makita DUC204 Cordless Chain Saw Instruction Manual

Cordless Chain Saw
INSTRUCTION MANUAL

DUC204 Cordless Chain Saw

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(Original instructions)

SPECIFICATIONS

(0 – 1,350 m/min)
Chain oil tank volume| 140 cm3

• Due to our continuing program of research and development, the specifications herein are subject to change  without notice.

• Specifications may differ from country to country.

• The weight may differ depending on the attachment(s), including the battery cartridge. The lightest and heaviest combination, according to EPTA-Procedure 01/2014, are shown in the table.
  Applicable battery cartridge
  BL1815N / BL1820 / BL1820B / BL1830 / BL1830B / BL1840 / BL1840B / BL1850 / BL1850B / BL1860B

• Some of the battery cartridges listed above may not be available depending on your region of residence.

WARNING: Only use the battery cartridges listed above. Use of any other battery cartridges may cause  injury and/or fire.
Saw chain, guide bar, and sprocket combination

NOTICE: When using 25AP saw chain, use with Sprocket 9 (optional accessory).
****WARNING: Use appropriate combination of the guide bar and saw chain. Otherwise personal injury may  result.

Symbols

The following show the symbols used for the equipment.
Be sure that you understand their meaning before use.

| Read instruction manual.
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| Wear safety glasses.
| Wear ear protection.
| Wear a helmet, goggles and ear protection.
| Use appropriate protection for foot-leg and hand-arm.
| This saw is to be used by properly trained  operators only.
| Do not expose to moisture.
| Maximum permissible cut length
| Always use two hands when operating the chain saw.
| Direction of chain travel
| Saw chain oil adjustment

Ni-MH Li-ion

| Only for EU countries
Do not dispose of electric equipment or battery pack together with household waste material!
In observance of the European Directives, on Waste Electric and Electronic Equipment and Batteries and Accumulator sand Waste Batteries and Accumulators and their implementation in accordance with national laws, electric equipment and  batteries and battery pack(s) that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

Intended use

The tool is intended for cutting branches and pruning  trees. It is also suitable for tree service.

Noise

The typical A-weighted noise level determined according to IEC62841-4-1:
Model DUC204
Sound pressure level (LpA) : 92.2 dB(A)
Sound power level (LWA) : 103.2 dB (A)
Uncertainty (K) : 2.5 dB(A)
Model DUC254
Sound pressure level (LpA) : 92.2 dB(A)
Sound power level (LWA) : 103.2 dB (A)
Uncertainty (K) : 2.5 dB(A)
Model DUC254C
Sound pressure level (LpA) : 92.2 dB(A)
Sound power level (LWA) : 103.2 dB (A)
Uncertainty (K) : 2.5 dB(A)
WARNING: Wear ear protection.

Vibration

The vibration total value (tri-axial vector sum) determined according to IEC62841-4-1:
Model DUC204
Work mode: cutting wood
Vibration emission (ah,W) : 3.1 m/s 2
Uncertainty (K) : 1.5 m/s 2
Model DUC254
Work mode: cutting wood
Vibration emission (ah,W) : 3.1 m/s 2
Uncertainty (K) : 1.5 m/s 2
Model DUC254C
Work mode: cutting wood
Vibration emission (ah,W) : 4.1 m/s 2
Uncertainty (K) : 1.5 m/s 2
NOTE: The declared vibration emission value has been  measured in accordance with the standard test method and may be used for comparing one tool with another.
NOTE: The declared vibration emission value may  also be used in a preliminary assessment of exposure.
WARNING: The vibration emission during actual use of the power tool can differ from the declared emission value depending on the ways in which the tool is used.
**WARNING:** Be sure to identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

EC Declaration of Conformity

For European countries only
The EC declaration of conformity is included as Annex A  to this instruction manual.

SAFETY WARNINGS

General power tool safety warnings
**WARNING: Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your  mains-operated (corded) power tool or battery-operated (cordless) power tool.
Cordless Chain saw safety warnings**

1. Keep all parts of the body away from the saw chain when the chain saw is operating. Before you start the chain saw, make sure the saw chain is not contacting anything. A moment of inattention while operating chain saws may cause entanglement of your clothing or body with the saw chain.

2. Always hold the chain saw with your right hand on the top handle and your left hand on the front handle. Holding the chain saw with a reversed hand configuration increases the risk of  personal injury and should never be done.

3. Hold the power tool by insulated gripping surfaces only, because the saw chain may contact hidden wiring. Saw chains contacting a “live”  wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

4. Wear safety glasses and hearing protection. Further protective equipment for head, hands, legs and feet is recommended. Adequate protective clothing will reduce personal injury by flying  debris or accidental contact with the saw chain.

