper use of a chain saw involves

1. the operator

2. the saw

3. the use of the saw.

45M6

Chain Saw listed in accordance with

American National Standard Safety

Specifications for Gasoline Powered

Chain Saws (ANSI B 175.1-1991).

Compliance with

CSA -Standards

Discription of symbols used on chain

saws:

Z 62.1-95 and

Z 62.3-96

Class 1A

ANSI B175.1-1991

Compliance with

ANSI -Standards

MaximumComputed Kickback Angle

(CKA)* with using the chain brake when

using the recommended bar and chain

combinations (In this example the CKA is 40°).

WARNING !

Prolonged use of chain saws exposing the operator

to vibrations may produce Whitefinger disease

(Raynaud’s phenomenon). This phenomenon

reduces the hand’s ability to feel and regulate

temperature, produces numbness and burning

sensations and may cause nerve and circulation

damage and tissue necrosis.

All MAKITA saws are therefore provided with an

antivibration system which is essential for those

using chain saws on a regular or sustained basis.

Antivibration systems do not guarantee that you will

not sustain Whitefinger disesase, however, they

reduce this danger considerably. Nevertheless,

continual and regular users should observe their

hands and fingers and in case of any abnormal

symptoms, seek medical advice immediately.

2

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.

Always use two hands when

operating the chain saw!

* 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.

Reduced Kickback Bar and

Chain combination that has been

evaluated with the power head

to achieve kickback protection

(according to ANSI and CSA

standards).

XXX.YYY.ZZZ

7

3

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.

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.

4

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.

Wear protective helmet,

eye and ear protection!

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.

8

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).

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 be-

cause you may lose control of the saw (fig. 6).

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 out-

doors. 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).

6a

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 semi-

throttle 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.

5

10 feet

9

Important adjustments

WARNING!

At correct idle speed, chain should not turn. For di-

rections to adjust idle speed, see the appropriate

section of this instruction manual.

Do not use a saw with incorrect idle speed adjust-

ment. 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 slip-

ping on freshly debarked logs.

Cutting instructions

Always hold the saw firmly with both hands when the

engine is running. Place your left hand on the tubular

handle and your right hand on grip and throttle lever.

Left-handers should follow these instructions too.

8

7

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.

Wrap your fingers tightly around the handles, keeping

the handles cradled between your thumb and forefin-

ger (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.

10

Position the chain saw in such a way that your body is

clear of the cutting attachment whenever the engine is

running (fig. 10).

Don’t put pressure on the saw when reaching the end

of a cut. The pressure may cause the bar and rotating

chain to pop out of the cut or kerf, go out of control and

strike the operator or some other object. If the rotating

chain strikes some other object a reactive force (see

pages 11 to 13 ) may cause the chain to strike the

operator.

Reactive forces during the cut, including kickback

WARNING!

Reactive forces, that may occur during any cut are

kickback, pushback and pull-in. Reactive forces

can be dangerous! In any chain saw, the powerful

force used to cut wood can be reversed (and work

against the operator).

If the rotating chain is suddenly stopped by contact

with any solid object like a log or branch or is

pinched, the reactive forces instantly occur. These

reactive forces may result in loss of control which

may, in turn, cause serious or fatal injury. An

understanding of the causes of these reactive

forces may help you avoid loss of control.

The most common reactive forces are

- kickback,

- pushback,

- pull-in.

In order to keep control of your saw, always maintain

a firm foothold. Never work on a ladder, in a tree or on

any other insecure support. Never use the saw above

shoulder height (fig. 9).

9

10

11

Many factors influence the occurence and force of

the kickback reaction. The type of bar and saw chain

you use is a factor in the force of the kickback reaction.

The speed of contact at which the cutter contacts

the object.

Kickback force increase with the rate of impact.

The contact angle between the nose of the bar

and the foreign object (fig. 11).

Kickback is most pronounced in the upper quadrant

of the bar nose.

MAKITA chain types are designed to reduce kickback

forces.

The depth gauges:

Improper lowering of the depth gauges also increases

the risk of a kickback.

Saw chain cutter sharpness:

WARNING!

A dull improperly sharpened chain may increase

the risk of kickback. Always cut with a properly

sharpened chain.

