I’m sorry you had a bad experience, but glad to hear your getting it all fixed up. I also wanted to share a few things with you that could help you enjoy your fixed saw for a longer timeframe than your first go around. I’ll start by saying that the saw you have is severely underpowered for the kind of tasks your putting it through. I hate to say it, but while you followed the instructions, there is also a lot of things that were done (I don’t want to say wrong) but certainly could have been done differently . I’m not trying to pick on you or make you feel bad, just trying to share some info in a learning moment and potentially preventing the same thing from happening again.
1.) big wood like you cut (4’ diameter hardwood) while it can be done with a smaller saw it does create a lot of extra drag and really works the saw out, and your better suited to upsize if your going to do much more of that kind of cutting as it can cause over heating
2.) milling is extra tough on saws and will shorten the life of any saw in any size when used consistently in that manor compared to making standard cross cuts. This is because your cutting parallel to the grain instead of perpendicular to it. I’m sure you noticed the chips looking more noodle like instead of like actual chips. One other thing that likely worked against you I s that the grind angle on standard chain vs ripping or milling chain is quite different. Ripping chain has a much more shallow angle to it so as to not bite into the wood as much causing the saw to be overworked. Here is a link with good info:
http://www.madsens1.com/bnc_rip.htm
3.) new epa saws in general run hotter than older pre epa saws, therefor they can suffer over heating easier especially when used in the ways you used it.
4.) warming the saw up before use is very important too before getting into cutting. Anything that heats up expands, so if you start the saw and get right into some wood your piston can/will actually change shape becoming oval as it heats up causing scoring on piston, cylinder or both. This expansion typically happens on exhaust side first as that’s where the heat is at.
5.) sharp chain is critical to saw performance and the life of a saw. While one might sharpen chain after every use, it may be that your angles, gullet depth or rakers are off. It’s all about the geometry and not just the going through the motions of filing if that makes sense. There are many ways to sharpen a chain and much of that info and tooling gizmos are completely useless and will lead you astray while some is completely invaluable. For example DO NOT count your filing strokes and do equal strokes on each tooth, that will screw you big time. Filing is an art and something all saw owners should strive to master. If you happen find yourself on you tube trying to learn to file a chain BE CAREFUL there is lots of bad info out there. I highly recommend
Buckin Billy Ray’s channel as he’s a logger/tree man and he explains filing in a very understandable way geared to help people understand the science who might not have much time on a saw but want to learn right the first time. It’s far easier to share a video than explain the process on here so have a look at some of his filing videos.
I hope some or all of this helps you and I hope your next go around with the saw is a much better experience.