5. Always keep proper footing.

6. When cutting a limb that is under tension be alert for spring back. When the tension in the wood fibres is released the spring loaded limb may strike the operator and/or throw the chain saw out of control.

7. Use extreme caution when cutting brush and saplings. The slender material may catch the saw chain and be whipped toward you or pull you off balance.

8. Carry the chain saw by the front handle with the chain saw switched off and away from your body. When transporting or storing the chain saw always fit the guide bar cover. Proper handling of the chain saw will reduce the likelihood of accidental contact with the moving saw chain.

9. Follow instructions for lubricating, chain tensioning and changing accessories. Improperly tensioned or lubricated chain may either break or increase the chance for kickback.

10. Keep handles dry, clean, and free from oil and grease. Greasy, oily handles are slippery causing loss of control.

11. Cut wood only. Do not use chain saw for purposes not intended. For example: do not use chain saw for cutting plastic, masonry or nonwood building materials. Use of the chain saw for operations different than intended could result in a hazardous situation.

12. Causes and operator prevention of kickback: Kickback may occur when the nose or tip of the guide bar touches an object, or when the wood closes in and pinches the saw chain in the cut. Tip contact in some cases may cause a sudden reverse reaction, kicking the guide bar up and back towards the operator. Pinching the saw chain along the top of the guide bar may push the guide bar rapidly back towards the operator. Either of these reactions may cause you to lose control of the saw which could result in serious personal injury. Do not rely exclusively upon the safety devices built into your saw. As a chain saw user, you should take several steps to keep your cutting jobs free from accident or injury. Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:
    • Maintain a firm grip, with thumbs and fingers encircling the chain saw handles, with both hands on the saw and position your body and arm to allow you to resist kickback forces. Kickback forces can be controlled by the operator, if proper precautions are taken. Do not let go of the chain saw.
    ► Fig.1 • Do not overreach and do not cut above shoulder height. This helps prevent unintended tip contact and enables better control of the chain saw in unexpected situations.
    • Only use replacement bars and chains specified by the manufacturer. Incorrect replacement bars and chains may cause chain breakage and/or kickback.
    • Follow the manufacturer’s sharpening and maintenance instructions for the saw chain. Decreasing the depth gauge height can lead to increased kickback.

13. Before starting work, check that the chain saw is in proper working order and that its condition complies with the safety regulations. Check in particular that:
    • The chain brake is working properly;
    • The run-down brake is working properly;
    • The bar and the sprocket cover are fitted  correctly;
    • The chain has been sharpened and tensioned in accordance with the regulations.

14. Do not start the chain saw with the chain cover being installed on it. Starting the chain saw with the chain cover being installed on it may cause  the chain cover to thrown out forward resulting in personal injury and damage to objects around the operator.

Top handle chainsaw specific safety warnings

1. This chain saw is designed especially for tree care and surgery. The chain saw is intended to be used by properly trained persons only. Observe all instructions, procedures and recommendations from the relevant professional organization. Otherwise fatal accidents may occur. It is recommend that always using a rising platform (cherry picker, lift) for sawing in trees. Rappelling techniques are extremely dangerous and require special training. The operators must be trained to become familiar with safety equipment usage and climbing techniques. Always use the appropriate belts, ropes and carabiners when working in trees. Always use restraining equipment for both the operator and the saw.
2. Perform cleaning and maintenance before storage in accordance with the instruction manual.
3. Ensure safe positioning of the chain saw during car transportation to avoid fuel or chain oil leakage, damage to the tool and personal injury.
4. Regularly check the functionality of chain brake.
5. Do not fill the chain oil near fire. Never smoke when you fill the chain oil.
6. National regulation may restrict the use of the chain saw.
7. If the equipment gets heavy impact or fall, check the condition before continuing work. Check the controls and safety devices for malfunction. If there is any damage or doubt, ask our authorized service center for the inspection and repair.
8. Always activate the chain brake before startingthe chain saw.
9. Hold the saw firmly in place to avoid skating (skid movement) or bouncing of the saw when starting a cut.
10. At the end of the cut, be careful to keep your balance due to the “drop”.
11. Take into account the direction and speed of the wind. Avoid sawdust and chain oil mist.

