Makita DUC256 Repair Manual
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- Instruction manual (96 pages) ,
- Instruction manual (145 pages)
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Summary of Contents for Makita DUC256
- Page 1 OFFICIAL USE For ASC CORDLESS CHAIN SAW 250MM(10")/ 300MM(12")/ 350MM(14")/ 400MM(16") DUC256, DUC256C/ DUC306/ DUC356/ DUC406 REPAIR MANUAL February 2020 Ver.1...
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Page 2: Table Of Contents
CONTENTS CONTENTS ....................................2 CAUTION ....................................3 NECESSARY REPAIRING TOOLS ............................3 LUBRICANT AND ADHESIVE APPLICATION ........................3 TIGHTENING TORQUE SPECIFICATIONS ..........................4 REPAIR ......................................5 Saw chain ..................................... 5 6-1-1 Disassembling ................................5 6-1-2 Assembling .................................. 5 Chain tension/ Chain Brake section ............................. 7 6-2-1 Disassembling ................................ -
Page 3: Caution
Retaining ring R-26 1R411 Push bar for lead wires fixing Lead wires LUBRICANT AND ADHESIVE APPLICATION Description Amount Makita grease FA No.2 Apply a little unless specified in the figure. Loctite 243 or ThreeBond 1342 (H) Fig. 1 3 / 32... -
Page 4: Tightening Torque Specifications
TIGHTENING TORQUE SPECIFICATIONS Tightening Parts to fasten Fastener Q'ty torque Adhesion (N∙m) Housing set ↔ Guide plate L M5x12 H. L. socket head bolt 4.0 - 6.0 Housing set ↔ Front handle 5x20 Tapping screw 1.5 - 2.0 Sprocket cover ass’y ↔ Nut cover 4x12 Tapping screw 0.8 - 1.0 * Apply the specified adhesive to M5x12 H. -
Page 5: Repair
REPAIR Saw chain 6-1-1 Disassembling Fig. 2 Remove Batteries [1] (2 pcs). Loosen Flange nut complete [2], then remove Sprocket cover ass’y [3]. Fig. 3 Lift up Saw chain section [1] and remove it. Note Disassemble the machine after cleaning wood dust etc. - Page 6 Fig. 5 Assemble Sprocket cover ass’y [2] to Housing set [1] and tighten Flange nut complete [3] lightly. Fig. 6 Adjust Drive gear [2] until Saw chain [3] fit tightly to Guide bar [1] while lifting Guide bar [1]. Fig. 7 Release the brake and use a screwdriver or the like to check that the tension of Saw chain [1] is not loose.
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Page 7: Chain Tension/ Chain Brake Section
Chain tension/ Chain Brake section 6-2-1 Disassembling Fig. 8 Pull Front hand guard complete [1] to release the brake. Tips Brake drum cannot be removed unless the brake is released and Brake band complete is widened. The brake section and Motor section cannot be disassembled unless Brake drum complete is removed. - Page 8 Fig. 11 Remove the following parts from Housing set [1]. 4x18 Tapping screws [2] (6 pcs) Spike bumper [3] Chain catcher [4] Housing R cover [5] Fig. 12 Lift up and release Compression spring 7 [2] with a slotted screwdriver [1].
- Page 9 Fig. 14 Remove M4x12 Pan head screws [2] (2 pcs) from Front hand guard complete [1], then remove Front hand guard retainer [3]. Fig. 15 Push Front hand guard retainer [1] forward and remove it while pulling it toward your side. Note Remove Compression springs 3 [2] and Hand guard guide [3] while holding them so as not to pop out.
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Page 10: Assembling
6-2-2 Assembling Fig. 16 Assemble Front hand guard complete [2] to Housing set [1]. Assemble Front hand guard retainer [3] to Front hand guard complete [2] with M4x12 Pan head screws [4] (2 pcs). Tips Apply the specified grease to the sliding portion of Front hand guard complete [2]. - Page 11 Fig. 18 Assemble Brake band complete [2] and Link plate 1R003 complete [3] to Housing set [1]. Compress Compression spring 7 [4] and assemble it to Housing set [1] with 1R003. Note Brake operation without Housing R cover causes a break of the rib of Housing set [1].
- Page 12 Fig. 20 Assemble the following parts to Housing set [1]. Grommet [2] Adjust screw [3] Tension slide [4] Straight bevel gears 14 [5] (2 pcs) Drive Gear [6] Guide plate L [7] M5x12 H. L. socket head bolt [8] ...
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Page 13: Electric Parts Section
Electric parts section 6-3-1 Disassembling Fig. 22 Remove Brake section (6-2-1). Remove M5x18 Pan head screws [2] (3 pcs) from Housing set [1]. Fig. 23 Remove 4x18 Tapping screws [1] (9 pcs) and Housing set [2]. Fig. 24 Remove Oil tube 3-100 [2] and Oil tube 3-130 [3] from Oil pump complete [1] with 1R311. - Page 14 Fig. 25 Remove the following parts from Housing set [1]. Catch lever [2] Torsion spring 10 [3] Switch lever [4] Switch C3JW-6BM-P [5] Switch units [6] (2 pcs/ 2 different type) Fig. 26 Remove the following parts from Housing set [1]. Remove Motor section by tapping the tip of Rotor [6] with a plastic hammer.
- Page 15 Fig. 27 Remove Oil tubing 3-100 [2] from Housing set [1] with 1R311. Remove Oil tube 3-130 [4] from Tank [3], then remove Spring [5] and Nipple [6]. Tips Clean up Spring [5] if wood dust is adhered. 1R311 Fig. 28 Remove Hook [2] and Hook support [3] from Housing set [1].
