Transcript
OFFICIAL USE for ASC & Sales Shop
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ECHNICAL INFORMATION
PRODUCT P 1/ 8
Model No.
DUC121/ DUC122
Description
14.4V/ 18V Cordless Chain Saw 115mm (4-1/2)
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CONCEPT AND MAIN APPLICATIONS
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Models DUC121 and DUC122 are cordless chain saws powered by the following Li-ion battery; DUC121 (14.4V): BL1415N (1.5Ah), BL1415NA (1.5Ah), BL1430 (3.0Ah), BL1430A (3.0Ah), BL1440 (4.0Ah) and BL1450 (5.0Ah) DUC122 (18V): BL1815N (1.5Ah), BL1820 (2.0Ah), BL1830 (3.0Ah), BL1840 (4.0Ah) and BL1850 (5.0Ah) These models feature higher operation efficiency and more convenience than the current 12V Model UC120D. Note: These products are not compatible with 1.3Ah battery BL1415/ BL1815.
W Dimensions: mm (") Length (L) 422 (16-5/8) Width (W) 195 (7-5/8) Height (H) 215 (8-1/2)
Specification Model Specification Voltage: V Capacity: Ah Battery Cell Energy capacity: Wh Charging time (approx.): min. Cutting length: mm (") Chain speed: m/s (m/min.) Type Chain blade Pitch Chain brake
DUC121
DUC122
14.4 1.5, 3.0, 4.0, 5.0
18 1.5, 2.0, 3.0, 4.0, 5.0 Li-ion
22, 44, 58, 72 27, 36, 54, 72, 90 15, 22, 36, 45 with DC18RC 15, 24, 22, 36, 45 with DC18RC 115 (4-1/2) 4.8 (290) 5.0 (300) 25AP-42E 1/4" Yes (Electric brake)
Weight according to EPTA-Procedure 01/2003*1: kg (lbs)
2.6 (5.7)*3
2.5 (5.4)*2
*1 With Guide bar, Saw chain *2 With Battery BL1430, BL1440 or BL1450 *3 With Battery BL1830, BL1840 or BL1850
Standard equipment
Battery*4 Battery cover*5 Charger*4 Plastic carrying case*4
File Oil supply (containing 100ml of chain oil) Guide bar cover
*4 Battery, Charger and Plastic carrying case are not supplied with “Z” model *5 Supplied with the same quantity of extra battery Note: The standard equipment may vary by country or model variation.
Optional accessories Chain blade 25AP-42E Guide bar Pruning extension set
Fast charger DC18RC Charger DC18SD/DC24SC Automotive charger DC18SE Four port multi charger DC18SF Two port multi fast charger DC18RD
For DUC121 Battery BL1415N Battery BL1415NA Battery BL1430 Battery BL1430A Battery BL1440 Battery BL1450
For DUC122 Battery BL1815N Battery BL1820 Battery BL1830 Battery BL1840 Battery BL1850
P2/8
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS Code No.
Description
Use for
1R237
Round bar for arbor 8-100
Installing Push nut
1R263
Bearing extractor
Removing Helical gear 50 with Spindle
1R280
Round bar for arbor 6-50
1R034
Bearing setting plate 12.2
Removing Spindle from Helical gear and Ball bearings Correcting the deformed Push nut Removing Spindle from Helical gear 50
[2] LUBRICATION To protect parts and product from unusual abrasion; 1)apply 7g of Makita grease FA No. 2 to Gear room. Note: Be sure to apply a little amount of the above grease to the inner periphery of Crank. 2)apply a little amount of Lubricant VG100 to O-ring 1.5 and insert the O-ring 1.5 to Oil pump complete. 3) apply sealing lubricant to the both surface of Flat washer 6 under Knob 60.