Protective equipment

1.  In order to avoid head, eye, hand or foot injuries as well as to protect your hearing the following protective equipment must be used during operation of the chain saw:
   — The kind of clothing should be appropriate, i. e.  it should be tight- fitting but not be a hindrance.  Do not wear jewelry or clothing which could become entangled with bushes or shrubs. If you have long hair, always wear a hairnet!
   —  It is necessary to wear a protective helmet whenever working with the chain saw. The  protective helmet is to be checked in regular intervals for damage and is to be  replaced after 5 years at the latest. Use only approved protective helmets.
   — The face shield of the protective helmet (or the goggles) protects against sawdust and wood chips. During operation of the chain saw always wear a goggle or a face shield to prevent eye injuries.
   — Wear adequate noise protection equipment (ear muffs, ear plugs, etc.)
   — The protective jacket consists of 22 layers of nylon and protects the operator against cuts. It is always to be worn when working from elevated platforms (cherry pickers, lifts), from platforms mounted on ladders or when climbing with ropes.
   — The protective brace and bib overall is made of a nylon fabric with 22 layers and protects against cuts. We strongly recommend its use.
   — Protective gloves made of thick leather are part of the prescribed equipment and must always be worn during operation of the chain saw.
   — During operation of the chain saw safety shoes or safety boots fitted with anti skid sole, steel toe caps and protection for the leg must always to be worn. Safety shoes equipped with a protective layer provide protection against cuts and ensure a secure footing. For working in trees the safety boots must be suitable for climbing techniques.

Vibration

1. Individuals with poor circulation who are exposed to excessive vibration may experience injury to blood vessels or the nervous system. Vibration may cause the following symptoms to occur in the fingers, hands or wrists: “Falling asleep” (numbness), tingling, pain, stabbing sensation, alteration of skin colour or of the skin. If any of these symptoms occur, see a physician! To reduce the risk of “white finger disease”, keep your hands warm during operation and well maintain the equipment and accessories.

SAVE THESE INSTRUCTIONS.
WARNING: DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to safety rules for the subject product. MISUSE or failure to follow the safety rules stated in this instruction manual may cause serious personal injury.

Important safety instructions for battery cartridge

1. Before using battery cartridge, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.
2. Do not disassemble battery cartridge.
3. If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns and even an explosion.
4. If electrolyte gets into your eyes, rinse them out with clear water and seek medical attention right away. It may result in loss of your eyesight.
5. Do not short the battery cartridge: (1) Do not touch the terminals with any conductive material. (2) Avoid storing battery cartridge in a container with other metal objects such as nails, coins, etc. (3) Do not expose battery cartridge to water or rain. A battery short can cause a large current flow, overheating, possible burns and even a breakdown.
6. Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50 °C (122 °F).
7. Do not incinerate the battery cartridge even if it is severely damaged or is completely worn out. The battery cartridge can explode in a fire.
8. Be careful not to drop or strike battery.
9. Do not use a damaged battery.

Important safety instructions for battery cartridge

1. Before using battery cartridge, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.
2. Do not disassemble battery cartridge.
3. If operating time has become excessively shorter, stop operating immediately. It may result in a risk of overheating, possible burns and even an explosion.
4. If electrolyte gets into your eyes, rinse them out with clear water and seek medical attention right away. It may result in loss of your eyesight.
5. Do not short the battery cartridge: (1) Do not touch the terminals with any conductive material. (2) Avoid storing battery cartridge in a container with other metal objects such as nails, coins, etc. (3) Do not expose battery cartridge to water or rain. A battery short can cause a large current flow, overheating, possible burns and even a breakdown.
6. Do not store the tool and battery cartridge in locations where the temperature may reach or exceed 50 °C (122 °F).
7. . Do not incinerate the battery cartridge even if it is severely damaged or is completely worn out. The battery cartridge can explode in a fire.
8. Be careful not to drop or strike battery.
9. Do not use a damaged battery.
10. The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. For commercial transports e.g. by third parties, forwarding agents, special requirement on packaging and labeling must be observed. For preparation of the item being shipped, consulting an expert for hazardous material is required. Please also observe possibly more detailed national regulations. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging.
11. Follow your local regulations relating to disposal of battery.
12. Use the batteries only with the products specified by Makita. Installing the batteries to non-compliant products may result in a fire, excessive heat, explosion, or leak of electrolyte.

SAVE THESE INSTRUCTIONS.
CAUTION: Only use genuine Makita batteries.
Use of non-genuine Makita batteries, or batteries that have been altered, may result in the battery bursting causing fires, personal injury and damage. It will  also void the Makita warranty for the Makita tool and charger.
Tips for maintaining maximum battery life

1. Charge the battery cartridge before completely discharged. Always stop tool operation and charge the battery cartridge when you notice less tool power.
2. Never recharge a fully charged battery cartridge. Overcharging shortens the battery service life.
3. Charge the battery cartridge with room temperature at 10 °C – 40 °C (50 °F – 104 °F). Let a hot battery cartridge cool down before charging  it.
4. Charge the battery cartridge if you do not use it for a long period (more than six months).