- Page 16 Fig. 30 Remove Rotor [2] from Stator [1] by tapping the tip with a plastic hammer. Fig. 31 Remove Retaining ring R-26 [2] from Stator [1] with 1R311. 1R311 Fig. 32 Remove Ball bearing 6000DDW [2] from Stator [1] by tapping it with a plastic hammer and 1R242. 1R242 16 / 32...
- Page 17 Fig. 33 Remove Ball bearing 696ZZ [2] from Rotor [1] with 1R269. 1R269 Fig. 34 Disconnect Connectors of Switch units [1] (2 pcs/ 2 different type). Pull out the receptacle terminals of Switch [2] and disconnect Connector. Tips Disconnect the receptacle terminal by pushing the tab of it with a slotted screwdriver.
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Page 18: Assembling
6-3-2 Assembling Fig. 36 Connect the connector and the receptacle terminals to Switch [1]. Note Connect the switch terminals (2 locations) so that the white to B1 and the red to B2. Fig. 37 Connect Flag receptacles to Terminals [1] (2 pcs). Note ... - Page 19 Fig. 39 Press-fit Ball bearing 6000DDW [2] into Stator [1] by tapping 1R030 with a plastic hammer. 1R030 Fig. 40 Assemble Retaining ring R-26 [2] to Stator [1] with 1R311 1R311. Fig. 41 Assemble Rotor [2] to Stator [1]. Note Be careful not to pinch your fingers between Stator [1] and Rotor [2].
- Page 20 Fig. 42 Assemble Stator and Motor housing [1] with M5x18 Pan head screws [2] (3 pcs). Assemble Worm gear [3] and Stop ring E-4 [4] to Motor housing [1]. Fig. 43 Assemble Spring [2] and Nipple [3] to Oil tube 3-130 [1] and insert into Tank [4].
- Page 21 Fig. 45 Assemble the following parts to Housing set [1] and fix the lead wires to Housing set [1] with 1R411. Controller [2] Switch units [3] (2 pcs/ 2 different type) Center case complete [4] Terminals [5] (2 pcs) ...
- Page 22 Fig. 47 Assemble Oil pump complete [2] to Motor housing [1] with 4x18 Tapping screw [3]. Tips Apply the specified grease to the gear portion of Oil pump complete [2]. Connect Oil tube 3-100 [4] and Oil tube 3-130 [5] to Oil pump complete [2].
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Page 23: Circuit Diagram
CIRCUIT DIAGRAM Fig. 50 Color index of lead wires' sheath White Gray Blue Green Yellow Brown Black Orange Purple 23 / 32... - Page 24 AWG14 Switch unit B (for detecting unlock-off) AWG16 Battery fuel gauge AWG22 Controller AWG24 Terminal A AWG26 Terminal B AWG28 Main switch Flag receptacle with lock (#250, t=0.8) Switch unit A (for preventing the kickback) Flag receptacle with lock (#187, t=0.8) Switch Closed end splice Circuit diagram of Switch unit A...
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Page 25: Wiring Diagram
WIRING DIAGRAM Stator section Fig. 51 Stator Stator base Magnet wires with Lead wires Be careful not to put Magnet wires with Lead wires on the protrusion (shaded area) of Stator. Pass Lead wires of Stator through this opening of Stator base. 25 / 32... -
Page 26: Switch/ Controller Section
Switch/ Controller section Fig. 52 Switch Inner wall of Housing Switch unit (for detecting unlock-off) Rib A Battery fuel gauge Fin of Controller Noise suppressor Controller Assemble Flag receptacle to Switch so that Lead wires come out in the direction shown in figure. Be careful not to put Lead wires on this Rib. -
Page 27: Main Switch Section
Main switch section Fig. 53 Main switch Switch unit (for preventing kickback) Switch Range A Put Controller lead wires of Switch unit (for preventing kickback) under this Connector. Be careful not to put Lead wires on these receptacles. Be careful not to slack Lead wires in Range A. Fix Lead wires of Switch, Lead wires of Main switch, Lead wires of Switch unit (for preventing kickback) in these Lead wire holders. -
Page 28: Closed End Splice Section
Closed end splice section Fig. 54 Closed end splice Be careful not to put Lead wires on the inner wall of Housing. Fix Lead wires (Orange, White, Blue or Purple) of Closed end splice in each Lead wire holders. Put Closed end splices in this space. 28 / 32... -
Page 29: Troubleshooting
TROUBLESHOOTING Whenever you find any trouble in your machine, first, see this list to check the machine for solution. Note for Repairing The content may vary depending on the model. Use a full charged battery which has a star mark. When Housing is disassembled, check the conditions of the electrical parts (Connectors, Lead wires, Switches, etc.), Rotor, Stator, Gear section, etc. - Page 30 Wait until the figure on Tester gets stable. Controller is in order if Tester indicates 1.0±0.1V. If Tester indicates 0V, 0.4V, 0.8V approx., Controller is broken. Replace it with a new one. 30 / 32...
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Page 31: Flowchart For Troubleshooting
Flowchart for Troubleshooting Check the items in the following flowchart in order from the top to bottom. (Description of the item is referred to CIRCUIT DIAGRAM in Fig. 50.) After corrective action, return to the start of Troubleshooting and re-check again. Symptom Cause Corrective action... - Page 32 (Continued to previous page) Three lamps of Lead wires are broken. Check Lead wires or replace Battery fuel gauge them. on each Battery light up. Controller is broken. Replace Controller. Rub marks on Stator is broken. Replace Stator. Rotor. Controller is broken. Replace Controller.