K53 and K54
BG353
1108
0011
BG100 BATTERY OPERATED GREASE GUN
INSTRUCTION MANUAL
INTRODUCTION
Thank you for purchasing a Macnaught BG100 Battery
Operated Grease Gun.
The Macnaught BG100 Battery Operated Grease Gun is
designed to give continuous reliable greasing to pressures
up to 5000 psi. The BG100 is suitable for bulk, cartridge or
grease pump filling with greases up to and including NLGI
No2 consistency.
A wide range of Macnaught greasing accessories including
Flexible Extentions, Needle Point Couplers, Adaptors and
Button Head Couplers are available from your Macnaught
dealer
Please read and retain this instruction sheet to assist you in
assembly and maintenance of this product.
OPERATION
The BG100 Battery operated grease gun will give continuous
grease flow when the trigger is pressed. Grease flow will stop
when the trigger is released.
WARNING
IMPORTANT INFORMATION
Read this information carefully before use. Failure to follow all
instructions listed below may result in electric shok, fire and/or
serious injury. The term “power tool” in all of the warnings
listed refers to your battery operated (cordless) power tool.
Make sure all operators have adequate access to the following instructions.
GENERAL SAFETY
WORK AREA
1) Keep work area clean and well lit. Cluttered and dark areas
invite accidents
2) DO NOT operate power tools in explosive atmospheres,
such as in the presence of flammable liquids, gases or
dust. Power tools create sparks, which may ignite the dust
or fumes
3) Keep children and bystanders away while operating a power
tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
4) Power plugs must match the outlet. Never modify the plug in
any way. Unmodified plugs and matching outlets will
reduce the risk of electric shock.
5) Avoid body contact with earthed or ground surfaces such as
pipes radiators, ranges and refrigerators. There is an
increased risk of electric shock if your body is earthed or
grounded
6) DO NOT expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
7) DO NOT abuse the power cord. Keep cord away from heat,
oil, sharp edges or moving parts. Damaged or entangled
cords increase 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 moment of inattention while
operating power tools may result in serious personal injury.
2) Use safety equipment. Always were eye protection. Safety
equipment such as dust mask, non skid safety shoes, hard
hat, or hearing protection used for appropriate conditions
will reduce personal injuries.
3) Avoid accidental starting. Carrying power tools with your
finger on the switch invites accidents.
4) DO NOT over reach. Keep proper footing and balance at all
times. This enables better control of the power tool in
unexpected situations.
5) Dress properly. DO NOT wear loose clothing or jewellery.
Keep your hair, clothing and gloves away from moving parts.
Loose clothes jewellery or long hair can be caught in
moving parts.
POWER TOOL USE AND CARE
6) 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.
1
7) 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.
8) Store idle power tools 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.
9) Maintain power tools. Check for misalignment or binding
of moving parts, breakage of parts and any other
condition that may affect the power tools operation. If
damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
10) Use the power tool, accessories and tool bits etc., in
accordance with these instructions and in the manner
intended for the particular type of power tool, taking into
account the working conditions and the work to be
performed. Use of the power tool for operations different
from intended could result in a hazardous situation.
SERVICE
Have your power tool serviced by a qualified repairperson
using only identical replacement parts. This will ensure that
the safety of the power tool is maintained.
BATTERY CHARGER SAFETY
Before using charger, read all instructions and cautionary
marking on charger, battery pack, and product using battery
pack.
WARNING
120/230/240 volts present at charging terminal. DO NOT
probe with conductive objects - Danger of electric shock or
electrocution.
WARNING
If battery-pack case is cracked or damaged, DO NOT insert
into charger - Danger of electric shock or electrocution.
1) The charger and battery pack is specially designed to
work together. DO NOT attempt to charge the battery pack
with any other chargers.
2) DO NOT expose charger to rain or snow.
3)The battery charger MUST NOT be used for any other use
than for charging the rechargeable batteries supplied with
the BG100 .
4) To reduce risk of damage to electric plug and cord, pull by
plug rather than cord when disconnecting charger.
5) Make sure cord is located so that it will not be stepped on,
tripped over, or otherwise subjected to damage or stress.
6) An extension cord should not be used unless absolutely
necessary. Use of improper extension cord could result in
risk of fire, electric shock, or electrocution.
6) An extension cord must have adequate wire size (AWG or
American Wire Gauge) for safety. When using more than
one extension, make sure each individual extension
contains at least the minimum wire size
Recommended Minimum AWG Size for Extension Cords
Total Extension cord length (feet)
25ft - 50ft - 75ft - 100ft - 125ft - 150ft - 175ft
Wire Guage
18 - 18 - 16 - 16 - 14
- 14
- 12
7) The charger is ventilated through slots in the top and the
bottom of the housing. DO NOT place any object on top
of charger or place the charger on a soft surface that might
block the ventilation slots and result in excessive internal
heat. Place the charger in a position away from any heat
source.