PARTS DESCRIPTION

► Fig.2

FUNCTIONAL DESCRIPTION

CAUTION: Always be sure that the tool is switched off and the battery cartridge is removed before adjusting or checking function on the tool. Installing or removing battery cartridge
CAUTION: Always switch off the tool before installing or removing of the battery cartridge.
CAUTION: Hold the tool and the battery cartridge firmly when installing or removing battery cartridge. Failure  to hold the tool and the battery cartridge firmly may cause them to slip off your hands  and result in damage to the tool and  battery cartridge and a personal injury.
► Fig.3: 1. Red indicator 2. Button 3. Battery cartridge To remove the battery cartridge, slide it from the tool  while sliding the button on the front of the cartridge.
To install the battery cartridge, align the tongue on the  battery cartridge with the groove in the housing and slip it into place. Insert it all the way until it locks in place with a little click. If you can see the red indicator on the upper side of the button, it is not locked completely.
CAUTION: Always install the battery cartridge fully until the red indicator cannot be seen. If not, it may accidentally fall out of the tool, causing injury to  you or someone around you.
CAUTION: Do not install the battery cartridge forcibly. If the cartridge does not slide in easily, it is not being inserted correctly. Indicating the remaining battery capacity Only for battery cartridges with the indicator
► Fig.4: 1. Indicator lamps 2. Check button
Press the check button on the battery cartridge to indicate the remaining battery capacity. The indicator lamps  light up for a few seconds.

NOTE: Depending on the conditions of use and the ambient temperature, the indication may differ slightly from the actual capacity.
Tool / battery protection system
The tool is equipped with a tool/battery protection system. This system automatically cuts off power to the  motor to extend tool and battery life. The tool will automatically stop during operation if the  tool or batteryis placed under one of the following conditions:
Overload protection
When the battery is operated in a manner that causes it to draw an abnormally high current, the tool automatically stops and the main power lamp blinks in green. In this situation, turn the tool off and stop the application that caused the tool to become overloaded. Then turn the tool on to restart.
Overheat protection
When the tool or battery is overheated, the tool stops automatically and the main power lamp lights up in red. In this case, let the tool and battery cool before turning the tool on again.
NOTE: In high temperature environment, the overheat protection likely to work and the tool stops automatically. Overdischarge protection When the battery capacity is not enough, the tool stops automatically and the main power lamp blinks in red. In this case, remove the battery from the tool and charge the battery.
Main power switch
WARNING: Always turn off the main power  switch when not in use.
To turn on the tool, press the main power switch until  the main power lamp lights up in green. To turn off,  press the main power switch again.
► Fig.5: 1. Main power lamp 2. Main power switch
NOTE: The main power lamp blinks in green if the  switch trigger is pulled under unrepeatable conditions. The lamp blinks in one of the following conditions.

• When you turn on the main power switch while  holding down the lock-off lever and the switch trigger.
• When you pull the switch trigger while the chain  brake is applied.
• When you release the chain brake while holding  down the lock-off lever and pulling the switch trigger.

NOTE: This chain saw employs the auto power-off  function. To avoid unintentional start up, the main  power switch will automatically shut down when the switch trigger is not pulled for a certain period after the main power switch is turned on.
You can use the tool in the Torque Boost mode for  cutting thick branches or hard branches. To use the tool  in the Torque Boost mode, when the tool is turned off,  press the main power switch for a few seconds until the main power lamp lights up in yellow.
NOTE: You can use the tool in the Torque Boost  mode up to 30 seconds. Depending on the usage  conditions, this mode shifts to the normal mode in less than 30 seconds.
NOTE: If the main power lamp blinks in yellow when you press the main power switch for a few seconds, the Torque Boost mode is not available. In this case,  follow the steps below.

• The Torque Boost mode is not available right  after the cutting operation. Wait for more than 10 seconds, and then press the main power switch again.
•  If you use the Torque Boost mode several times,  the use of the Torque Boost mode is restricted to  protect the battery. If the Torque Boost mode is  not available after waiting for more than 10 seconds, replace the battery cartridge with a fully charged
  one, or recharge the battery cartridge.

NOTE: If the main power lamp lights up in red or blinks in red or green, refer to the instructions for tool/ battery protection system.
NOTE: The Torque Boost mode cannot be used when  the battery cartridge BL1815N, BL1820, or BL1820B is installed.

