Duc256 WW
Duc256 WW
Duc256 WW
For ASC
REPAIR MANUAL
February 2020
Ver.1
1 CONTENTS
1 CONTENTS ................................................................................................................................................................................. 2
2 CAUTION .................................................................................................................................................................................... 3
3 NECESSARY REPAIRING TOOLS ........................................................................................................................................... 3
4 LUBRICANT AND ADHESIVE APPLICATION ...................................................................................................................... 3
5 TIGHTENING TORQUE SPECIFICATIONS ............................................................................................................................ 4
6 REPAIR ........................................................................................................................................................................................ 5
6-1 Saw chain ............................................................................................................................................................................. 5
6-1-1 Disassembling ............................................................................................................................................................. 5
6-1-2 Assembling.................................................................................................................................................................. 5
6-2 Chain tension/ Chain Brake section ..................................................................................................................................... 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/ Controller section .................................................................................................................................................. 26
8-3 Main switch section ........................................................................................................................................................... 27
8-4 Closed end splice section ................................................................................................................................................... 28
9 TROUBLESHOOTING ............................................................................................................................................................. 29
9-1 Note for Repairing ............................................................................................................................................................. 29
9-2 Test for checking the short-circuit in FET (Field Effect Transistor) of controller .............................................................. 29
9-3 Flowchart for Troubleshooting........................................................................................................................................... 31
2 / 32
2 CAUTION
Repair the machine in accordance with "Instruction manual" or "Safety instructions".
Follow the instructions described below in advance before repairing:
Wear gloves.
In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what the parts are.
It is also recommended to have boxes ready to keep disassembled parts by group.
Handle the disassembled parts carefully. Clean and wash them properly.
Remove Batteries, except when they are necessary to check the operation of the machine.
Fig. 1
3 / 32
5 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 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 M5x12 H. L. socket head (4 LUBRICANT AND ADHESIVE APPLICATION).
For screws except above, see Repair basic manual, Chapter 2.
4 / 32
6 REPAIR
6-1 Saw chain
6-1-1 Disassembling
Fig. 2
1 Remove Batteries [1] (2 pcs).
[1] [2]
[1]
[2]
[3]
[1]
Fig. 3
3 Lift up Saw chain section [1] and remove it.
Note
Disassemble the machine after cleaning wood dust
etc. with a brush and an air duster.
Guide bar in all photos is not the actual one.
However, the removing/ assembling way is the
[1]
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]
[5] with care of the orientation in accordance with the
[2] picture shown on Sprocket cover.
Tips
[3] Pick up the top side of Guide bar [1] and swing the
[4] [1] rear side. Saw chain [3] can be fit into the groove of
Guide bar [1].
Adjust Drive gear [5] to put the hook of Tension
slide [4] into the lower hole of Guide bar [1].
[1]
[3]
5 / 32
Fig. 5
2 Assemble Sprocket cover ass’y [2] to Housing set
[1] and tighten Flange nut complete [3] lightly.
[3]
[2]
[1]
Fig. 6
3 Adjust Drive gear [2] until Saw chain [3] fit tightly
[1] to Guide bar [1] while lifting Guide bar [1].
[3]
[1]
[2]
[3]
Fig. 7
4 Release the brake and use a screwdriver or the like
to check that the tension of Saw chain [1] is not
[1] loose. If Saw chain does not fit securely into
Sprocket, it may loosen. And so, do tension
adjustment again.
Note
Tighten Flange nut [2] while pushing the top of Guide
bar case [3] to the workbench and lifting up the
machine body.
[3]
[2]
6 / 32
6-2 Chain tension/ Chain Brake section
6-2-1 Disassembling
Fig. 8
1 Pull Front hand guard complete [1] to release the
brake.
Tips
Brake drum cannot be removed unless the brake is
[1] released and Brake band complete is widened.
The brake section and Motor section cannot be
disassembled unless Brake drum complete is
removed.
Fig. 9
2 Remove the following parts from Housing set [1].
Stop ring E-7 [2]
[2] Sprocket 6 or Sprocket 9 [3]
[3]
O ring 10 [4]
[3]
Brake drum complete [5]
[2]
[4]
[5]
[5]
[1]
Fig. 10
3 Push Front hand guard complete [1] forward to
activate the brake.
Note
[1] The brake operation after removing Housing R cover
[5] may cause the damage, therefore, be sure to
[5] activate the brake to stretch Compression spring 7
before removing Housing R cover [5].