[3] DISASSEMBLY/ ASSEMBLY [3]-1. Disassembling/ Assembling Sprocket Cover Section DISASSEMBLING 1) Remove Sprocket cover section by turning Knob 60 counterclockwise. 2) Put Sprocket cover section on worktable and turn Knob 60 counterclockwise (Fig. 1) while holding Sprocket cover so that the one of Knob 60’s hook can be placed in the depression in Sprocket cover section. (Fig. 2) Note: The hooked portions are very fragile. Therefore, turn Knob 60 carefully. 3) Remove the hooks of Knob 60 from the groove of Sprocket cover, and Knob 60 can be removed. ASSEMBLING 1) Apply sealing lubricant to the both side of Flat washer 6. (Fig. 2) 2) Set Knob 60 and Flat washer 6 on Sprocket cover, then fit the hooks of Knob 60 into the groove of Sprocket cover by turning Knob 60 clockwise carefully. 3) Insert the protrusion of Sprocket cover into Handle R and assemble Sprocket cover section to Handle L by tightening Knob 60. Fig. 1
Fig. 2 hooks of Knob 60
Sprocket cover
worktable
Knob 60
Flat washer 6
depression of Sprocket cover groove of Sprocket cover
protrusion of Sprocket cover for fitting to Handle R
P3/8
Repair [3] DISASSEMBLY/ ASSEMBLY (cont.) [3]-2. Disassembling/ Assembling Gear Section DISASSEMBLING 1) Remove Stop ring E-8 from Spindle then remove Sprocket 9 and Lock washer 12. 2) Loosen four 4x18 Tapping screws (Fig. 3) then strike Spindle end using plastic hammer. (Fig. 4) Bearing housing can be removed. Note: Do not strike Leaf spring near Spindle. Fig. 3
Fig. 4 4x18 Tapping screws (4 pcs.)
Spindle
Leaf spring
Bearing housing 3) Install Lock washer 12 and Sprocket 9 to Spindle, and hook Stop ring 8 to the groove of Spindle to prevent Lock washer 12 and Sprocket 9 from being removed. Note: It is not necessary to set Stop ring 8 in place in this step. 4) Hook Lock washer 12 with two 1R263. Gear section can be removed from the machine. (Fig. 5) 5) Put Gear section on 1R034 as illustrated in Fig. 6, and press down round shaped Spindle end slightly to relieve the press-fit. 6) Mount 1R280 on round shaped Spindle end (Fig.7) and push out Spindle from Gear section using arbor press. Fig. 5
Fig. 6
Lock Sprocket 9 washer 12
Stop ring E-8 hooked to Spindle’s groove
Round shaped Spindle end Ball bearing 696ZZ Cam
Ball bearing 609LLB 1R263 (2 pcs.)
1R034
Fig. 7 Arbor press 1R280
Oval shaped Spindle end
1R034
Arbor press Helical gear 50
Oval shaped Spindle end put in the hole of 1R034
P4/8
Repair [3] DISASSEMBLY/ ASSEMBLY (cont.) [3]-3. Disassembling/ Assembling Gear Section ASSEMBLING
1) As illustrated in Fig. 8, press-fit the components of Gear section. Note: * Helical gear 50 is directional. Therefore, press-fit Helical gear 50 so that its stepped portion can face the direction of Ball bearing 609LLB. (Fig. 8) * Cam is not directional. Press-fit Cam to the position that is in contact with Helical gear 50. 2) Insert Gear section straight into Handle R, and then fix Bearing housing to Handle R by tightening 4x18 Tapping screws (4 pcs. ...Refer to Fig. 3) 3) Mount Lock washer 12 and Sprocket 9 to Spindle, and secure them by pinching Stop ring E-8 completely to the groove of Spindle. (Fig. 9) Fig. 8
Fig. 9 Stop ring E-8Sprocket 9Lock washer 12
Ball bearing 609LLB Stepped portion of Helical gear 50
Spindle
Cam
groove of Spindle
Ball bearing 696ZZ
[3]-4. Disassembling/ Assembling Oil Pump Section When Chain oil is not delivered, check the cause in accordance with the following flowchart and repair the machine. Fig. 10
DISASSEMBLING 1) Remove Gear section. (Refer to [3]-3.) 2) Pull off Crank and check if O ring 1.5 on its end of pin portion has damaged or not. 3) Pour approx. 30cc of Makita genuine chain oil (Refer to LUBRICANT) or commercial oil VG32-100 to Oil tank. Rise and fall Crank by hand while checking if Chain oil is delivered from chain oil exit designated by arrow in Fig. 10. Note: Filter in Oil tank has to be dipped into chain oil during checking. Chain oil Not delivered After removing one end of Connector from the chain oil exit on Handle R, check if the oil can be delivered to the end. Not delivered After removing the other end of Connector from Oil pump, insert the pin portion of Crank into the bottom of Oil pump several time and check if the oil can be delivered to the open end of Oil pump.
Delivered
chain oil exit
Delivered Normal condition (If Chain oil is not delivered from the exit after completing repairing, there is the possibility that Filter in chain oil exit is clogged. Therefore, clean Filter with kerosene.