Switch action

WARNING: For your safety, this tool is  equipped with lock-off lever which prevents the tool from unintended starting. NEVER use the tool if it runs when you simply pull the switch trigger without pressing the lock-off lever. Return the tool to our authorized service center for proper repairs BEFORE further usage.
WARNING: NEVER tape down or defeat pur- pose and function of lock-off lever.
CAUTION: Before installing the battery car- tridge into the tool, always check to see that the switch trigger actuates properly and returns to the “OFF” position when released.
NOTICE: Do not pull the switch trigger hard without pressing the lock-off lever. This  can cause switch breakage.
To prevent the switch trigger from being accidentally  pulled, a lock-off lever is provided. To start the tool,  depress the lock-off lever and pull the switch trigger.
The tool speed increases by increasing pressure on the  switch trigger. Release the switch trigger to stop.
► Fig.6: 1. Switch trigger 2. Lock-off lever

Checking the chain brake

CAUTION: Hold the chain saw with both  hands when switching it on. Hold the top handle with your right hand, the front handle with your left. The bar and the chain must not be in contact with any object.
CAUTION: Should the saw chain not stop  immediately when this test is performed, the saw may not be used under any circumstances.
Consult our authorized service center.

1. Press the lock-off lever, then pull the switch trigger. The saw chain starts immediately.

2. Push the front hand guard forwards with the back of your hand. Make sure that the chain saw comes to an immediate standstill.
   ► Fig.7: 1. Front hand guard 2. Unlocked position

3. Locked position

Checking the run-down brake
CAUTION: If the saw chain does not stop  within two seconds in this test, stop using the chain saw and consult our authorized service center.
Run the chain saw then release the switch trigger completely. The saw chain must come to a standstill within  two seconds.
Adjusting the chain lubrication
You can adjust the oil pump feed rate with the adjusting  screw using the universal wrench. The amount of oil  can be adjusted in 3 steps.
► Fig.8: 1. Adjusting screw
Carabiner (rope attachment point)
You can hang the tool by attaching the rope to the carabiner. Pull up the carabiner, and then tie it with the rope.
Electronic function
The tool is equipped with the electronic functions for  easy operation.

• Soft start
  The soft-start function minimizes start-up shock,  and makes the tool start smoothly.

ASSEMBLY

CAUTION: Always be sure that the tool is  switched off and the battery cartridge is removed before carrying out any work on the tool.
CAUTION: Do not touch the saw chain with  bare hands. Always wear gloves when handling the saw chain.

Removing or installing saw chain
CAUTION: The saw chain and the guide bar are still hot just after the operation. Let them cool down enough before carrying out any work on the tool.
CAUTION: Carry out the procedure of installing or removing saw chain in a clean place free from sawdust and the like.

To remove the saw chain, perform the following steps:

1. Release the chain brake by pulling the front handguard.

2. Loosen the chain adjusting screw, then the retaining nut.
   ► Fig.9: 1. Chain adjusting screw 2. Retaining nut

3. Remove the sprocket cover then remove the sawchain and guide bar from the chain saw body.

To install the saw chain, perform the following steps:

1. Check the direction of the saw chain. Match the direction of the saw chain with that of the mark on the chain saw body.

2. Fit one end of the saw chain on the top of the guide bar.

3. Fit the other end of the saw chain around the sprocket, then attach the guide bar to the chain saw body, aligning the hole on the guide bar with the pin onthe chain saw body.
   ► Fig.10: 1. Sprocket 2. Hole

4.   Insert the protrusion on the sprocket cover to the  chain saw body, and then close the cover so that the
   bolt and pins on the chain saw body meet their counterparts on the cover.
   ► Fig.11: 1. Protrusion 2. Sprocket cover 3. Bolt 4. Pin

5. Tighten the retaining nut to secure the sprocket  cover, then loosen it a bit for tension adjustment.
   ► Fig.12: 1. Retaining nut

Adjusting saw chain tension
CAUTION: Do not tighten the saw chain too  much. Excessively high tension of saw chain may cause breakage of saw chain, wear of the guide bar and breakage of the adjusting dial.
CAUTION: A chain which is too loose can  jump off the bar and it may cause an injury accident.
The saw chain may become loose after many hours  of use. From time to time check the saw chain tension before use.

1. Release the chain brake by pulling the front hand guard.

2. Loosen the retaining nut a bit to loosen the sprocket cover lightly.
   ► Fig.13: 1. Retaining nut

3. Lift up the guide bar tip slightly and adjust the  chain tension. Turn the chain adjusting screw clockwise  to tighten, turn it counterclockwise to loosen.

For chain blade 90PX and 91PX:
Tighten the saw chain until the lower side of the saw  chain fits in the guide bar rail as illustrated.
► Fig.14: 1. Guide bar 2. Saw chain 3. Chain adjusting screw
For chain blade 25AP:
Tighten the saw chain so that the gap between the center of the lower side of the guide bar and the saw chain becomes approximately 1 mm to 2 mm. 4. Keep holding the guide bar lightly and tighten the sprocket cover.
For chain blade 90PX and 91PX:
Make sure that the saw chain does not loose at the lower side.
For chain blade 25AP:
Make sure that the gap between the center of the lower side of the guide bar and the saw chain is approximately 1 mm to 2 mm.
5. Tighten the retaining nut to secure the sprocket  cover.
► Fig.15: 1. Retaining nut
Make sure the saw chain fits snugly against the lower  side of the bar.

