NAKAYAMA PRO PC4100, PC4610, PC5610 Chainsaws Instruction Manual

PC4100 – PC4610 – PC5610
ART NO: 036456 – 036463 – 036470

PRO PC4100, PC4610, PC5610 Chainsaws

CAUTION: Before using the chain saw, please read this manual carefully to understand the proper use of your unit.
Keep this manual handy.

Safety First
Instructions contained in warnings must be taken into consideration to prevent possible serious bodily injury, and for this reason, you are requested to read all such instructions carefully and follow them without fail.
Instructions contained in warnings within this manual marked with a symbol concern critical points which must be taken into consideration to prevent possible serious bodily injury, and for this reason, you are requested to read all such instructions carefully and follow them without fail.

Main parts (A1)

1. Front guard
2. Starter knob
3. Air cleaner
4. Choke knob
5. Throttle interlock
6. Right handle| 7. Throttle lever
8. Engine switch
9. Fuel tank
10. Oil tank
11. Left handle
12. Saw chain
13. Guide bar
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Warning Labels on the machine (A2)
From left to right:
Read the owner’s manual before operating this machine.
Wear head, eye, and ear protection.
Use the chainsaw with two hands.
Warning! Kickback’s danger.
Warning/Attention.
Never touch a hot surface.
Use appropriate protections for the foot-leg and hand arm.
This saw is for trained tree service operators only.

Important: If warning stickers peel off or become soiled and impossible to read, you should contact the dealer from which you purchased the product to order new seals and affix the new seal(s) in the required location(s).
Warning: Never remodel the product. We won’t warrant the machine if you use the remodeled product or you don’t observe the proper usage written in the manual.

Symbols on the machine (A3)

For safe operation and maintenance symbols are carved in relief on the machine.
a. The port to refuel the “MIX GASOLINE”.
Position: Fuel takes cap.
b. The port to refuel the “CHAIN OIL”.
Position: Oil cap.
c. The indication regarding the switch.
Flipping the engine switch to the “O” (STOP) direction, the engine stops. Position: rear-left of the unit.
d. The indication regarding the choke.
Pulling out the choke knob, the choke closes.
Position: rear-right of the unit.
e. The indication regarding the chain oil adjuster nut.
“MIN” direction –the oil flow decrease.
“MAX” direction – the oil flow increase.
Position: Bottom of the clutch side.
f. The position of the H-needle.
The position of the L-needle.
The position of the idle adjusting screw.
Position:rear-left of the unit.

Safety Precautions

Before using the machine
a. Read this owner’s manual carefully to understand how to operate this unit properly.
b. You should never use the product when under the influence of alcohol when suffering from exhaustion or lack of sleep, when suffering from drowsiness as a result of having taken cold medicine, or at any other time when a possibility exists that your judgment might be impaired or that you might not be able to operate the machine properly and in a safe manner.
c. Avoid running the engine indoors. The exhaust gases contain harmful carbon monoxide.
d. Never use the product under circumstances like those described below :

1. When the ground is slippery or when other conditions exist which might make it not possible to maintain a steady posture.
2. At night, at times of heavy fog, or at any other times when your field of vision might be limited and it would be difficult to gain a clear view of the area.
3. During rain storms, lightning storms, at times of strong or gale-force winds, or at any other times when weather conditions might make it unsafe to use this product. e. When using this product for the first time, before beginning actual work, learn to handle it from a skilled worker.
   f. Lack of sleep, tiredness, or physical exhaustion results in lower attention spans, and this in turn leads to accidents and injury.
   Limit the amount of time using the machine continues to somewhere around 10 minutes per session, and take 10-20 minutes of rest between work sessions. Also, try to keep the total amount of work performed in a single day under 2 hours or less.
   g. Be sure to keep this manual handy so that you may refer to it later whenever any questions arise.
   h. Always be sure to include this manual when selling, lending, or otherwise transferring the ownership of this product.
   i. Never allow children or anyone unable to fully understand the directions given in this manual to use this product.

