Makita DUC256 Repair Manual Download

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February 2020

Ver.1

OFFICIAL USE

For ASC

CORDLESS CHAIN SAW

250MM(10")/ 300MM(12")/

350MM(14")/ 400MM(16")

DUC256, DUC256C/ DUC306/

DUC356/ DUC406

REPAIR MANUAL

Summary of Contents for DUC256

Page 1: ...February 2020 Ver 1 OFFICIAL USE For ASC CORDLESS CHAIN SAW 250MM 10 300MM 12 350MM 14 400MM 16 DUC256 DUC256C DUC306 DUC356 DUC406 REPAIR MANUAL...

Page 2: ...ion 7 6 2 1 Disassembling 7 6 2 2 Assembling 10 6 3 Electric parts section 13 6 3 1 Disassembling 13 6 3 2 Assembling 18 7 CIRCUIT DIAGRAM 23 8 WIRING DIAGRAM 25 8 1 Stator section 25 8 2 Switch Contr...

Page 3: ...the operation of the machine 3 NECESSARYREPAIRINGTOOLS Code No Description Use for 1R003 Retaining ring pliers ST 2N assembling Compression spring 7 1R026 Pipe 8 16 50 press fitting Ball bearing 696Z...

Page 4: ...Guide plate L M5x12 H L socket head bolt 1 4 0 6 0 Housing set Front handle 5x20 Tapping screw 2 1 5 2 0 Sprocket cover ass y Nut cover 4x12 Tapping screw 1 0 8 1 0 Apply the specified adhesive to M5x...

Page 5: ...is not the actual one However the removing assembling way is the same 6 1 2 Assembling Fig 4 1 Remove Guide bar case then fit Saw chain 3 to the grooves of Guide bar 1 and Sprocket 6 2 with care of t...

Page 6: ...elease the brake and use a screwdriver or the like to check that the tension of Saw chain 1 is not loose If Saw chain does not fit securely into Sprocket it may loosen And so do tension adjustment aga...

Page 7: ...s removed Fig 9 2 Remove the following parts from Housing set 1 Stop ring E 7 2 Sprocket 6 or Sprocket 9 3 O ring 10 4 Brake drum complete 5 Fig 10 3 Push Front hand guard complete 1 forward to activa...

Page 8: ...an be removed with 1R311 in accordance with Fig 13 Tips When Link plate complete 3 is fully bent the spring force is the weakest and therefor it is easy to remove Fig 13 7 Remove the following parts f...

Page 9: ...guard retainer 3 Fig 15 9 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 n...

Page 10: ...with M4x12 Pan head screws 4 2 pcs Tips Apply the specified grease to the sliding portion of Front hand guard complete 2 Fig 17 3 Assemble Hand guard guide 2 and Compression spring 3 3 to Housing set...

Page 11: ...sing R cover causes a break of the rib of Housing set 1 Therefore assemble Housing R cover in place when brake operation is carried out Tips Assemble Compression spring 7 4 with Link plate complete 3...

Page 12: ...21 8 Assemble the following parts with Front hand guard 1 is lifted and the brake is released Brake drum complete 3 O ring 10 4 Sprocket 6 5 Sprocket 9 6 Stop ring E7 7 Tips There are two types of Spr...

Page 13: ...n head screws 2 3 pcs from Housing set 1 Fig 23 3 Remove 4x18 Tapping screws 1 9 pcs and Housing set 2 Fig 24 4 Remove Oil tube 3 100 2 and Oil tube 3 130 3 from Oil pump complete 1 with 1R311 5 Remov...

Page 14: ...ever 4 Switch C3JW 6BM P 5 Switch units 6 2 pcs 2 different type Fig 26 7 Remove the following parts from Housing set 1 Remove Motor section by tapping the tip of Rotor 6 with a plastic hammer Control...

Page 15: ...then remove Spring 5 and Nipple 6 Tips Clean up Spring 5 if wood dust is adhered Fig 28 10 Remove Hook 2 and Hook support 3 from Housing set 1 Fig 29 11 Remove the following parts from Motor section M...