Spike bumper

Optional accessory
When cutting thick branches, using the spike bumper is recommended. To install the spike bumper, perform the  following steps:

1. Remove the sprocket cover, saw chain, and guide bar.
2. Align the holes of the spike bumper with the holes on the chain saw body, and then tighten the screws firmly.
   ► Fig.16: 1. Screw 2. Spike bumper

OPERATION

Lubrication
Saw chain is automatically lubricated when the tool is in operation. Check the amount of remaining oil in the oil tank periodically through the oil inspection window.
To refill the tank, lay the chain saw on its side and  remove the oil tank cap. The proper amount of oil is 140  ml. After refilling the tank, make sure that the oil tank  cap is tightened securely.
► Fig.17: 1. Oil tank cap 2. Oil inspection window After refilling, hold the chain saw away from the   tree. Start it and wait until lubrication on saw chain is adequate.
► Fig.18
NOTICE: When filling the chain oil for the first time, or refilling the tank after it has been completely emptied, add oil up to the bottom edge of the filler  neck. The oil delivery may otherwise be impaired.
NOTICE: Use the saw chain oil exclusively for Makita chain saws or equivalent oil available in the market.
NOTICE: Never use oil including dust and particles or volatile oil.
NOTICE: When pruning trees, use botanical oil.
Mineral oil may harm trees.
NOTICE: Before the cutting operation, make sure that the provided oil tank cap is screwed in place.
WORKING WITH THE CHAIN SAW
CAUTION: The first time user should, as a minimum practice, do cutting logs on a saw-horse or cradle.
CAUTION: When sawing precut timber, use a safe support (saw horse or cradle). Do not steady the workpiece with your foot, and do not allow anyone else to hold or steady it.
CAUTION: Secure round pieces against rotation.
CAUTION: Keep all parts of the body away from the saw chain when the motor is operating.
CAUTION: Hold the chain saw firmly with both hands when the motor is running.
CAUTION: Do not overreach. Keep proper footing and balance at all times.
NOTICE: Never toss or drop the tool.
NOTICE: Do not cover the vents of the tool.
Pruning trees
Bring the chain saw body into contact with the branch to be cut before switching on. Otherwise it may cause the guide bar to wobble, resulting in injury to operator. Saw  the wood to be cut by just moving it down by using the  weight of the chain saw.
► Fig.19
If you cannot cut the timber right through with a single stroke:
Apply light pressure to the handle and continue sawing and draw the chain saw back a little.
► Fig.20
When cutting thick branches, first make a shallow  undercut and then make the finish cut from the top.
► Fig.21
If you try to cut off thick branches from the bottom, the branch may close in and pinch the saw chain in the cut. If you try to cut off thick branches from the top without a shallow undercut, the branch may splinter.
► Fig.22
Bucking

1. Rest the chain saw body on the wood to be cut. ► Fig.23
2. With the saw chain running, saw into the wood while using the top handle to raise the saw and the front one to guide it.
3. Continue the cut by applying slight pressure to the top handle, easing the saw back slightly.
   NOTICE: When making several cuts, switch the chain saw off between cuts.
   CAUTION: If the upper edge of the bar is used for cutting, the chain saw may be deflected in your direction if the chain becomes trapped. For this reason, cut with the lower edge, so that the saw will be deflected away from your body.
   ► Fig.24
   When you cut a wood under tension, cut the pressured side (A) first. Then make the final cut from the tensioned  side (B). This prevents the bar from becoming trapped.
   ► Fig.25

Limbing

CAUTION: Limbing may only be performed by trained persons. A hazard is presented by the risk of kickback. When limbing, support the chain saw on the trunk if possible. Do not cut with the tip of the bar, as this presents a risk of kickback. Pay particular
attention to branches under tension. Do not cut unsupported branches from below. Do not stand on the felled trunk when limbing.

Carrying tool

Before carrying the tool, always apply the chain brake and remove the battery cartridges from the tool. Then  attach the guide bar cover. Also cover the battery cartridge with the battery cover.
► Fig.26:

1. Guide bar cover
2. Battery cover

MAINTENANCE

CAUTION: Always be sure that the tool is switched off and the battery cartridge is removed before attempting to perform inspection or maintenance.
CAUTION: Always wear gloves when performing any inspection or maintenance.
NOTICE: Never use gasoline, benzine, thinner, alcohol or the like. Discoloration, deformation or cracks may result.
To maintain product SAFETY and RELIABILITY,  repairs, any other maintenance or adjustment should  be performed by Makita Authorized or Factory Service Centers, always using Makita replacement parts.

