Makita DCG140, DCG180 - Cordless Caulking Gun Manual

SPECIFICATIONS

Model		DCG140		DCG180
Max feed force		5,000 N
Feed speed		0 - 28 mm/s
Stroke	with short (300 ml) holder	214 mm
	with long (600 ml) holder	350 mm
Overall length	with short (300 ml) holder	404 mm
	with long (600 ml) holder	538 mm
Standard battery cartridge		BL1415 / BL1415N	BL1430 / BL1430B / BL1440 / BL1450 / BL1460B	BL1815 / BL1815N / BL1820 / BL1820B	BL1830 / BL1830B / BL1840 / BL1840B / BL1850 / BL1850B / BL1860B
Net weight	with short (300 ml) holder	2.0 kg	2.2 kg	2.1 kg	2.3 kg
	with long (600 ml) holder	2.4 kg	2.6 kg	2.5 kg	2.7 kg
Rated voltage		D.C. 14.4 V		D.C. 18 V

• Due to our continuing program of research and development, the specifications herein are subject to change without notice.
• Specifications and battery cartridge may differ from country to country.
• Weight, with battery cartridge, according to EPTA-Procedure 01/2003

Intended use

This tool is intended for applying caulking material to surface.

Noise

The typical A-weighted noise level determined according to EN60745:
Sound pressure level (L_pA): 70 dB (A) or less
Uncertainty (K): 3 dB (A)
The noise level under working may exceed 80 dB (A)

Wear ear protection

Vibration

The vibration total value (tri-axial vector sum) determined according to EN60745:
Vibration emission (a_h): 2.5 m/s² or less Uncertainty (K): 1.5 m/s²

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.

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.

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).

General Power Tool Safety Warnings

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.

CORDLESS CAULKING GUN SAFETY WARNINGS

1. Keep hands and clothes away from the rod and the plunger area. Otherwise your finger or clothes may be pinched.
2. Always be sure you have a firm footing.
3. Hold the tool firmly.
4. Always work in well ventilated area and wear proper protections in accordance with the operation.
5. Read and follow the manufacture's instructions on caulking material or adhesive material before usage.

SAVE THESE INSTRUCTIONS.

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.
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.

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).

FUNCTIONAL DESCRIPTION

• 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

► Fig.1:

1. Red indicator
2. Button
3. Battery cartridge

• Always switch off the tool before installing or removing of the battery cartridge.
• 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.

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.

• 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.
• Do not install the battery cartridge forcibly. If the cartridge does not slide in easily, it is not being inserted correctly.

Battery protection system

The tool is equipped with a battery protection system. This system automatically cuts off power to the motor to extend battery life. The tool will automatically stop during operation if the tool and/ or battery are placed under one of the following conditions:

• Overloaded:
  The tool is operated in a manner that causes it to draw an abnormally high current. In this situation, release the switch trigger on the tool and stop the application that caused the tool to become overloaded. Then pull the switch trigger again to restart. If the tool does not start, the battery is overheated. In this situation, let the battery cool before pulling the switch trigger again.
• Low battery voltage:
  The remaining battery capacity is too low and the tool will not operate. In this situation, remove and recharge the battery.

NOTE: The overheat protection works only with a battery cartridge with a star mark.

► Fig.2:

1. Star marking

Indicating the remaining battery capacity

Only for battery cartridges with the indicator

► Fig.3:

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.

Indicator lamps			Remaining
Lighted	Off	Blinking	capacity
			75% to 100%
			50% to 75%
			25% to 50%
			0% to 25%
			Charge the battery.
			The battery may have malfunctioned.

NOTE: Depending on the conditions of use and the ambient temperature, the indication may differ slightly from the actual capacity.

Speed adjusting dial

► Fig.4:

1. Speed adjusting dial

The tool speed can be adjusted by turning the dial. Higher speed is obtained when the dial is turned in the direction of number 5, lower speed is obtained when it is turned in the direction of number 1.

NOTE:

• The speed adjusting dial can be turned only as far as 5 and back to 1. Do not force it past 5 or 1, or the speed adjusting function may no longer work.
• Depending on the type and conditions of caulking material, it may not be fed at low speed. In this case, set the speed adjusting dial higher.