Not delivered Remove the rubber tube end to Oil tank from Oil pump end under the condition that the oil occupies a half in Oil tank. Not delivered Filter in Oil tank is clogged. After removing Handle L, pick the filter out of Tank. And Clean Filter with kerosene. Then check the delivery of oil again.
Delivered Oil pump is out of order. Replace Oil pump by the new, then check the delivery of oil again.
ASSEMBLING Take the reverse step of disassembling. Note: Do not damage Connector and rubber tube to Oil tank when connecting them with Oil tank/ Handle R/ Oil pump. Connect the above parts securely to prevent the oil leaking.
P5/8
Repair [3] DISASSEMBLY / ASSEMBLY (cont.) [3]-5. Disassembling/ Assembling Filter in Handle R DISASSEMBLING 1) Strike the center of Push nut gently using Phillips screwdriver No.2 (Fig. 11), Push nut can be removed, and Filter can be picked out of chain oil exit of Handle R. Note: Do not deform Push nut hard by strong shock. 2) Try operation without Filter and check if the delivery of oil is normal or not. If it is normal, there is not problem with Oil pump. 3) Wash Filter with kerosene oil when finding the attached dirt on Filter.
Fig. 11 Phillips screwdriver No. 2 Push nut chain oil exit
ASSEMBLING The removed Push nut can be reused. Note: 1) Correct the deformed Push nut so that its concave can be reduced by striking on 1R034 or solid worktable. (Fig. 12) 2) Do not reuse the wrong Push nut that has curved or broken tabs. Install Filter in chain oil exit of Handle R, and insert Push nut using 1R237.
Fig. 12 Push nut
Expand its diameter to reduce the depression.
[3]-6. Disassembling/ Assembling Motor Section DISASSEMBLING 1) Remove Carbon brushes. 2) Remove 4x18 Tapping screws and 4x30 Tapping screws to separate Front hand guard, Handle L and Motor housing in order. (Fig. 13) 3) Pull Armature out of Motor housing. Note: It is not needed to remove 4x18 Tapping screws (4 pcs.) for fixing Motor housing R and L when replacing Armature only. If Armature is left in Motor housing, grab Fan carefully and remove Armature with Fan from Motor housing. When replacing Yoke unit or Endbell complete, remove the above 4x18 Tapping screws (4 pcs.) to separate Motor housing L and R. Fig. 13 Front hand guard
4x18 Tapping screws 4x30 Tapping screws
Long-nose screwdriver is needed to remove this screw.
Front handle
Handle L Motor housing L Motor housing
4x18 Tapping screws (4 pcs.) for fixing Motor housing L and R.
Motor housing R
P6/8
Repair [3] DISASSEMBLY / ASSEMBLY [3]-6. Disassembling/ Assembling Motor Section (cont.)
Fig. 14
ASSEMBLING
Notch of Yoke
1) When mounting Yoke on Motor housing R, fit the notch of Yoke into the protrusion of Motor housing R. (Fig. 14) 2) Insert Armature gear shaft to gear room of Handle R, and fix Motor housing to Handle R by tightening 4x30 Tapping screws (4 pcs.). Note: Magnetic force pulls Motor housing with Yoke and Armature. Therefore, Do not pinch finger and Lead wires (Fig. 14) in this step. 3) Set Ring 30, Switch lever and Lock-off button in place, then Match Handle L with Handle R and tighten Tapping screws. (Fig. 13) Note: Magnetic force pulls Motor housing with Yoke and Armature. Therefore, Do not pinch Lead wires (Fig. 15) in this step.
Protrusion of Motor housing R
Fig. 15
Lock-off button
Switch lever
Do not pinch finger and Lead wires between Motor housing and Handle.
Do not pinch finger and Lead wires in this area.
Ring 30
P7/8
Circuit diagram Fig. D-1
1 2 3
Color index of lead wires' sheath Black White Red Yellow
Pass Lead wires through Line filter one by one. Line filter (if used)
Switch
Terminal Endbell complete Controller
Wiring diagram Fig. D-2 Lead wire holder Endbell complete
Fix Lead wires for Endbell complete with Lead wire holders.
Motor housing
P8/8
Wiring diagram Fig. D-3
Fix Lead wires from Endbell complete and Lead wires between Switch and Terminal in each Lead wire holder as drawn below. Switch Lead wire holders
Lead wire holder
Line filter (if used) Pass Lead wires through Line filter one by one. Controller Motor housing
Terminal