Sharpening the saw chain

Sharpen the saw chain when:

• Mealy sawdust is produced when damp wood is  cut;

• The chain penetrates the wood with difficulty, even  when heavy pressure is applied;

• The cutting edge is obviously damaged;

• The saw pulls to the left or right in the wood.  (caused by uneven sharpening of the saw chain or damage to one side only)
  Sharpen the saw chain frequently but a little each time.  Two or three strokes with a file are usually sufficient for  routine resharpening. When the saw chain has been resharpened several times, have it sharpened in our authorized service center.
  Sharpening criteria:
  WARNING: An excessive distance between the cutting edge and depth gauge increases the risk of kickback.
  ► Fig.27: 1. Cutter length 2. Distance between cutting edge and depth gauge 3. Minimum cutter length (3 mm)
  — All cutter length must be equal. Different cutter  lengths prevent the saw chain from running smoothly and may cause the saw chain to break.
  — Do not sharpen the chain when the cutter length has reached 3 mm or shorter. The chain must be  replaced with new one.
  — The chip thickness is determined by the distance  between the depth gauge (round nose) and the cutting edge.
  — The best cutting results are obtained with following  distance between cutting edge and depth gauge.

• Chain blade 90PX : 0.65 mm

• Chain blade 91PX : 0.65 mm

• Chain blade 25AP : 0.65 mm
  ► Fig.28
  — The sharpening angle of 30° must be the same on  all cutters. Different cutter angles cause the chain to run roughly and unevenly, accelerate wear, and lead to chain breaks.
  — Use a suitable round file so that the proper sharpening angle is kept against the teeth.

•  Chain blade 90PX : 55°

• Chain blade 91PX : 55°

• Chain blade 25AP : 55°
  File and file guiding
  — Use a special round file (optional accessory) for  saw chains to sharpen the chain. Normal round files are not suitable.
  — Diameter of the round file for each saw chain is as  follows:

• Chain blade 90PX : 4.5 mm

• Chain blade 91PX : 4.0 mm

• Chain blade 25AP : 4.0 mm
  — The file should only engage the cutter on the forward stroke. Lift the file off the cutter on the return  stroke.
  — Sharpen the shortest cutter first. Then the length  of this shortest cutter becomes the standard for all other cutters on the saw chain.
  — Guide the file as shown in the figure.
  ► Fig.29: 1. File 2. Saw chain
  — The file can be guided more easily if a file holder  (optional accessory) is employed. The file holder  has markings for the correct sharpening angle of 30° (align the markings parallel to the saw chain)  and limits the depth of penetration (to 4/5 of the
  file diameter).
  ► Fig.30: 1. File holder
  — After sharpening the chain, check the height of the depth gauge using the chain gauge tool (optional accessory).
  ► Fig.31
  — Remove any projecting material, however small,  with a special flat file (optional accessory).
  — Round off the front of the depth gauge again.

Cleaning the guide bar

Chips and sawdust will build up in the guide bar groove.
They may clog the bar groove and impair the oil flow.
Clean out the chips and sawdust every time when you sharpen or replace the saw chain.
► Fig.32
Cleaning the sprocket cover
Chips and saw dust will accumulate inside of the sprocket cover. Remove the sprocket cover and saw chain from the tool then clean the chips and saw dust.
► Fig.33
Cleaning the oil discharge hole
Small dust or particles may be built up in the oil discharge hole during operation. These dust or particles  may impair the oil to flow and cause an insufficient  lubrication on the whole saw chain.
When a poor chain oil delivery occurs at the top of guide bar, clean the oil discharge hole as follows.

1. Remove the sprocket cover and saw chain from the tool.
2. Remove the small dust or particles using a slotted screwdriver with a slender shaft or the like. ► Fig.34: 1. Slotted screwdriver 2. Oil discharge hole
3.  Insert the battery cartridge into the tool. Pull the  switch trigger to flow built-up dust or particles off the oil  discharge hole by discharging chain oil.
4. Remove the battery cartridge from the tool. Reinstall the sprocket cover and saw chain on the tool.

Replacing the sprocket

CAUTION: A worn sprocket will damage a  new saw chain. Have the sprocket replaced in this case.

Before fitting a new saw chain, check the condition of  the sprocket.
► Fig.35: 1. Sprocket 2. Areas to be worn out Always fit a new locking ring when replacing the  sprocket.
► Fig.36: 1. Locking ring 2. Sprocket
NOTICE: Make sure that the sprocket is installed as shown in the figure.

Storing the tool

1. Clean the tool before storing. Remove any chips and sawdust from the tool after removing the sprocket cover.
2. After cleaning the tool, run it under no load to lubricate the saw chain and guide bar.
3. Cover the guide bar with the guide bar cover.
4. Empty the oil tank.

