Makita DCS230T Handbuch

Continuous Rating (W)

Voltage (V) Cycle (Hz) Input Output Max. Output (W)

740

Models No.

Description

NEW TOOL

Current (A)

TECHNICAL INFORMATION

CONCEPT AND MAIN APPLICATIONS

Specification

Standard equipment

Optional accessories

Note: The standard equipment for the tool shown above may differ by country.

P 1 / 20

DCS230T/ PS-220TH

DCS231T/ PS-221TH

Engine Chain Saw 250mm

Primarily targeted at professionals who frequently prune

fruit trees or street trees, these new models have been developed

as "the lightest-in-the world*" top handle engine chain saws.

(*Note: according to our investigation, in the category of engine

chain saw and at the date of August, 2004)

Other benefits are:

Inertia chain brake

Automatic adjustable chain oiling

Easy start system

Idling start

DCS230T and PS-220TH feature no load speed of 11,500rpm whilst

DCS231T and PS-221TH feature 10,500rpm.

DCS230T and DCS231T are Makita brand models.

PS-220TH and PS-221TH are Dolmar brand models.

Chain blade 250mm (25AP-60E for carving bar or 91VG-40E for sprocket nose bar)

Guide bar (Carving bar or Sprocket nose bar)

Chain oil

Engine oil

Chain blade 250mm .......... 1 (25AP-60E for Carving bar or 91VG-40E for Sprocket nose bar)

Guide bar ........................... 1 (Carving bar or Sprocket nose bar)

Guide bar scabbard ............ 1

Wrench 13-16 .................... 1

250 (9-7/8)

22.2

Standard guide bar: mm (")

DCS230T

PS-220TH

DCS231T

PS-221TH

Specification

Model

Displacement: ml

11,500 10,500

No load speed: min-1=rpm

1/4

0.050Gauge (")

Chain blade

0.2Fuel tank capacity: l

0.74Max output: kw

2.5 (5.5)Power head weight: kg (lbs)

Pitch (")

Carving bar

Sprocket nose bar bar 3/8

0.050Gauge (")

Pitch (")

0.19Chain oil tank capacity: l

Dimensions: mm (")

Width (W)

Height (H)

Length (L)

215 (8-1/2)

202 (8)

242 (9-1/2)

[II] Disassembly/Assembly/Adjustment

1. Necessary Repairing Tools

2. Lubrication/Sealing

After you have disassembled the following parts, do lubrication or sealing as instructed below.

Needle bearing on clutch drum: Apply Makita grease N No. 2.

Spiral spring of recoil starter: Apply Makita grease N No. 2.

Engine: Apply Three bond 1215 to the contact surface between Crankcase and Cylinder.

Description Use forTool No.

Bearing Setting Tool 20-12.21R028

Retaining Ring Pliers ST-2N Disassembling/assembling kickback brake

(inertia chain brake) system

1R003

Bearing Setting Plate 12.2 Press-fitting Bearing to Crankshaft1R034

Drill Chuck Remover 111R048

Copper Round Bar 20-100 Removing Flywheel1R091

Air Tightness Tester Testing Carburetor1R127

T-type Hex Wrench 3-127 Removing/installing M4 Hex socket head bolt1R170

T-type Hex Wrench 4-130 Removing/installing M5 Hex socket head bolt1R171

1/4" Hex Shank Bit for M5 Removing Engine1R229

Bearing Extractor Removing Bearing from Crankshaft1R269

13mm Hex Socket Bit Removing/installing Clutch and Flywheel

Impact Driver (6990D, 6916D or the like)

Iron Hammer Removing Flywheel

0.3mm Thickness Gauge Fixing and adjusting Ignition coil complete

0.7mm Spark Plug Gauge Adjusting spark gap of Spark plug

2 / 20

1) Clutch can be easily removed using Impact driver without locking Spindle.

2) Do not remove Spark plug because Clutch is removed using compression resistance.

CAUTION: Be sure to turn off Engine stop switch to avoid injury from accidental engine startup.

3) Attach 13mm hex socket bit to Impact driver. Clutch is left-handed. Therefore, remove Clutch by turning the hexagonal

portion in the center of Clutch clockwise with the Impact driver. (Fig. 1)

3-1. Clutch Section

3-2. Inspection of Clutch Drum

Fig. 1 Fig. 2

Fig. 3 Fig. 4

Fig. 6

3 / 20

1) Apply Makita grease N No. 2 to the Needle bearing on

Clutch drum, and insert Clutch drum in Crankshaft.