[4]
[3]
[2]
7 / 32
Fig. 11
5 Remove the following parts from Housing set [1].
4x18 Tapping screws [2] (6 pcs)
[5] Spike bumper [3]
[1] Chain catcher [4]
[3] Housing R cover [5]
[2]
[4]
Fig. 12
6 Lift up and release Compression spring 7 [2] with a
slotted screwdriver [1]. Also, it can be removed
with 1R311 in accordance with Fig. 13.
[3]
Tips
[1] [2]
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 from Housing set [1]
1R311 with 1R311.
Drive gear [2]
[7]
[8] Straight bevel gears 14 [3] (2 pcs)
Tension slide [4]
Adjust screw [5]
[7] [6] [1]
Grommet [6]
Compression spring 7 [7]
[2] Link plate complete [8]
[4] Brake band complete [9]
[3]
[9]
[5]
[2]
[4]
8 / 32
Fig. 14
8 Remove M4x12 Pan head screws [2] (2 pcs) from
[1] Front hand guard complete [1], then remove Front
hand guard retainer [3].
[2]
[3]
[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
[4] [1] guide [3] while holding them so as not to pop out.
[3]
[2]
9 / 32
6-2-2 Assembling
Fig. 16
1 Assemble Front hand guard complete [2] to
[2] Housing set [1].
[1]
2 Assemble Front hand guard retainer [3] to Front
hand guard complete [2] with M4x12 Pan head
[4] screws [4] (2 pcs).
[2]
Tips
[3]
Apply the specified grease to the sliding portion of
Front hand guard complete [2].
[3]
Fig. 17
3 Assemble Hand guard guide [2] and Compression
spring 3 [3] to Housing set [1].
[1] [2]
Tips
Push Compression spring 3 [3] to the bottom with a
slotted screwdriver.
Apply the specified grease to the tip of Hand guard
[3] guide [2].
[2]
10 / 32
Fig. 18
4 Assemble Brake band complete [2] and Link plate
1R003 complete [3] to Housing set [1].
Note
Brake operation without Housing R cover causes a
[4] break of the rib of Housing set [1]. Therefore,
assemble Housing R cover in place when brake
operation is carried out.
[2] Tips
Assemble Compression spring 7 [4] with Link plate
complete [3] bent fully.
Apply the specified grease to Link plate complete
[3] and Compression spring 7 [4].
[1]
Fig. 19
6 Assemble Housing R cover [2] to Housing set [1]
with 4x18 Tapping screws [3] (4 pcs).
[1] [4]
[2]
[3]
11 / 32
Fig. 20
7 Assemble the following parts to Housing set [1].
[1]
Grommet [2]
[7] Adjust screw [3]
[9]
[2] Tension slide [4]
[4]
Straight bevel gears 14 [5] (2 pcs)
[6]
Drive Gear [6]
[8] Guide plate L [7]
M5x12 H. L. socket head bolt [8]
[5] [11] Spike bumper [9]
[10]
Chain catcher [10]
5x20 Tapping screws [11] (2 pcs)
[6] Note
[4] Assemble Chain catcher [10] all the way to the dotted
[3]
line shape of Housing set [1].
Apply the specified adhesive to M5x12 H. L. socket
head bolt [8].
Fig. 21
8 Assemble the following parts with Front hand
guard [1] is lifted and the brake is released.
[1] Brake drum complete [3]
[2]
O ring 10 [4]
Sprocket 6 [5]/ Sprocket 9 [6]
Stop ring E7 [7]
[7]
[7] Tips
There are two types of Sprockets and they have
different shapes on their front and back. However,
[3] each orientation does not matter.
[5]
Apply the specified grease to the two flat sides of
Sprocket.
When it is difficult to assemble Stop ring E-7 [7],
[7] [4] Rotor is moved to the bottom with the clearance on
[5] the axial direction, so move out the shaft by tapping
[3] [6] Housing set with a plastic hammer.
[5]
12 / 32
6-3 Electric parts section
6-3-1 Disassembling
Fig. 22
1 Remove Brake section (6-2-1).
[1] [2]
2 Remove M5x18 Pan head screws [2] (3 pcs) from
Housing set [1].
Fig. 23
3 Remove 4x18 Tapping screws [1] (9 pcs) and
Housing set [2].
[2] [1]
Fig. 24
4 Remove Oil tube 3-100 [2] and Oil tube 3-130 [3]
from Oil pump complete [1] with 1R311.