Page 16: ...tator 1 by tapping the tip with a plastic hammer Fig 31 13 Remove Retaining ring R 26 2 from Stator 1 with 1R311 Fig 32 14 Remove Ball bearing 6000DDW 2 from Stator 1 by tapping it with a plastic hamm...

Page 17: ...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 Fig 35 18 Pull out the receptacle te...

Page 18: ...als 1 2 pcs Note Connect Flag receptacles on the following color lead wire ends to the tabs of Terminal 1 orange to marked tab white to AS marked tab blue to marked tab Connect the other Terminal 1 as...

Page 19: ...h a plastic hammer Fig 40 6 Assemble Retaining ring R 26 2 to Stator 1 with 1R311 Fig 41 7 Assemble Rotor 2 to Stator 1 Note Be careful not to pinch your fingers between Stator 1 and Rotor 2 Tips If i...

Page 20: ...l tube 3 130 1 and insert into Tank 4 Note Assemble Spring 2 so that its clearance between each part is 0 5mm or less because Spring has a filter function Tips Apply the specified grease to the gromme...

Page 21: ...2 Switch units 3 2 pcs 2 different type Center case complete 4 Terminals 5 2 pcs Switch C3JW 6BM P 6 Note Be careful that the actuator part of Switch units 3 is easily broken by a lateral load Fig 46...

Page 22: ...gear portion of Oil pump complete 2 16 Connect Oil tube 3 100 4 and Oil tube 3 130 5 to Oil pump complete 2 Fig 48 17 Assemble Hook 1 and Hook support 2 to Housing set 3 Fig 49 18 Assemble Housing R...

Page 23: ...IT DIAGRAM Fig 50 Color index of lead wires sheath White Gray Blue Green Yellow Brown Red Black Orange Purple 1 7 1 1 1 3 3 2 2 2 3 1 7 6 5 6 9 7 6 6 4 6 8 7 7 20 16 11 10 15 12 14 13 22 21 19 18 17 2...

Page 24: ...rminal B 6 AWG28 19 Main switch 7 Flag receptacle with lock 250 t 0 8 20 Switch unit A for preventing the kickback 8 Flag receptacle with lock 187 t 0 8 21 Switch 9 Closed end splice 22 Circuit diagra...

Page 25: ...tion Fig 51 1 Stator 3 Stator base 2 Magnet wires with Lead wires 4 Be careful not to put Magnet wires with Lead wires on the protrusion shaded area of Stator 5 Pass Lead wires of Stator through this...

Page 26: ...figure 10 Be careful not to put Lead wires on this Rib 11 Fix Lead wires of Switch unit for detecting lock off in this Lead wire holder 12 Route Lead wires of Switch unit for detecting lock off betwe...

Page 27: ...careful not to slack Lead wires in Range A 8 Fix Lead wires of Switch Lead wires of Main switch Lead wires of Switch unit for preventing kickback in these Lead wire holders Fix Lead wires red and whit...

Page 28: ...on Fig 54 1 Closed end splice 2 Be careful not to put Lead wires on the inner wall of Housing 3 Fix Lead wires Orange White Blue or Purple of Closed end splice in each Lead wire holders 4 Put Closed e...

Page 29: ...at Normal speed 5 Use the following Repairing tools for diagnosing LED and Switch Repairing tools Purpose 1R402 For checking variable resistance value or electrical continuity at contact points 1R402...

Page 30: ...30 32 3 Wait until the figure on Tester gets stable 4 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...

Page 31: ...No No Yes Replace Controller Controller is broken Check Lead wires or replace them Lead wires are broken Three lamps of Battery fuel gauge on each Battery light up Controller is broken No problem Che...

Page 32: ...ace both 18V batteries with fully charged and check them again 2 If the green blinking does not disappear after replacing both 18V batteries with fully charged change the batteries to 14 4V Voltage do...

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