2) Set Flat washer 8 in place so that the chamfered side of

the washer faces the engine side. (Fig. 2)

3) Assemble Clutch to Crankshaft first by turning it

counterclockwise by hand, then turning counterclockwise

for one second with Impact driver. (Fig. 1)

1) If the sprockets are dirty or worn down, clean them or

replace Clutch drum by new one. (Fig. 3)

2) At the same time, check the drive links of saw chain

for damage or wear. And if necessary, replace them

by new ones. (Fig. 4)

3-3. Oil Pump Section

DISASSEMBLY

ASSEMBLY

1) Remove Worm gear by turning counterclockwise with thin screwdriver. (Fig. 5)

2) Unscrew 4x18 Tapping screw, and remove Oil pump cover and Chain slider (L).

3) Remove two M4x12 Pan head screws. While levering up Connector a little bit,

pull off Connector and Oil tube from Oil pump. Now Oil pump can removed. (Fig. 6)

Note: Be sure to replace Oil pump entirely by new one.

4) Check if Connector and Oil tube is cracked or clogged and if Spring (oil filter) is clogged. (Fig. 6)

loosen

tighten

Flat washer 8

Fig. 5

Worm gear Connector

Oil pump

Oil tube Spring

3. Disassembly/Assembly

CAUTION: Be sure to remove gasoline and saw chain from the machine for safety before repair/ maintenance!

Refer to the instruction manual for detailed information on how to remove or adjust saw chain.

IMPORTANT: When replacing Oil pump, also replace chain oil by fresh one.

3-3. Oil Pump Section (cont.)

3-4. Adjusting the Flow of Chain Oil

Fig. 10

Fig. 11

4 / 20

The flow of chain oil can be adjusted by turning the adjusting screw on the bottom of the machine using the slotted

screwdriver portion of Wrench 13-16 supplied.

Turn clockwise to increase the flow, and counterclockwise to decrease. (Fig. 8)

3-5. Ignition System

1) Fasten two M4x12 Pan head screws, first A then B so that Worm gear does not touch Oil pump. (Fig. 7)

2) Do not forget to set Flat washer 10 in place. (Fig. 7)

3) Install Oil pump cover and Worm gear, first Oil pump cover, then Worm gear.

4) After installation of Worm gear, make sure that Worm gear can be turned easily by hand.

1) Remove Plug cap from Spark plug. Then using circuit tester, check the

electrical conduction between Plug cap spring and the ground (earth)

terminal of Ignition coil complete. If the value of electrical resistance

is about 7k ohms, the conduction is normal. (Fig. 9)

2) If there is no or unstable electrical resistance, check if Plug cap spring

is properly connected with the ignition cable of Ignition coil complete.

Lubricate the inside of Plug cap using aerosol spray lubricant, and then

pull the ignition cable and Plug cap together spring out of Plug cap

using pliers. (Fig. 10)

3) Check if Plug cap spring is properly connected with the ignition cable.

If not, connect in the correct way as described below in 4).

Also check if Plug cap is cracked. If cracked, replace it by new one.

4) Install Plug cap spring on the ignition cable of Ignition coil complete

by piercing the needle portion of the spring in the center of the cable.

While taking care not to let Plug cap spring fall off the cable, grab the

cable with pliers and pull the spring back into Plug cap. (Fig. 11)

5) Check if Plug cap spring is properly connected with the ignition cable

of Ignition coil complete using circuit tester as described above in 1).

Defective connection can cause weak or no spark at Spark plug.

INSPECTION OF PLUG CAP

Fig. 8

Fig. 7

Flat washer 10

Pan head screw

M4x12 Decrease

Increase

Fig. 9

Plug cap

Ignition coil

complete

Ignition cable

Aerosol spray

lubricant

Plug cap

Plug cap spring

Plug cap

Pull with pliers.

Pierce in the center

of ignition cable.

ASSEMBLY

Ground (earth)

terminal

3-5. Ignition System (cont.)

5 / 20

3-7. Inspection/Replacement of Stop Switch

1) Remove Plug cap, and remove Spark plug with supplied Wrench 13-16.

Note: If Spark plug is wet with fuel, wipe it off with a clean cloth and

dry Spark plug with power blower.

2) Remove carbon deposits on the center electrode and the ground

electrode of Spark plug using wire brush.

3) Adjust the spark gap to 0.6-0.7mm by inserting a 0.7mm Spark plug

gauge in the spark gap. (Fig. 12)

4) Check if the spark occurs in the spark gap as described below:

Install Plug cap on Spark plug, touch the threaded portion of the plug

to the engine block, and then pull Recoil starter rope.

5) If no spark occurs, check the electrical conduction as described above

in 1) of CHECKING PLUG CAP.

And if the conduction is normal, replace Spark plug by new one and

re-check for a spark in the spark gap.

INSPECTION OF SPARK PLUG

1) Remove Top handle cover by removing four 4x18 Tapping screws.

2) Using circuit tester, check the electrical conduction between the terminals.