Instructions for periodic maintenance

To ensure long life, prevent damage and ensure the full functioning of the safety features, the following maintenance must be performed regularly. Warranty claims can be recognized only if this work is performed regularly and properly. Failure to perform the prescribed maintenance work can lead to accidents! The user of the chain saw must not perform maintenance work which is not described in the instruction manual. All such work must be carried out by our authorized service center.

Check item / Operating time| Before
operation| Everyday| Every week| Every 3
month| Annually| Before
storage
---|---|---|---|---|---|---
Chain saw| Inspection.| √| –| –| –| –| –
Cleaning.| –| √| –| –| –| –
Check at authorized service center.| –| –| √| –| √| –
Saw chain| Inspection.| √| –| –| –| –| –
Sharpening if necessary.| –| –| –| –| –| √
Guide bar| Inspection.| √| √| –| –| –| –
Remove from the chain saw.| –| –| √| –| –| –
Chain brake| Check the function.| √| –| –| –| –| –
Have it inspected regularly at authorized service center.| –| √| –| –| –| –
Chain lubrication| Check the oil feed rate.| √| –| –| –| –| –
Switch trigger| Inspection.| √| –| –| –| –| –
Lock-off lever| Inspection.| √| –| –| –| –| –
Oil tank cap| Check tightness.| √| –| –| –| –| –
Chain catcher| Inspection.| –| –| √| –| –| –
Screws and nuts| Inspection.| –| –| √| –| –| –

TROUBLESHOOTING

Before asking for repairs, conduct your own inspection first. If you find a problem that is not explained in the manual,  do not attempt to dismantle the tool. Instead, ask Makita Authorized Service Centers, always using Makita replacement parts
for repairs.

charged battery cartridge.
Battery problem (low voltage).| Recharge the battery cartridges. If recharging is not effective, replace the battery cartridge.
Main power switch is off.| The chain saw is automatically turned off if it is un-operated for a certain period. Turn on the main power switch again.
The saw chain does not run.| Chain brake activated.| Release chain brake.
The motor stops running after a lithe use.| Battery’s charge level is low.| Recharge the battery cartridges. If recharging is not effective, replace the battery cartridge.
No oil on the chain.| Oil tank is empty.| Fill the oil tank.
Oil guide groove is dirty.| Clean the groove.
Poor oil delivery.| Adjust the amount of oil delivery with the adjusting screw.
The chain saw does not reach maximum RPM.| Battery cartridge is installed improperly.| Install the battery cartridges as described in this manual.
Battery power is dropping.| Recharge the battery cartridge. If recharging is not effective, replace the battery cartridge.
The drive system does not work correctly.| Ask the authorized service center in your region for repair.
The main power lamp is blinking in green.| Switch trigger is pulled under an unoperat- able condition.| Pull the switch trigger after the main power switch is turned on and the chain brake is released.
Chain does not stop even the chain brake is activated:
Stop the machine immediately!| The brake band is worn down.| Ask the authorized service center in your region for repair.
Abnormal vibration:
Stop the machine immediately!| Loose guide bar or saw chain.| Adjust the guide bar and saw chain tension.
Tool malfunction.| Ask the authorized service center in your region for repair.
The Torque Boost mode is not available after replacing the battery cartridge with a fully charged one.| Depending on the usage conditions, the Torque Boost mode is not available after replacing the battery cartridge.| Use the tool in the normal mode until the installed battery cartridge becomes empty, and then replace the battery cartridge with a fully charged one, or recharge the battery cartridge.

OPTIONAL ACCESSORIES

CAUTION: These accessories or attachments  are recommended for use with your Makita tool specified in this manual. The use of any other  accessories or attachments might present a risk of injury to persons. Only use accessory or attachment  for its stated purpose. If you need any assistance for more details regarding these accessories, ask your local Makita Service Center.

• Saw chain
• Guide bar
• Guide bar cover
• Sprocket
• Spike bumper
• File
• Tool bag
• Makita genuine battery and charger

WARNING: If you purchase a guide bar of  different length from the standard guide bar, also purchase a suitable guide bar cover together. It must fit and fully cover the guide bar on the chain saw.
NOTE: Some items in the list may be included in the tool package as standard accessories. They may  differ from country to country.

Makita Europe N.V.
Makita Corporation
Jan-Baptist Vinkstraat 2, 3070 Kortenberg, Belgium
3-11-8, Sumiyoshi-cho, Anjo, Aichi 446-8502 Japan
www.makita.com
885630-993
EN, FR, DE, IT, NL,  ES, PT, DA, EL, TR
20180315

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| makita DUC204 Cordless Chain Saw [pdf] Instruction Manual
DUC204 Cordless Chain Saw, DUC204, Cordless Chain Saw, Chain Saw, Saw
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