Overload warning lamp

► Fig.5:

1. Warning lamp

The warning lamp flickers in red when the tool is overloaded. If the load reaches some point, the lamp keeps lighting in red and the tool stops. To restart the tool, release the trigger and pull the trigger again.

NOTE: Check what causes the overload when the lamp flickers or lights up. Change the parameter of the speed adjusting dial lower, or increase the diameter of the nozzle.

Switch action

• Before inserting the battery cartridge into the tool, always check to see that the switch trigger actuates properly and returns to the "OFF" position when released.
• When not operating the tool, push the trigger-lock button from A side to lock the switch trigger in the OFF position.

► Fig.6:

1. Lock lever
2. Switch trigger

To prevent the switch trigger from accidentally pulled, the trigger-lock button is provided.
To start the tool, push the trigger-lock button from B side and pull the switch trigger. Tool speed is increased by increasing pressure on the switch trigger. Release the switch trigger to stop.
After use, press in the trigger-lock button from A side.

Lighting up the lamp

• Do not look in the light or see the source of light directly.

► Fig.7:

1. Lamp

Pull the switch trigger to light up the lamp. The lamp keeps on lighting while the switch trigger is being pulled. The lamp goes out approximately 10 seconds after the switch trigger is released.

NOTE:

• Use a dry cloth to wipe the dirt off the lens of lamp. Be careful not to scratch the lens of lamp, or it may lower the illumination.
• When the tool is overheated, the lamp flickers. Cool down the tool fully before operating again.

Drip preventive function
The motor keeps running for a short time even after the trigger is released. It releases the pressure of the caulking material and prevents dripping.

ASSEMBLY

• Always be sure that the tool is switched off and the battery cartridge is removed before carrying out any work on the tool.
• Always place the tool on the ground or workbench when carrying out any assembling work. The tool without being held tight may loose balance and cause injury.

Installing holder joint

► Fig.8
Attach the holder joint firmly along the tool, set the plate, and fix them with screws tightly. To remove the holder joint, follow above procedure in reverse.

NOTE:

• There are two types of holders (optional accessory), short holder (300ml) and long holder (600ml). Use appropriate holder joint accordingly.

Installing rod and piston

► Fig.9

► Fig.10
Insert the rod into the slit of the tool.
Attach the piston and tighten it with a screw. To remove the rod and piston, follow the installation procedure in reverse.

NOTICE:

• The teeth on the rod must point down.
• There are three types of pistons. Piston A for cartridges. Piston B for film type packs. Piston C for direct filling.
• Choose appropriate piston in accordance with the type of caulking material container. Improper piston may cause leakage or tool breakage.
• There are two types of rods. The short rod for the short holder (300ml), and the long rod for long holder (600ml). Use appropriate rod in accordance with holder type.
• Always keep the rod and piston clean. Adhering caulk may damage the tool.

Installing holder

► Fig.11

► Fig.12
Hold the bottom of the holder and the holder joint, then turn the holder clockwise. Tighten it firmly until it stops. Make sure the holder is tightened firmly. Otherwise the tool may be damaged.
To remove the holder, turn it counter clockwise.

NOTE:

• You can rotate the holder in accordance with required situations to facilitate the operation.
• The short holder (300ml) is intended for the cartridges only. Use only piston A with short holder (300ml), and do not use it with film type packs or direct filling. Also use appropriate rod in accordance with the holder type.

NOTICE:

• Make sure the piston A is attached to the rod. Do not use other type of piston for cartridge.

Installing the cartridge into the short holder (300ml)

► Fig.13:

1. Rod handle

Pull the rod handle backwards slowly until it stops.

► Fig.14

Insert the cartridge into the holder as illustrated. Push the rod gently until the piston touches the bottom of the cartridge.
To remove the cartridge, pull the rod backwards until it stops, then lift out the cartridge.

Installing the cartridge into the long holder (600ml)

► Fig.15:

1. Holder cap
2. Rod handle

Remove the holder cap from the holder.
Pull the rod handle backwards slowly until it stops.

