MODEL 40421, 40421BT
40V MAX LITHIUM ION
CORDLESS POLE SAW
Instruction Manual
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IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,
trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM
CONTENTS
WELCOME 3
Introduction ..................................................................................................... 3
Specifications ................................................................................................... 3
SAFETY 4
General Safety Rules ........................................................................................ 4
Specific Rules for Pole Saws ........................................................................... 6
Specific Rules for the Battery & Charger .......................................................... 8
About the Battery ........................................................................................... 10
About the Charger .......................................................................................... 11
Electrical Information ..................................................................................... 12
BEFORE OPERATING 13
Know Your Pole Saw .......................................................................................13
Assembly & Adjustment ................................................................................. 14
OPERATION & MAINTENANCE 17
Operation ....................................................................................................... 17
Maintenance ................................................................................................... 19
Storage ...........................................................................................................20
Exploded View & Parts List .............................................................................21
Warranty Statement ....................................................................................... 24
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INTRODUCTION
Thanks for purchasing the WEN Pole Saw. We know you are excited to put your tool to work, but first, please take
a moment to read through the manual. Safe operation of this tool requires that you read and understand this operator’s manual and all the labels affixed to the tool. This manual provides information regarding potential safety
concerns, as well as helpful assembly and operating instructions for your tool.
SAFETY ALERT SYMBOL: Indicates danger, warning, or caution. The safety symbols and the explanations
with them deserve your careful attention and understanding. Always follow the safety precautions to reduce the
risk of fire, electric shock or personal injury. However, please note that these instructions and warnings are not
substitutes for proper accident prevention measures.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur.
WEN reserves the right to change this product and specifications at any time without prior notice.
At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual,
please visit wenproducts.com for the most up-to-date manual or contact our customer service at 1-800-232-1195.
Keep this manual available to all users during the entire life of the tool and review it frequently to maximize
safety for both yourself and others.
SPECIFICATIONS
Model Number 40421, 40421BT
Motor 40V Brushless Motor
Guide Bar 10 inch
Speed (no-load) 4800 RPM
Maximum Reach 10 feet
Oil Tank Capacity 3.4 ounces
Saw Chain Model 91PJ040X
Guide Bar Model 100SDEA041
Chain Pitch 3/8 inch
Chain Gauge 1/2 inch
Drive Links 40
Battery 40V Max Lithium Ion, 2Ah
Charger Input 100-120V AC, 60Hz, 100W
Charger Output 42V DC, 2A
Battery Model 40401
Charger Model 40400C
Weight with Battery 12 pounds
Product Dimensions
Extended 111 x 5.1 x 6.3 inches
Shortened 77 x 5.1 x 6.3 inches
NOTE: Model 40421BT does not include battery or charger.
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GENERAL SAFETY RULES
Safety is a combination of common sense, staying alert and knowing how your item works.
SAVE THESE SAFETY INSTRUCTIONS.
WARNING: Read and understand all warnings, cautions and operating instructions before
using this tool. Failure to follow all instructions listed below may result in personal injury and tool
damage.
WORK AREA SAFETY
1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liq
uids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the
risk of electric shock.
4. Keep children and bystanders away while operating a power tool. Distractions can cause you to
lose control.
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ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter
plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk
of electric shock.
2. Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrig
erators. There is an increased risk of electric shock if your body is earthed or grounded.
3. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep
cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk
of electric shock.
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4. If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter
(GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not
use a power tool while you are tired or under the influence of drugs, alcohol or medication. A mo
ment of inattention while operating power tools may result in serious personal injury.
2. Use personal protective equipment. Always wear eye protection. Protective equipment such as a
dust mask, non-skid safety shoes and hearing protection used for appropriate conditions will reduce
the risk of personal injury.
3. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from mov
ing parts. Loose clothes, jewelry or long hair can be caught in moving parts.
4. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left at
tached to a rotating part of the power tool may result in personal injury.
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GENERAL SAFETY RULES
5. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power
source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on
the switch or energizing power tools that have the switch on invites accidents.
6. Do not overreach. Keep proper footing and balance at all times. This enables better control of the
power tool in unexpected situations.
7. If devices are provided for the connection of dust extraction and collection facilities, ensure these
are connected and properly used. Use of dust collection can reduce dust-related hazards.