8) DO NOT operate charger with damaged cord or plug have them replaiced immediatly.
9) DO NOT operate charger if it has received a sharp blow,
been dropped, or otherwise damaged in any way; take it to
an authorized service centre.
10) DO NOT disassemble charger; take it to an authorized
service centre when service or repair is required.
11) To reduce risk of electric shock, unplug charger from
outlet before attempting any cleaning. Removing the
battery pack will not reduce this risk.
12) NEVER attempt to connect 2 chargers together.
13) DO NOT store or use the tool and battery pack in
locations where the temperature may reach or exceed
40°C/105°f (such as outside sheds or metal buildings in
summer).
14)The charger is designed to operate on standard
household electrical power. DO NOT attempt to use it on
any other voltage!
BATTERY SAFETY INFORMATION
NOTE: The battery pack is not fully charged out of the carton!
Fully charge battery prior to first use. First read the safety
instructions below. Then follow charging notes and procedures.
1) To install the battery pack into the tool handle, align the
base of the tool with the notch inside the tool‘s handle and
slide the battery pack firmly into the handle until you hear
the lock snap into place.
2) To remove the battery pack from the tool, press the release
buttons and firmly pull the battery pack out of the tool
handle.
3) Insert it into the charger as described in the charger section
of this manual.
4) DO NOT incinerate the battery pack even if it is severely
damaged or is completely worn out. The battery pack can
explode in a fire.
5) A small leakage of liquid from the battery pack cells may
occur under extreme usage or temperature conditions.
This does not indicate a failure. However, if the outer seal
is broken and this leakage gets on your skin:
a. Wash quickly with soap and water.
b. Neutralize with a mild acid such as lemon juice or
vinegar.
c.If battery liquid gets into your eyes, flush them
with clean water for a minimum of 10 minutes and
seek immediate medical attention. (Medical note: The
liquid is 25-35% solution of potassium hydroxide.)
6) DO NOT attempt to open the battery pack for any reason.
If the plastic housing of the battery pack breaks or cracks,
immediately discontinue use and do not recharge.
2
7) DO NOT carry extra battery packs in aprons, pockets, or
toolboxes along with their metal objects. Battery pack could
be short circuited causing damage to the battery pack and
possibly causing severe burns or fire.
NOTE: The battery pack should be recharged when the gun
fails to deliver sufficient grease flow. DO NOT CONTINUE to use
under these conditions. Follow the charging procedure. You
may also charge a partially used pack whenever you desire
with no adverse affect on the battery pack.
8) Charge the battery packs only in battery charger provided.
NOTE: Review and observe all of the “Important Charging
Notes” in the charger instruction section of this manual.
NOTE: The batteries in the battery pack are the nickel-cadmium types. Cadmium is considered to be a toxic material
by the Environmental Protection Agency. Before disposing of
damaged or worn out Nickel-Cadmium battery packs, check
with your state Environmental Protection Agency to find out
about special restrictions on the disposal of these battery
packs.
BATTERY CHARGING INSTRUCTIONS
READ ALL OF THE INSTRUCTIONS IN THE BATTERY CHARGER SAFETY
SECTION
OF THIS MANUAL BEFORE ATTEMPTING TO CHARGE THE BATTERY PACK.
Charger is a one hour fast charge. Light on indicates
charging, light off indicates fully charged. Remove battery
as soon as possible after light turns off.
1) To install the battery pack into the charger, align the rib on
the battery pack with the notch inside charger and slide
the battery pack firmly into place. DO NOT force the battery
into the charger.
DO NOT charge the battery in damp or wet environment.
Longest life and best performance can be obtained if the
battery pack is charged when the air temperature is between
18°C/65°f and 24°C/75°f. DO NOT charge the battery pack in
an air temperature below +4.5°C/+40°f, or above +40.5°C/
105°f. This is important and will prevent serious damage to
the battery pack.
The charger and battery pack may become warm to touch
while charging. This is a normal condition, and does not
indicate a problem
Under certain conditions, with the charger plugged in to the
power supply, the exposed charging contacts inside the
charger can be shorted by foreign material. Foreign materials
of a conductive nature such as, but not limited to, steel
wool,
aluminium foil, or any build-up of metallic particles
should be kept away from charger cavities. Always unplug
the charger from the power supply when there is no battery
pack in the cavity. Unplug charger before attempting to clean.