Working Gear And Clothing
a. When using the product, you should wear proper clothing and protective equipment:

• Helmet
• Protection goggles or face protector
• Thick work gloves
• Non-slip sole work boots
• Ear protectors

b. And you should carry with you:

1. Attached are tools and files.
2. Properly reserved fuel and chain oil.
3. Things to notify your working area (Rope, Warning signs)
4. Whistle (for collaboration or emergency)
5. Hatchet or saw (for removal of obstacles)

c. Never use the product when wearing pants with loose cuffs, when wearing sandals, or when barefoot.

Warnings considering the handling of fuel
a. The engine of this product is designed to run on a mixed fuel that contains highly flammable gasoline. Never store cans of fuel or refill the fuel tank in any place where there is a boiler, stove, wood fire, electrical sparks, welding sparks, or any other source of heat or fire which might ignite the fuel.
b. Smoking while operating the product or refilling its fuel tank is extremely dangerous. Always be sure to keep lit cigarettes away from the product at all times.
c. When refilling the tank always turn off the engine first and take a careful look around to make sure that there are no sparks or open flames anywhere nearby before refueling.
d. If any fuel spillage occurs during refueling, use a dry rag to wipe up spills before turning the engine back on again.
e. After refueling, screw the fuel cap back tightly onto the fuel tank and then carry the product to a spot 3m or more away from where it was refueled before turning on the engine.

Before Starting Engine
Check the working place, the cutting object, and the cutting direction. if there is an obstacle, remove it. Never start cutting until you have a clear work area, secure footing, and a planned retreat path from the falling tree.
Use caution and keep bystanders and animals out of the working area whose diameter is 2.5 times of a cutting object.
Inspect the machine for worn, loose, or damaged parts. Never operate a machine that is damaged, improperly adjusted, or not completely and securely assembled. Make sure that the saw chain stops moving when the throttle control trigger is released.

When starting the engine
Always hold the machine firmly with both hands when the engine is running. Use a firm grip with thumb and fingers encircling the handles.
Keep all parts of your body away from the machine when the engine is running.
Before starting the engine, make sure the saw chain is not contacting anything.

Additional warnings
Keep the handles dry, clean, and free of oil or fuel mixture.
Never touch the muffler, spark plug, or other metallic parts of the engine while the engine is in operation or immediately after stopping the engine. Doing so could result in serious burns or electrical shock.
Use extreme caution when cutting small-size brushes and saplings because slender material may catch the saw chain and be whipped toward you or pull you off balance.
When cutting a limb that is under tension, be alert for spring back so that you will not be struck when the tension in the wood fibers is released.
Check the tree for dead branches that could fall during the felling operation.
Always turn off the engine before setting it down.

Kickback safety precautions for chain saw users
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. Tip contact in some cases may cause a lightning-fast reverse reaction, kicking the guide bar up and back toward the operator. Pinching the saw chain along the top of the guide bar may push the guide bar rapidly back toward the operator. Either of these reactions may cause you to lose control of the saw which could result in serious personal injury.
Do not rely exclusively on the safety devices built into your saw. As a chain saw user you should take several steps to keep cutting jobs free from accident or injury.

1. With a basic understanding of kickback, you can reduce or eliminate the element of surprise. Sudden surprise contributes to accidents.
2. Keep a good grip on the saw with both hands, the right hand on the rear handle, and the left hand on the front handle when the engine is running. Use a firm grip with thumbs and fingers encircling the chainsaw handles. A firm grip will help you reduce kickback and maintain control of the saw.
3. Make certain that the area in which you are cutting is free from obstructions. Do not let the nose of the guide bar contact a log, branch, or any other obstruction which could be hit while you are operating the saw.
4. Cut high engine speed.
5. Do not overreach or cut above shoulder height.
6. Follow manufacturer sharpening and maintenance instructions for the saw chains.
7. Only use replacement bars and chains specified by the manufacturer or the equivalent.

Maintenance
In order to maintain your product in proper working order, perform the maintenance and checking operations described in the manual at regular intervals.
Always be sure to turn off the engine before performing any maintenance or checking procedures.
Warning: The metallic parts reach high temperatures immediately after stopping the engine.
Leave all maintenance other than the items listed in the owner’s manual to your competent servicing dealer.
Transportation
Always carry the unit with the engine stopped, the guide bar covered with the protector to the rear, and the muffler away from your body.