POWER TOOL USE AND CARE
1. Do not force the power tool. Use the correct power tool for your application. The correct power
tool will do the job better and safer at the rate for which it was designed.
2. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must be repaired.
3. Disconnect the plug from the power source and/or the battery pack from the power tool before
making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
4. Store idle power tools indoors and out of the reach of children and do not allow persons unfamiliar
with the power tool or these instructions to operate the power tool. Power tools are dangerous in the
hands of untrained users.
5. Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and
any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
6. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into
account the working conditions and the work to be performed. Use of the power tool for operations
different from those intended could result in a hazardous situation.
BATTERY USE AND CARE
1. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one
type of battery pack may create a risk of fire when used with another battery pack.
2. Use power tools only with specifically designated battery packs. Use of any other battery packs
may create a risk of injury and fire.
3. When battery pack is not in use, keep it away from other metal objects, like paper clips, coins,
keys, nails, screws or other small metal objects, that can make a connection from one terminal to
another. Shorting the battery terminals together may cause burns or a fire.
4. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
SERVICE
Have your power tool serviced by a qualified repair person using only identical replacement parts.
This will ensure that the safety of the power tool is maintained.
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SPECIFIC SAFETY RULES FOR POLE SAWS
WARNING: Do not let comfort or familiarity with the product replace strict adherence to
product safety rules. Failure to follow the safety instructions may result in serious personal injury.
WARNING: Do not operate near electrical power lines. The pole saw has not been designed
to provide protection from electric shock from contact with power lines. Contact with or use near
power lines may cause serious injury, electric shock, or death.
1. TOOL PURPOSE. The purpose of this pole saw is for limbing trees and cleaning up branches. Do not
push it beyond its limits or its capacities. Using the pole saw in a way for which it was not designed
can result in serious injuries, machine damage and voiding of the warranty. Only use with WEN 40V
Max Lithium Ion battery 40401.
2. Hold the pole saw by the insulated gripping surfaces only. If the pole saw contacts a live wire, the
exposed metal parts of the pole saw may become live and could cause electric shock. Hold the pole
saw with two hands to avoid loss of control.
3. Keep all parts of the body away from the saw chain. The saw chain continues to move after the
switch is turned off. Allow the saw chain to completely stop before clearing jammed material.
4. Keep bystanders, especially children, at a safe distance away from the saw during operation.
5. Wear eye and hearing protection. Other personal protection equipment for the head, hands, legs and
feet is recommended especially when using the pole saw overhead. Falling debris can result in serious
injury.
6. Do not operate the saw while sitting or standing in a tree. Maintain a safe, secure stance at all times.
Only use the saw when standing on solid, safe and level ground.
7. Use particular caution when cutting brush and young trees. The thin material may get caught in the
chain and hit you or throw you off balance.
8. Carry the switched-off pole saw using the handle with the chain pointing away from your body. Al
ways put on the protective cover when transporting or storing the pole saw. Carefully handling the saw
greatly reduces the risk of accidentally touching the sharp cutting chain.
9. Keep the handles dry, clean and free from gas, oil and grease. Slippery handles may lead to a loss
of control.
10. Remain alert; pay attention to what you are doing and proceed sensibly when working with an electric tool. Do not use the machine if you are tired or under the influence of drugs, alcohol or medication.
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11. Inspect the saw thoroughly before use for damage. If any parts or pieces appear to be missing or
damaged, do not operate the saw.
12. Do not operate during adverse weather conditions, particularly during lightening and rain. This
decreases the risk of being struck by lightning.
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SPECIFIC SAFETY RULES FOR POLE SAWS
WARNING: To reduce the risk of electric shock, always unplug the charger before performing any cleaning or maintenance. Do not allow water to flow into the charger. Use a Ground Fault
Circuit Interrupter (GFCI) to reduce shock hazards.
13. Sawing wood under tension necessitates an increased amount of caution. Wood that is suddenly
released from tension can react in a completely uncontrolled manner. This can result in severe to
deadly injuries. Such work may only be performed by trained specialists.
14. To reduce the risk of electrocution, never use near any electrical power lines. Contact with or use
near power lines may cause serious injury or electric shock resulting in death.