Devices for reducing the risk of kickback injury

MAKITA have developed a special chain brake to

reduce the risk of kickbacks.

This chain brake increases the safety factor on the

job, e.g. when the saw suddenly bucks upwards the

chain stops rotating within a fraction of a second. A

deflection guard on the disengaging lever of the chain

brake and a scoop rear handle ensure that the opera-

tor’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.

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.

13

12

13

45°

= cutting down area

2

1

2

First clear the tree base and work area from inter-

fering limbs and brush and clean its lower portion an

axe (see fig. 18).

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:

45°

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.

17

18

19

Then, determine the placement of the felling notch

(fig. 21). The felling notch when properly placed de-

termines 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.

1/10∅

1/5∅

1

/

2

"

(4cm)

Felling notch

Hinge

Felling cut

Direction of fall

Hinge

Felling notch

First cut

Second cut

If the tree has large buttress roots, cut into the largest

buttresses vertically first (horizontally next) and re-

move (fig. 20).

20

21

22

23

14

Begin the felling cut slighty higher than the felling

notch and on the opposite side of the tree (fig. 22).

Then cut horizontally through towards the felling notch.

Apply the chain saw with its spikes directly behind the

uncut portion of wood and cut toward the notch (fig.

23). Leave approximately 1/10 of the tree diameter

uncut! This is the hinge (fig. 23). Do not cut through the

hinge because you could lose control of the direction

of the fall. Drive wedges into the felling cut where

necessary to control the direction of the fall. Wedges

should be of wood, light alloy or plastic - never of steel,

which can cause kickback and damage to the chain.

Always keep to the side of the falling tree. When the

tree starts to fall, shut off the engine, withdraw the bar

and walk away on the pre-planned escape path.

Watch out for falling limbs.

WARNING!

Be extremely careful with partially fallen trees which

are poorly supported.

When the tree hangs or for some other reason does

not fall completely, set the saw aside and pull the

tree down with a cable winch, block and tackle or

tractor. If you try to cut it down with your saw, you

may be injured.

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.

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.

24

Plunge-Cut Method

Timber having a diameter more than twice the length

of the guide bar reauires the use of the plunge-cut

method before making the felling cut.

First, cut a large, wide notch. Make a plunge cut in the

center of the notch.

The plunge cut is made with the guide bar nose. Begin

the plunge cut by applying the lower portion of the

guide bar nose to the tree at an angle (fig. 25). Cut until

depth of the kerf is about the same as the width of the

guide bar (fig. 26). Next, align the saw in the direction

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)

25

26

27

28

1

23

15

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.

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.

29

30

Bucking

Bucking is cutting a log into sections.

16

17

Denomination of components

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)

Indicate when ordering spare parts!

13

25

21

2223

24

18

20

19

17

16

32

1

5

7

6

12

4

8

14

15

11

10

9

DCS5200

21" (530mm)

0405 123456

443.053.661

027.100. 653

523.102.672

22045 Hamburg,Germany

Serial no.

Year of manufacture

Identification plate

(example model DCS5200)

18

Stroke volume cu. in 2.7 (43 cm

3

) 3.2 (52 cm

3

) 3.3 (54 cm

3

) 3.2 (52 cm

3

)

Bore inch 1.57 (40 mm) 1.73 (44 mm) 1.77 (45 mm) 1.73 (44 mm)

Stroke inch 1.34 (34 mm) 1.34 (34 mm) 1.34 (34 mm) 1.34 (34 mm)

Max. power at speed kW / rpm 2.0 / 9,000 2.4 / 9,000 2.2 / 9,000 2.7 / 9,000

Max. torque at speed Nm / rpm 2.4 / 6,000 2.9 / 6,000 3.0 / 6,000 3.1 / 6,000

Idling speed rpm 2,500 2,500 2,500 2,500

Coupling speed rpm 3,600 3,600 3,600 3,600

Sound Pressure Level at the operator’s ear

at full load according to ANSI B 175.1 db(A) 102 102 102 102

Sound Pressure Level at the bystander’s position

(50ft/15 m distance) according to ANSI B 175.1

db(A) 75 75 75 75

Carburetor (for CANADA) Type Walbro WT 465

TILLOTSON HU 116

Walbro WT 465

1)