Installing guide bar and saw chain
Open the box and install the guide bar and the saw chain on the power unit as follows:
Warning: The saw chain has very sharp edges. Use thick protective gloves for safety.

1. Pull the guard towards the front handle to check that the chain brake is not on.

2. Loosen the nuts and remove the chain cover.

3. Install the attached spike to the power unit.

4. Gear the chain to the sprocket and, while fitting the saw chain around the guide bar, mount the guide bar to the power unit. Adjust the position of the chain tensioner nut on the chain cover to the lower hold of the guide bar (F1). (1) Tensioner Nut, (2) Chain cover
   Pic. F40*: Remove the spiked bumper
   Release the two nuts (1), the spiked bumper is removed.
   Install the spiked bumper
   Put the spiked bumper in its position shown in the picture, and tighten the two nuts (1). The spiked bumper is fixed in its position.
   Note: Pay attention to the correct direction of the saw chain (F2).
   (1) Moving direction

5. Fit the chain cover to the power unit and fasten the nuts to finger tightness.

6. While holding up the tip of the bar, adjust the chain tension by turning the tensioner screw until the tie straps just touch the bottom side of the bar rail (F3).

7. Tighten the nuts securely with the bar tip held up (12-15N.m). Then check the chain for smooth rotation and proper tension while moving it by hand. If necessary, readjust with the chain cover lose.

8. Tighten the tensioner screw.

9. Loosen

10. Tighten

11. Tensioner screw

Note: A new chain will expand its length at the beginning of use. Check and read just the tension frequently as a loose chain can easily derail or cause rapid wear of itself and the guide bar.

Fuel And Chain Oil
Warning: Gasoline is very flammable. Avoid smoking or bringing any flame or sparks near the fuel.
Wipe up all spills before starting the engine.
Make sure to stop the engine and allow it cool before starting the engine.
Keep open flames away from the area where fuel is handled or stored.
Important: Never use oil for 4-cycle engine use or water-cooled 2-cycle engine.
Never use “FUEL WITH NO OIL (RAW GASOLINE)”.
Never use fuel laced with water.
Mixed fuel which has been left unused for a period of one month or more may clog the carburetor or result in the engine failing to operate properly. Put remained fuel into an air-tight container and keep it in a dark and cool room.
Please ask for “mixed gasoline for air-cooled 2-cycle engines” at your nearest gas station, or use fuel made by putting unlead-ed 95 octane gasoline and air- cooled 2-cycle special engine oil into a mixing container in accordance with the following ratios and then shaking to mix well.
Mixing ratios:
Use a special type 2-cycle oil (30ml of oil for each 1L of unleaded gasoline 95).
Chain oil lube
Use an appropriate chainsaw chain lube.
Note: Do not use wasted or regenerated oil that can cause damage to the oil pump.

Main operation

Warning: It is very dangerous to run a chain saw that mounts broken parts or lacks any parts. Before starting the engine, make sure that all the parts including the bar and chain are installed properly.
Starting Engine

1. Fill fuel and chain oil tanks respectively, and tighten the caps securely (F7).

2. Put the switch to the “I” position (F8).

3. Pull out the choke knob to the closed position (F9).

4. Chain oil

5. Fuel

6. Switch* not included in all models

7. Choke knob
   Note: When restarting immediately after stopping the engine, leave the choke knob in the open position.

8. While holding the saw unit securely on the ground, pull the starter rope vigorously (F10).
   Warning: Do not start the engine while hanging the chain saw with a hand. The saw chain may touch your body. It is very dangerous.

9. When the engine has ignited first, pull the throttle lever slightly to return the choke knob to the open position and pull the starter again to start the engine.

10. Allow the engine to warm up with the throttle lever pulled slightly.
    *At once pulling the throttle lever out, the choke knob is automatically returned to the operating position (not included in all models).
    Warning: Keep clear of the saw chain as it will start rotating upon starting the engine.