[1] [1]
[5]
[4] [2]
[2]
13 / 32
Fig. 25
6 Remove the following parts from Housing set [1].
Catch lever [2]
Torsion spring 10 [3]
Switch lever [4]
[6]
Switch C3JW-6BM-P [5]
Switch units [6] (2 pcs/ 2 different type)
[4]
[6]
[3]
[1] [5]
[2]
[6]
Fig. 26
7 Remove the following parts from Housing set [1].
[3] Remove Motor section by tapping the tip of Rotor
[6] with a plastic hammer.
[1]
[6] Controller complete [2]
Terminals [3] (2 pcs)
Center case complete [4]
Motor section [5]
[4]
[3]
[5]
[2]
[1]
14 / 32
Fig. 27
8 Remove Oil tubing 3-100 [2] from Housing set [1]
with 1R311.
[1]
9 Remove Oil tube 3-130 [4] from Tank [3], then
[2] remove Spring [5] and Nipple [6].
Tips
1R311 Clean up Spring [5] if wood dust is adhered.
[4]
[5]
[6] [4]
[3]
Fig. 28
10 Remove Hook [2] and Hook support [3] from
[1] Housing set [1].
[3] [2]
[2]
Fig. 29
11 Remove the following parts from Motor section.
M5x18 Pan head screws [1] (3 pcs)
[4] Stop ring E-4 [2]
Worm gear [3]
Motor housing [4]
[3]
[2]
[1]
15 / 32
Fig. 30
12 Remove Rotor [2] from Stator [1] by tapping the tip
with a plastic hammer.
[2]
[1]
Fig. 31
13 Remove Retaining ring R-26 [2] from Stator [1]
with 1R311.
1R311
[1]
[2]
Fig. 32
14 Remove Ball bearing 6000DDW [2] from Stator
[1] by tapping it with a plastic hammer and 1R242.
1R242
[1]
[2]
16 / 32
Fig. 33
15 Remove Ball bearing 696ZZ [2] from Rotor [1]
with 1R269.
[2] [1]
1R269
[2]
Fig. 34
16 Disconnect Connectors of Switch units [1] (2 pcs/ 2
different type).
[1]
17 Pull out the receptacle terminals of Switch [2] and
disconnect Connector.
[1]
Tips
Disconnect the receptacle terminal by pushing the tab
of it with a slotted screwdriver.
[2]
Fig. 35
18 Pull out the receptacle terminals of Terminals [1] (2
pcs).
Tips
Disconnect the receptacle terminal by pushing the tab
of it with a slotted screwdriver.
[1]
[1]
17 / 32
6-3-2 Assembling
Fig. 36
1 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.
[1]
Fig. 37
2 Connect Flag receptacles to Terminals [1] (2 pcs).
Note
Connect Flag receptacles on the following color
lead wire ends to the tabs of Terminal [1].
orange (to + marked tab)
[1] white (to AS marked tab)
blue (to – marked tab)
Connect the other Terminal [1] as follows:
[1] red (to + marked tab)
yellow (to AS marked tab)
black (to – marked tab)
(Fig. 50)
[2]
Fig. 38
4 Press-fit Ball bearing 696ZZ [2] into Rotor [1] with
1R033 and 1R026.
1R026
[2]
[1] 1R033
18 / 32
Fig. 39
5 Press-fit Ball bearing 6000DDW [2] into Stator [1]
by tapping 1R030 with a plastic hammer.
1R030
[1]
[2]
Fig. 40
6 Assemble Retaining ring R-26 [2] to Stator [1] with
1R311 1R311.
[1]
[2]
Fig. 41
7 Assemble Rotor [2] to Stator [1].
Note
Be careful not to pinch your fingers between Stator
[1] and Rotor [2].
Tips
[2] If it is difficult to insert, tap Rotor [2] with a plastic
hammer.
[1]
19 / 32
Fig. 42
8 Assemble Stator and Motor housing [1] with
M5x18 Pan head screws [2] (3 pcs).
[2]
9 Assemble Worm gear [3] and Stop ring E-4 [4] to
[3]
Motor housing [1].
[4]
[1]
[4]
Fig. 43
10 Assemble Spring [2] and Nipple [3] to Oil tube
3-130 [1] and insert into Tank [4].
Note
Assemble Spring [2] so that its clearance between
[3] [2] [1] each part is 0.5mm or less, because Spring has a filter
function.
Tips
Apply the specified grease to the grommet portion of
Oil tube 3-130 [1].
[4]
[6]
[5]
Fig. 44
12 Assemble Motor housing [2] to Housing set [1]
[3]
[2] with M5x18 Pan head screws [3] (3 pcs).