15. Always use two hands when operating the pole saw. Hold the pole saw with both hands to avoid
loss of control.
16. This tool is not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their safety. Children should be
supervised to ensure that they do not play with the appliance.
17. Wait until the chain has come to a standstill completely before placing it down.
18. Any servicing should be performed by an authorized service representative. If you need assis
tance, contact WEN customer service at 1-800-232-1195.
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REDUCING KICKBACK
Kickback can occur when the tip of the guide bar touches an object or when the wood closes in and
pinches the saw chain inside of the cut. Tip contact can kick the guide bar up and back towards the op
erator. Pinching the saw chain along the top of the guide bar can push the bar rapidly towards the operator. Either of these reactions may cause a loss in control of the pole saw, increasing the chances of
serious personal injury. Do not rely on the safety devices built into the saw. Pole saw users should take
as many precautions as possible to minimize on-site accidents. Kickback is the result of tool misuse
and/or incorrect operating procedures. These conditions can be minimized with the following steps:
1. Maintain a firm grip, with thumbs and fingers encircling the pole saw handle. Both hands should
be on the saw with your body and arms in a position to resist kickback forces. Kickback forces can be
controlled by the operator, if proper precautions are taken. Do not let go of the pole saw.
2. Do not overreach and do not cut above shoulder height. This helps prevent unintended tip contact
and enables better control of the pole saw in unexpected situations.
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3. Only use replacement bars and chains specified by WEN. Incorrect replacement bars and chains may
cause chain breakage and/or kickback.
4. Follow the manufacturer’s sharpening and maintenance instructions for the pole saw. Decreasing the
depth gauge height can lead to increased kickback.
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SPECIFIC SAFETY RULES FOR THE BATTERY & CHARGER
WARNING: Do not let comfort or familiarity with the product replace strict adherence to
product safety rules. Failure to follow the safety instructions may result in serious personal injury.
Despite all the safety precautions, caution must always be exercised when handling batteries. The
following points must be obeyed at all times to ensure safe use. Safe use can only be guaranteed if
undamaged cells are used. Incorrect handling of the battery pack can cause cell damage.
1. TOOL PURPOSE. This charger is designed for recharging WEN 40V Max Lithium Ion batteries (mod
el numbers 40401 and 40404). Charging any other battery or using a different charger to charge these
batteries could result in fire, injury, or damage. Using the charger for any other purpose for which it is
not designed may result in serious injuries, machine damage and voiding of the warranty.
2. AVOID DANGEROUS ENVIRONMENTS. Do not charge the battery pack in rain, snow or in damp or
wet locations. Do not use the battery pack or charger in the presence of explosive atmospheres (gas
eous fumes, dust or flammable materials) because sparks may be generated when inserting or removing the battery pack, which could lead to a fire.
3. CHARGE IN A WELL-VENTILATED AREA. Do not block the charger vents. Keep them clear to allow
for proper ventilation. Do not allow smoking or open flames near a charging battery pack. Vented gases
may explode.
NOTE: The safe temperature range for charging the battery is 50°F to 104°F. Do not charge the battery
outside in freezing weather; charge it at room temperature.
4. MAINTAIN CHARGER CORD. When unplugging the charger, pull the plug, not the cord, from the
receptacle to reduce the risk of damage to the electrical plug and cord. Never carry the charger by its
cord or yank it by the cord to disconnect it from the receptacle. Keep the cord away from heat, oil and
sharp edges. Make sure the cord will not be stepped on, tripped over or subjected to damage or stress
when the charger is in use. Do not use the charger with a damaged cord or plug. Replace a damaged
charger immediately.
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5. DO NOT USE AN EXTENSION CORD UNLESS IT IS ABSOLUTELY NECESSARY. Using the wrong,
damaged or improperly wired extension cord poses a risk of fire and electric shock. If an extension
cord must be used, plug the charger into a properly-wired 16AWG or larger extension cord with the
female plug matching the male plug on the charger. Make sure that the extension cord is in good elec
trical condition.
6. CHARGER IS RATED FOR 120V, 60Hz AC ONLY. The charger must be plugged into an appropriate
receptacle.
7. USE ONLY RECOMMENDED ATTACHMENTS. Use of an attachment not recommended or sold by
WEN Products may result in risk of fire, electric shock or personal injury.
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