DO NOT freeze or immerse charger any type of liquid.
WARNING
DO NOT allow any liquid to get inside charger. Electric shock
may result. To facilitate the cooling of the battery pack after
use, avoid placing the charger or battery pack in a warm
environment such as in a metal shed, or an uninsulated
trailer.
CAUTION: Never attempt to open the battery pack for any
reason. If the plastic housing of the battery pack breaks or
cracks, return to a service centre for recycling.
IMPORTANT: The electrical component of this product is not
user serviceable. There are no user serviceable parts inside
the charger. Servicing at an authorized service centre is required to avoid damage to static sensitive internal
components.
Always use correct battery pack (pack supplied or replacement pack exactly like it.) Never install any other battery
pack. It will ruin your tool and may create a hazardous
condition.
GREASE GUN OPERATION
SELECT FOLLOWER POSITION
NOTE :
Refer to Fig1 for th correct follower position
How to select Follower position
This battery pack has an internal temperature limit that, when
exceeded, will temporarily stop the full charge current. The
normal charge cycle will resume when the temperature falls
below the preset limit. The charge time may be extended
beyond the indicated time. To prevent overheating, do not
cover the charger and do not charge battery packs in direct
sunlight or near heat sources.
2) If the battery pack does not charge properly.
a) Check current at receptacle by plugging in a lamp or
other appliance.
(Fig 1)
b) Check to see if receptacle is connected to a light switch,
which turns power off when you turn out the lights.
c) Move charger and battery pack to a location where the
surrounding air temperature is approximately 18°C/65°f
d) If the battery pack does not charge properly Check
current at receptacle by plugging in a lamp or other
appliance.
3
HOW TO INSTALL A CARTRIDGE
Note: Select the correct follower position (see Fig 1 )
1) Pull the follower rod back until the rod groove can be pulled
into the barrel slot.
2) Remove the large end cap from the cartridge.
3) Slide the large open end first into the barrel.
4) Remove the small end cap from the cartridge.
NOTE: The most common reason for no grease delivery or
slow grease recovery, is either the grease gun has not
been bled of air correctly or oil seperation from the grease
has occurred and the grease is now too thick to flow through
the gun correctly.
To help prevent oil seperation of the grease. When the gun
is not in use, release the spring tension from the follower,
by pulling back the follower rod, and lock it into the back of
the barrel.
5) Screw the gun body assembly onto the barrel.
6) Unlock the follower rod from the barrel.
7) Lock follower rod (Fig 2), and apply light pressure on the
pull handle (Fig.3), at the same time press the ball in the
filler bleeder until grease appears.
DISASSEMBLY
(Fig 2)
(Fig 3)
8) Pull the trigger. If grease does not appear at the coupler
repeat step 7.
9) Unlock the follower rod and push the rod into the barrel.
HOW TO BULK FILL BY SUCTION
1) To remove the battey, press the two buttons located on
either side of the battery at the same time pull the battery
out of the handle assembly
2) Unscrew and remove the 4 pozi-drive screws (4) .
Note: Select the correct follower position (see Fig 1)
1) Lock follower (Fig 2)
3) Carefully remove the head assembly (6) from the handle
assembly (3 ).
4) Remove the 4 pozi-drive screws (12) and carefully remove
the nozzle casting assembly (11 ) from the head (6 ).
2) Unscrew the barrel from the gun body 2 to 3 turns.
3) Pull the rod back and retain in barrel slot (Fig.4)
5) Carefully remove all the components (springs and balls )
from the nozzle casting (11) and head assembly (6), clean
and inspect for any signs of wear or damage.
4) Unscrew the barrel from the gun body.
5) Release the follower rod from the barrel slot.
6) Insert the open end of the barrel into the
grease, pull the rod back slowly, and at same
time push the barrel into the grease.
Pull back the rod until the groove in the rod
appears then push the rod into the barrel
NOTE: The electrical components of the BG100 grease gun
are not user serviceable (eg, Battery Charger, Battery, Trigger
Switch or Motor). Any if any electrical component in this gun is
found to be defective or damaged, either the complete
Handle assembly (includes = Motor, Trigger Switch, Plastic
body housing) or Battery or Battery charger must be ordered.
6) Replace any worn or damaged components. Do not reuse
the original pozi-drive screws.
(Fig 4)
7) Wipe clean and screw the gun body assembly onto the
barrel.
8) Repeat steps (7), (8), (9) refer (How to install a cartridge).
FAST FILLING WITH A J2 GREASE PUMP
Note: Select the correct follower position (see Fig 1 )
ASSEMBLY
1) Ensure that both ball seats in the head casting (6 ) are
clean and contamination free before assembly.