[1]
[1]
20 / 32
Fig. 45
13 Assemble the following parts to Housing set [1]
and fix the lead wires to Housing set [1] with
1R411.
Controller [2]
[5]
Switch units [3] (2 pcs/ 2 different type)
Center case complete [4]
Terminals [5] (2 pcs)
[4] Switch C3JW-6BM-P [6]
[5]
Note
[1] Be careful that the actuator part of Switch units [3] is
easily broken by a lateral load.
[2]
[3]
[1]
[6]
[3]
Fig. 46
14 Assemble the following parts to Housing set [1].
[2] Switch lever [2]
Torsion spring 10 [3]
[3] Catch lever [4]
[1]
[4]
21 / 32
Fig. 47
15 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
[2] pump complete [2].
[5]
16 Connect Oil tube 3-100 [4] and Oil tube 3-130 [5]
to Oil pump complete [2].
[1]
[2]
[3] [4]
Fig. 48
17 Assemble Hook [1] and Hook support [2] to
Housing set [3].
[1]
[2] [1]
[3]
Fig. 49
18 Assemble Housing R [1] in place, then tighten 4x18
Tapping screws [2] (9 pcs).
[2]
[1] 19 Assemble Chain tensioner and Brake section
(6-2-2).
22 / 32
7 CIRCUIT DIAGRAM
Fig. 50
2 12
13
2
7
1 1
2
6 3
14 6
1
10
15 5 17
7
16
8
7
19 6 1
3
20
6 1
4
11
18
7
6 3
22
23 24
7
25 21
23 26
23 / 32
1 AWG14 14 Switch unit B (for detecting unlock-off)
2 AWG16 15 Battery fuel gauge
3 AWG22 16 Controller
4 AWG24 17 Terminal A
5 AWG26 18 Terminal 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 diagram of Switch unit A
10 Connector 3P 23 Black
11 Connector 2P 24 White
12 Stator 25 Circuit diagram of Switch unit B
13 Noise suppressor 26 Blue
24 / 32
8 WIRING DIAGRAM
8-1 Stator section
Fig. 51
4
1
2
1
5
25 / 32
8-2 Switch/ Controller section
Fig. 52
2
10
12
11 13
13 4
14
26 / 32
8-3 Main switch section
Fig. 53
10
9
11
3 4 7
27 / 32
8-4 Closed end splice section
Fig. 54
28 / 32
9 TROUBLESHOOTING
Whenever you find any trouble in your machine, first, see this list to check the machine for solution.
2 When Housing is disassembled, check the conditions of the electrical parts (Connectors, Lead wires, Switches, etc.),
Rotor, Stator, Gear section, etc.
3 Be sure to test the machine 10 times to correctly diagnose functions such as variable speed control, etc.
4 In order to make it easier to reproduce symptoms, run the motor at Normal speed.
5 Use the following Repairing tools for diagnosing LED and Switch.
9-2 Test for checking the short-circuit in FET (Field Effect Transistor) of controller
Fig. 55
1 Set Digital tester 1R402 to Diode mode.
1.0v
1R402
Fig. 56
2 Connect Black probe to the plus pole of Terminal
and Red probe to the minus pole.
Tips
1R402-B By attaching 1R402-B to each probe of 1R402, you
can make your hands free for easier check.
Note
Be careful not to reverse them. The reversed contacts
could spoil the test.
1R402-B
29 / 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.
30 / 32
9-3 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.
No
Power source lamp Controller is broken. Replace Controller.
lights up.
Yes
Motor runs when the Three lamps of Lead wires are broken. Check Lead wires or replace
machine is switched Yes Battery fuel gauge No them.
on. Try 10 times. In on each Battery
case of occasional light up.
starting, go to “No”.
Controller is broken. Replace Controller.
Yes
Connectors are poorly Connect Connectors firmly.
connected.
Variable speed
No control works
properly by
Trigger. Lead wires are broken. Check Lead wires or replace
No them.
Power source lamp Switch unit for preventing Replace Switch unit for
blinks in green when kickback is broken. preventing kickback
Trigger switch is Yes
pulled.
No
31 / 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. No
Yes
Yes
Rotor is broken. Replace Rotor.
*1: When the mode lamp blinks in green, the thick branch mode is prohibited. In this case, follow the next and check.
[1] Replace 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
does not matter) and turning on the power lamp in green. Then turn off the power lamp, replace the battery with a fully charged 18V
battery and check again.
If the thick branch mode is prohibited even after carrying out [1] and [2], replace Controller.
32 / 32