► Fig.16:

1. Holder cap

Insert the cartridge into the holder.
Attach the holder cap. Make sure it is tightened firmly. Push the rod gently until the piston touches the bottom of the cartridge.
To remove the cartridge, remove the holder cap, then take out the cartridge.

NOTICE:

• Always check the cartridge for puncture or damage before installing. Do not use damaged cartridge, otherwise the tool may be damaged.
• When using a partially used cartridge, remove any adhered material on the cartridge.

Installing film type pack
NOTICE:

• Make sure the piston B is attached to the rod. Do not use other type of piston for film type pack.
• Film type pack can be installed in the long holder (600ml) only.

Remove the holder cap, the nozzle and the rubber ring from the holder.

Pull the rod handle backwards slowly until it stops.

► Fig.17

Cut off the tip of the film type pack.
Insert the film type pack into the holder.

► Fig.18:

1. Rubber ring
2. Nozzle
3. Holder cap

Attach the rubber ring, the nozzle and the holder cap.
Make sure holder cap is tightened firmly. Push the rod gently until the piston touches the bottom of the film type pack.

NOTE:

• Always check the film type pack for puncture or damage before installing. Do not use damaged pack, otherwise the tool may be damaged.

NOTICE:

• Make sure the piston C is attached to the rod. Do not use other type of piston for direct filling.
• Direct filling can only be performed with the long holder (600ml).

Remove the holder cap, the nozzle and the rubber ring from the holder.
Make sure the rod handle is placed at the most front position. Dip the mouth of the holder into the caulking material. Pull the rod handle slowly until required amount of caulking material is filled in the holder.
Attach the rubber ring, the nozzle and the holder cap.
Make sure holder cap is tightened firmly.

NOTICE:

• Clean the holder with appropriate solvent after every day's work. Otherwise adhered caulking material may cause tool breakage.

OPERATION

• Do not touch the rod during operation. Otherwise your finger may be pinched between the rod and the housing of the tool.
• Always wear goggles during operation.

NOTICE:

• Do not cover vents, or it may cause overheating and damage to the tool.
• If you can not pull out the rod, turn the speed adjusting dial to 1, and pull the switch trigger for a moment, and try to pull the rod out after the motor stopped. If the rod is still clogged, perform the same action until the rod is able to move. Cut off the tip of the nozzle suitable for individual operation. Be careful how much you cut the nozzle. The diameter of the nozzle affects the amount of caulking material dispensed.

Pull the trigger to dispense caulking material. The amount of the caulking material dispensed is determined by the trigger, the speed adjusting dial, the diameter of the nozzle opening, caulking material type, and temperature. It is recommended that the speed adjusting dial is set to '1' and pull the trigger slowly at the first time to test how much amount of caulking material is dispensed.

When the rod reaches front end, the motor starts idling. Replace the caulking material when it happens.

NOTE: If the caulking material is not dispensed, check the following items:

• Nozzle tip is not cut adequately. Cut the nozzle tip suitable for individual operation.
• Hardened material gets clogged in the nozzle. Remove the hardened material.
• The cartridge is damaged. Replace the cartridge.
• Caulking material is stiff. Warm the material until it becomes soft.
• The wrong piston is used. Use appropriate piston.

MAINTENANCE

• Always be sure that the tool is switched off and the battery cartridge is removed before attempting to perform inspection or maintenance except for the following troubleshooting related to the light.
• Never use gasoline, benzine, thinner, alcohol or the like. Discoloration, deformation or cracks may result.
• Clean the holder and the rod after every day's work. Keep them free from the adhesive material. Remove the caulking material before it hardens. Remained adhesive material may cause breakage of the tool.

To maintain product SAFETY and RELIABILITY, repairs, carbon brush inspection and replacement, any other maintenance or adjustment should be performed by Makita Authorized Service Centers, always using Makita replacement parts.

OPTIONAL ACCESSORIES

• 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.

• Piston A
• Piston B
• Piston C
• Short holder (300ml) set
• Long holder (600ml) set
• Nozzle
• Safety goggles
• Makita genuine battery and charger

NOTE:

• Some items in the list may be included in the tool package as standard accessories. They may differ from country to country.