Stop switch is normal if the terminals are not conducted with the engine

turnded on and conducted with the engine turned off. (Fig. 10)

INSPECTION Fig. 15

Spark gap = the distance between the center

electrode and the ground electrode

Fig. 12

0.6 - 0.7mm

Center electrode

Ground electrode

3-6. Removal/Installation of Ignition Coil Complete

1) Before removing Ignition coil complete, remove Starter case, pull Plug cap off from Spark plug and pull the ground

(earth) wire off from the terminal on Ignition coil complete. (Fig. 13)

2) Remove two M4x20 Hex socket head bolts. Now Ignition coil complete can be removed. (Fig. 14)

Note: Be careful not to lose two Spacers through which the Hex socket bolts are inserted.

REMOVAL

1) Put Spacers and Ignition coil complete in place, and pretighten M4x20 Hex socket head bolts. Do not tighten the bolts

securely in this step. Insert a 0.3mm thickness gauge between Ignition coil complete and the magnet portion of Flywheel.

Ignition coil complete will stick to the magnet portion of Flywheel. Then tighten the bolts securely.

2) Remove the thickness gauge, then turn Flywheel to make sure that Ignition coil complete does not touch Flywheel.

INSTALLATION

Fig. 14Fig. 13

Ground (earth) wireGround (earth) terminal M4x20 Hex socket head bolt (2pcs)

Spacer

(2pcs)

Flywheel

Switch

3-7. Inspection/Replacement of Stop Switch (cont.)

6 / 20

3) Using circuit tester, also check the conduction between

the engine block and the terminal connector of the

ground (earth) wire of Ignition coil complete. (Fig. 16)

At the same time, check wrong wiring, loose screws,

loose connections or broken wires.

1) Disconnect lead wires from Switch. Now Switch can be

removed by pushing from the inside of Top handle cover.

2) Route the two lead wires (black and red) under the two

fuel tube. (Fig. 17)

REPLACEMENT Fig. 17

Fig. 16

Terminal connector of

the ground (earth) wire

of Ignition coil

3-8. Disassembling/Assembling Flywheel

1) Flywheel can be removed easily with Impact driver

without locking Piston as well as Clutch. (Fig. 18)

2) Do not remove Spark plug because Clutch is removed

using compression resistance.

CAUTION: Be sure to turn off Engine stop switch

to avoid injury from accidental engine startup.

3) Attach 13mm hex socket bit to Impact driver.

Then remove Hex nut M8 by turning counterclockwise

with the Impact driver. (Fig. 19)

Note: Be sure that Hex nut M8 is right-handed.

4) Remove Flywheel by hitting Crankshaft hard with Copper

round bar 20-100 (1R091) and iron hammer. (Fig. 19)

5) Two Ratchets on Flywheel can be removed by removing

M5x12 Hex socket button bolts with T-type hex wrench

3-127 (1R170).

DISASSEMBLING

1) Install two Torsion spring 15 on Flywheel as illustrated

on Flywheel, then fasten two Ratchets to Flywheel with

Hex socket button bolts. (Fig. 20)

2) Fitting the protrusion (key) on the center hole of

Flywheel to the groove in Crankshaft, assemble Flywheel

to Crankshaft.

3) Set Spring washer 8 in place, then fasten Hex nut M8 to

Crankshaft by turning clockwise for one second using

13mm hex socket bit and Impact driver.

ASSEMBLING

Fig. 18

Fig. 19

Fig. 20

Fuel tubes

Lead wires

Turn Hex nut M8

counterclockwise.

Flywheel

1R091

3-9. Replacement of Recoil Starter Rope

7 / 20

Fig. 22

Fig. 23

Fig. 25Fig. 24

1) Remove Side handle, and separate Recoil starter assembly from

the machine.

2) If Recoil starter rope is connected with both Starter knob and Reel,

pull Starter knob to draw the rope out of Starter case and cut it.

If the rope cannot be cut, pull Starter knob to draw out the rope till

Reel rotates one turn. Then hook the rope on the U-shaped notch in

Reel as illustrated in Fig. 21, and turn Reel counterclockwise till

Spiral spring is unwound enough.

CATION: Reel rotates very fast if you release Recoil starter rope

being pulled. Be very careful not to cut your hands.

3) Unscrew Set screw, and remove Cam and Torsion spring.

4) Remove Reel while pushing Spring case so that it does not get out

of place. (Fig. 22)

5) Untie the knots at Starter knob and Reel, then remove worn rope.

DISASSEMBLING

1) If Spiral spring has been removed, first put it in place.

2) Put new Recoil starter rope through Starter case. (Fig. 23)

Note: When using a commercial rope, cut it to 750mm.

3) Tie knots at Reel and Starter knob as illustrated in Fig. 24,25.

Do not forget to install Rope stopper as illustrated in Fig. 25

before tying a knot at Starter knob.