Carburetor (for USA) Type Walbro WT 465

TILLOTSON HU 116

Walbro WT 465

1)

Ignition system Type electronic electronic electronic electronic

Spark plug Type BOSCH WSR 6F BOSCH WSR 6F BOSCH WSR 6F BOSCH WSR 6F

Electrode gap inch .020 .020 .020 .020

or spark plug Type NGK BPMR 7A NGK BPMR 7A NGK BPMR 7A NGK BPMR 7A

Fuel consumption at max. load kg/h 0.90 1.08 1.30 1.21

Specific consumption at max. load g/kWh 450 450 590 450

Fuel tank capacity oz 18.6 18.6 18.6 18.6

Chain oil tank capacity oz 9.3 9.3 9.3 9.3

Mixture ratio (fuel/two-stroke oil) see chapter "Fuel"

Chain brake Engages manually or in case of kickback.

Weight

(fuel tank empty, without chain and guide bar) 10 lbs 10 lbs 10 lbs 2 oz 10 lbs 2 oz

1)

DCS5200 = Walbro WT 465 / DCS5200i = TILLOTSON HU 116

Technical data

DCS520 / 520i DCS540 DCS5200 / 5200i

DCS430 / 431

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 SAW CHAIN

length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664

16" (40 cm) .325" 445 040 631 523 085 666

18" (45 cm) .325" 445 045 631 523 085 672

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

Models DCS520, DCS520i, DCS540, DCS5200, DCS5200i

GUIDE BAR SAW CHAIN

length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664

16" (40 cm) .325" 445 040 631 523 085 666

18" (45 cm) .325" 445 045 631 523 085 672

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

18" (45 cm) 3/8" 443 045 661 523 102 664

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

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

Guide bar and saw chain combinations meeting kick-

back requirements of CSA Z62.3-96 for the use in

CANADA

Models DCS430, 431, 520, 520i, 540 and DCS5200, 5200i

GUIDE BAR SAW CHAIN

length pitch part no. part no.

15" (38 cm) .325" 445 038 631 523 085 664

16" (40 cm) .325" 445 040 631 523 085 666

18" (45 cm) .325" 445 045 631 523 085 672

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

15" (38 cm) 3/8" 443 038 651 522 094 656

18" (45 cm) 3/8" 443 045 651 522 094 664

21" (53 cm) 3/8" 443 053 651 522 094 672

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

Approved bar and chain combinations

"Low-kickback saw chain is a chain which has met the kickback performance requirements of ANSI B 175.1-1991

(American National Standard for Power Tools-Gasoline-Powered Chain Saws-Safety Requirements) when tested on the

representative sample of chain saws below 3.8 c.i.d. specifed in ANSI B 175.1-1991". The approved bar and chain

combinations are low kickback chains according to ANSI B 175.1-1991 and also meet the kickback requirements of

CSA Z62.3-96 for chains saws below 80 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.

19

CAUTION: Before doing any work on the guide bar or

chain, always switch off the engine and pull

the plug cap off the spark plug (see "Replacing

the spark plug"). Always wear protective gloves!

CAUTION: Start the chain saw only after having assem-

bled it completely and inspected!

PUTTING INTO OPERATION

A

- Always release the chain brake before removing or

replacing the sprocket guard (B/4). To do so, pull the hand

guard (A/1) towards the tubular handle (A/2) until you feel

it catch.

E

F

10

8

11

- 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!

- 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.

10

12

Mounting the guide bar and saw chain

Use the universal wrench delivered with the chain saw for the

following work.

Put the chain saw on a stable surface and carry out the

following steps for mounting the guide bar and chain:

2

1

B

3

STOP

C D

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

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

- 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.

4

8

9

6

7

- Unscrew retaining nuts (B/3).

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

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

properly.

5

20

- 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.

- 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.

J

L

1

2

3

I

6

G

6

H

4

3

Tightening the saw chain

- Slightly lift the end of the guide bar and turn the chain

adjusting screw (I/6) to the right (clockwise) until the chain

rests against the bottom side of the guide bar.

- While still holding up the tip of the guide bar, tighten the

retaining nuts (H/3) with the universal wrench.

STOP

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.

Chain brake

K

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