Checking oil supply
Warning: Make sure to set up the bar and the chain when checking the oil supply. If not, the rotating parts may be exposed. It is very dangerous.
After starting the engine, run the chain at medium speed and see if chain oil is scattered off as shown in figure (F12).
(1) Chain oil
The chain oil flow can be changed by inserting a screwdriver in the hole on the bottom of the clutch side. Adjust according to your work conditions (F13).
(1) Adjuster
Note: The oil tank should become nearly empty by the time fuel is used up. Be sure to refill the oil tank every time when refueling the unit.
Adjusting the carburetor (F14)
The carburetor on your unit has been factory adjusted but may require fine- tuning due to the change in operating conditions.
Before adjusting the carburetor, make sure that provided are clean air/fuel filters and fresh, properly mixed fuel.
When adjusting, take the following steps :
Note: Be sure to adjust the carburetor with the bar chain attached.

1. Stop the engine and screw in both H and L needles until they stop. Never force. Then set them back to the initial number of turns as shown below.
   | 4500| 5200
   ---|---|---
   H Needle| 1 ± 3/8| 1 ± 3/8
   L Needle| 1 1/4 ± 1/4| 1 1/2 ± 1/4
2. Start the engine and allow it to warm up at half-throttle.
3. Turn the L needle slowly clockwise to find a position where the idling speed is maximum, then set the needle back a quarter (1/4) turn counter-clockwise.
4. Turn idle adjusting screw (T) counter-clockwise to that the saw chain does not turn. If the idling speed is too slow, turn the screw clockwise.
5. Make a test cut and adjust the H needle for the best cutting power, not for maximum speed.
6. L needle
7. H needle
8. Idle adjusting screw

Carburetor anti-freeze mechanism
Operating the chain saw in temperatures of 0-5 0C at times of high humidity may result in ice forming within the carburetor, and this in turn may cause the output power of the engine to fail to operate smoothly.
This product has accordingly been designed with a ventilation hatch on the back of the air cleaner cover to allow warm air to be supplied to the engine and thereby prevent icing from occurring.
Under normal circumstances, the product should be used in normal operating mode, i.e., in the model to which it is set at the time of shipment. However, when the possibility exists that icing may occur, the unit should be set to operate in anti-freeze mode before use.
Warning: Continuing to use the product in the anti-freeze model even when temperatures have risen and returned to normal may result in the engine failing to start properly or in the engine failing to operate at its normal speed, and for this reason, you should always be sure to return the unit to normal operating model if there is no danger of icing occurring.

How to switch between operating modes (F16)

1. Flip the engine switch to turn off the engine.
2. Remove the air cleaner cover and remove the screen on the back of the air cleaner cover.
3. Reattach the screen right side left so the anti-icing plate is on the right. Reinstall the cover.
4. Air cleaner cover
5. Anti-icing plate
6. Screw
7. Normal operating mode
8. Anti-freeze mode
9. Screen

Warning: Continuing to use the product in the anti-freeze mode even when temperatures have risen and returned to normal may result in the engine failing to start properly or in the engine failing to operate at its normal speed, and for this reason, you should always be sure to return the unit to normal operating mode if there is no danger of icing occurring.
Note: When using the unit at times when it is snowing. We recommend that you also use a snow protector effective in preventing the air filter from freezing (F17). (1) Snow protector (not included).
Chain Brake (F18)
This brake can be operated manually with the front guard turned down to the guide bar.
To release the brake, pull up the front guard toward the front handle till the “Click” sound is heard.

1. Break (Front guard)
2. Released
3. Operated

Caution: Be sure to confirm brake operation on the daily inspection.
In case the brake is not effective, ask for expert inspection and repair.
The engine, if being kept rotated at high speed with the brake engaged the clutch, causing trouble.
When the brake is operated while in operation, immediately release your fingers from the throttle lever and keep the engine idling.

Stopping engine

1. Release the throttle level to allow the engine to idle for a few minutes.
2. Put the switch in the “O” (STOP) position (F20).
3. Switch