Important: Rope stopper is not reversible when assembled to

Starter knob. Be sure to put it through Recoil starter rope as

illustrated in Fig. 25.Failure to follow this instruction can result

in broken rope.

ASSEMBLING

Fig. 21

U-shaped notch

Recoil starter rope

Spring case

Reel

Push Spring case.

Rope stopper

Starter knob

Reel

3-9. Replacement of Recoil Starter Rope (cont.)

8 / 20

4) Connect Reel with Spiral spring by

turning clockwise while tilting it

as illustrated in Fig. 26.

By rotating Reel clockwise about

half a turn, Reel will move down

to touch Spring case completely,

indicating that it has been correctly

connected with Spiral spring.

Remember the point at which Reel

moved down.

CATION: No force is required to

connect Reel with Spiral spring.

Take care not to deform Spiral

spring by forcing Reel against

Spiral spring.

5) Put Torsion spring and Cam in place, and fasten them securely

with Set screw. (Fig. 27)

Important: Reel is not correctly connected with Spiral spring

if it does not turn smoothly after secure tightening of Set screw.

Reassemble Reel to Spiral spring as described above in 4).

6) Turn Reel counterclockwise to wind up Recoil starter rope.

(Fig. 28)

7) The loose portion can be eliminated from the rope by hooking

the rope on the U-shaped notch in Reel, turning Reel clockwise

two times, then removing the rope from the U-shaped notch.

(Fig. 29)

Remark:There are two points at which Reel hooks on Spiral spring.

Therefore, turn Reel so that it moves down to touch Spring case

at the same position as it did at first in 4).

Fig. 26

Spiral spring

[Start of connecting]

[Correctly connected]

Take care not to

hook this portion

on Spiral spring.

Tilt down Reel so that this portion

can be hooked on Spiral spring.

Put in place without being

caught by Spiral spring

Lift up this portion

so that it cannot

touch Spiral spring.

Hooked on

Spiral spring

Fig. 27

Fig. 28

Fig. 29

Torsion spring Cam

3-9. Replacement of Recoil Starter Rope (cont.)

9 / 20

1) Fix the straight end of Spiral spring in the small hole on Spring case

as illustrated in Fig. 30.

Then set Spiral spring in Spring case by winding up clockwise. (Fig. 31)

2) Spiral spring is factory-lubricated with red grease. However, you may use

Makita grease N No. 2 when repairing. Apply a little amount.

Fig. 30

Fig. 31

Spring case

If Spiral Spring Gets Out of Spring Case

Spiral spring

small hole

3-10. Disassembling/Assembling Carburetor

1) Remove Cleaner case cover.

2) Remove Choke lever by unscrewing PT3x10 Tapping screw using

slotted screwdriver. (Fig. 32)

3) Remove two M5x45 Pan head screws that fasten Cleaner case and

Carburetor. Then remove Cleaner case. (Fig. 33)

Note: If the pan head screws are left on Cleaner case, Cleaner case

cannot be removed. Be sure to remove the pan head screws from

Cleaner case before separating Cleaner case from the engine block.

4) Remove two tubes, then while tilting Carburetor so that it does not touch

Throttle wire, separate Carburetor from the engine block. (Fig. 34)

REMOVING FROM ENGINE BLOCK Fig. 32

Fig. 33

Fig. 34

Choke lever

slotted screwdriver

M5x45 Pan head screw

Throttle wire

Carburetor

3-10. Disassembling/Assembling Carburetor (cont.)

10/ 20

1) Remove Diaphragm cover and Diaphragm gasket set

by unscrewing four Pan head screws.

Note: If Gasket is sticking, carefully remove it

because it is easily broken.

2) Replace Metering diaphragm if it shows any sign of

wear, wrinkles, curling or tears.

3) Controller set can be removed by unscrewing

M3x4 (+) Screw. (Fig. 35)

4) Controller set includes Control lever, Inlet needle,

Spring and Hinge pin. When repairing Controller set,

replace the four parts at a time. (Fig. 35)

Fig. 35

DISASSEMBLING & CLEANING

Control lever Spring

Inlet needle

M3x4 (+) Screw

5) Before assembling Controller set, be sure to check

Inlet needle for wear or deformation. (Fig. 36)

Hinge pin

Fig. 36

6) When installing Control lever, make sure that the upper end of Spring is correctly placed over the protrusion of

Control lever. (Fig. 37)

[Inlet needle]

GOOD WORN DOWN

Use of worn-down

Inlet needle will

result in air pressure

leakage.

Fig. 37

Control lever

[WRONG]

Metering

diaphragm

Inlet needle

Control lever

[CORRECT]

[WRONG] [WRONG]

Dust or debris on the

valve seat will result in

air pressure leakage.

The upper end of Spring

is not placed over the

protrusion of Control lever.

[WRONG]

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