Sawing
Warning: Before proceeding to your job, read the “For Safe Operation ” section it is recommended to first practice sawing easy logs. This also helps you get accustomed to your unit.
Always follow the safety regulations. The chain saw must only be used for cutting wood. It is forbidden to cut other types of material. Vibrations and kickbacks vary with different materials and the requirements of the safety regulations would not be respected. Do not use the chain saw as a lever for lifting, moving, or splitting objects. Do not lock it over fixed stands. It is forbidden to hitch tools or applications to the P.T.O that are not specified by the manufacturer.
It is not necessary to force the saw into the cut. Apply only light pressure while running the engine at full throttle.
When the saw chain is caught in the cut, do not attempt to pull it out by force, but use a wedge or a lever to open the way.
Guard against kickback (F21)
It is extremely important that the chain brake is checked for proper operation before each use and that the chain be sharp in order to maintain the kickback safety level of this saw. Removal of the safety devices, inadequate maintenance, or incorrect replacement of the bar or chain may increase the risk of serious personal injury due to kickbacks.
Warning: Do not use an unstable foothold or ladder.
Do not overreach.
Do not cut above shoulder height.
Always use both hands to grip the saw.

Maintenance

Warning: Before cleaning, inspecting, or repairing your unit, make sure that the engine has stopped and is cool.
Disconnect the spark plug to prevent accidental starting.
Maintenance after each use

1. Air filter
   Dust on the cleaner surface can be removed by tapping a corner of the cleaner against a hard surface. To clean dirt in the meshes, split the cleaner into halves and brush in gasoline. When using compressed air, blow from the inside (F27).
   To assemble the cleaner halves, press the rim until it clicks.
   Note: When installing the main filter, make sure that the grooves on the filter edge correctly fit with the projections on the cylinder cover.

2. Oiling port
   Dismount the guide bar and check the oiling port for clogging (F28).
   (1) Oiling port

3. Guide bar
   When the guide bar is dismounted, remove sawdust in the bar groove and oiling port (F29).
   Grease the nose sprocket from the feeding port on the tip of the bar (F30).
   (1) Oiling port
   (2) Grease Port
   (3) Sprocket

4. Others
   Check for fuel leakage and loose fastenings and damage to major parts, especially handle joints and guide bar mounting. If any defects are found, make sure to have them repaired before operating again.

Periodical service points

1. Cylinder fins
   Dust clogging between the cylinder fins will cause overheating of the engine. Periodically check and clean the cylinder fins after removing the air cleaner and the cylinder cover. When installing the cylinder cover, make sure that switch wires and grommets are positioned correctly in place (F31).
   Note: Be sure to block the air intake hold.

2. Fuel filter
   (a) Using a wire hook, take out the filter from the filler port (F32).
   (1) Fuel filter
   (b) Disassemble the filter and wash it with gasoline, or replace it with a new one if needed.

3. Oil tank
   With a wire hook, take out the oil filter through the filler port and clean in gasoline. When putting the filter back into the tank, make sure that it comes to the front right corner. Also, clean off dirt in the tank (F33).
   (2) Oil filter

4. Spark plug (F34)
   Clean the electrodes with a wire brush and reset the gap to 0.6~0.7mm as necessary.

5. Sprocket (F35)
   Check for cracks and for excessive wear interfering with the chain drive. If the wearing is found obviously, replace it with a new one. Never fit a new chain on the worn sprocket or a worn chain on a new sprocket.

6. Front and rear dampers
   Replace if the adhered part is peeled or a crack is observed on the rubber part.

Maintenance of saw chain and guide bar
Saw chain
Warning: It is very important for smooth and safe operation to keep the cutters always sharp.
Your cutters need to be sharpened when:
Sawdust becomes powder-like.
You need extra force to see in.
The cut way does not go straight.
Vibration increases.
Fuel consumption increases.
Warning: Be sure to wear safety gloves.

Guide bar
Reverse the bar occasionally to prevent partial wear.
The bar rail should always be a square.
Check for wear of the bar rail.
Apply a ruler to the bar and the outside of a cutter.
If a gap is observed between them, the rail is normal. Otherwise, the bar rail is worn.
Such a bar needs to be corrected or replaced (F39).

Troubleshooting

Case 1. Starting failure
Make sure the icing prevention system is not working.

When your unit seems to need further service, please consult with our service shop in your area.

Technical Data

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described /illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• Please note that our equipment has not been designed for use in commercial, trade, or industrial applications. Our warranty will be voided if the machine is used in commercial, trade, or industrial businesses or for equivalent purposes.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair, or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

ART NO: 036456 – 036463 – 036470
WWW.NAKAYAMATOOLS.COM

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