2) Fit the 2 steel balls (8) into the head casting (6) followed by
the 2 check valve springs (9).
3) Check that the face seal (10 ) is not damaged. Replace if
found to be worn or damaged.
1) Lock the follower rod (Fig.2)
4) Carefully fit the nozzle casting (11) to the head casting (6),
ensuring that all the springs, balls and plunger remain in
position, and fit the 4 new socket head screws (12).
2) Slide the filler bleeder into the nozzle
on the pump (Fig.5).
3) Fill with grease until the groove in the
rod is visible at the end of the barrel.
4) Repeat steps (7), (8), (9) refer
(How to instal a cartridge).
5) Carefully align the flat on the motor shaft to the
corrosponding flat in bore of the shaft in the head casting
and slide together.
(Fig 5)
Note: Should the gun fail to deliver grease refer to the Trouble
Shooting Guide on page 8.
4
6) Rotate the head into the correct location and fit the 4 new
pozi-drive screws (4) to lock the head and handle
assemblies firmly together. (Torque setting 4 nm / 3 ft.lb)
1
BATTERY CHARGER
7) After the battery has been fully charged, locate the battery
into position
400 gram model follower pictured
15
20
17
18
16
19
5
6
4
8
10
9
12
13
14
21
8
3
9
11
7
ORDER FOR REPACEMENT
Item
450gram
400gram
Part No
Part No
450 gram model
400 gram model
Part / Set
Part / Set
No Off
K27-2K
K14A-1K
Kit Ref Description
(B)
1
BG307
BG307
1
BG307s
BG307s
BATTERY CHARGER (AUST)
1
BG308
BG308
1
BG308s
BG308s
BATTERY CHARGER (USA)
1
BG309
BG309
1
BG309s
BG309s
BATTERY CHARGER (EURO)
1
BG310
BG310
1
BG310s
BG310s
BATTERY CHARGER (UK)
2
BG304
BG304
BG300A
BG300A
1
BG304s
BG300s incl item 4
BG304s
BG300s incl item 4
BATTERY
3
4
N100
N100
4
N100s
N100s
POZI DRIVE SCREWS
N170s
BG200s (BSP/450gram)
N171s
5
N170
N171
1
6
BG200A
BG201B
1
6
BG201N
HANDLE ASSEMBLY
B
SEAL WASHER
BG201Bs (BSP)
HEAD ASSEMBLY
BG201Ns (NPT)
HEAD ASSEMBLY
KF85s
FILLER BLEEDER
7
KF85
KF85
1
8
N401
N401
2
9
BG208
BG208
2
BG209s
BG209s
10
BG207
BG207
1
incl item 12
incl item 12
11
BG202
BG202
1
BG202s incl item 10,12
BG202s incl item 10,12
11
BG202N
BG202N
1
BG202Ns incl item 10,12
BG202Ns incl item 10,12
NOZZLE (NPT)
12
MS444
MS444
4
MS444s
MS444s
POZI DRIVE SCREWS
1
KF52s
KF52s
FLEXIBLE EXTENTION (BSP)
KF52Ns
KF52Ns
FLEXIBLE EXTENTION (NPT)
13
KF52-1
KF52-1
13
KF52-1N
KF52-1N
KF85s
2
FOLLOWER KIT
9/32" STEEL BALLS
CHECK VALVE SPRINGS
FACE SEAL
NOZZLE (BSP)
14
KY-1
KY-1
1
KY
KY
COUPLER (BSP)
14
KY-1N
KY-1N
1
KY-BC
KY-BC
COUPLER (NPT)
15
KF111
KF27
1
16
KF26
KF26
1
17
KF30
KF25
1
KF110s incl item 5
KF27s incl item 5
BARREL
KF30s incl item 20
KF30s incl item 20
FOLLOWER ROD
END CAP
18
KF104
KF104
1
19
K27-2K
KF14A
1
K27-2K incl item 5
KF14A-2K incl item 5
FOLLOWER SPRING
20
KB13
KB13
1
KB13S
KB13S
PULL HANDLE
21
BG214
BG214
1
BG214s
BG214s
SEAL PLUG
B
FOLLOWER ASSEMBLY
5
NOTES:
6
DECLARATION OF CONFORMITY
We declare that this product is in conformity with the following
standards or standardisation documents: EN50144, EN55014-1 and
EN55014-2 for Battery Powered Tools; and EN60335-1, EN6035-229, EN55014-1, EN5014-2, EN61000-3-2, EN61000-3-3, EN610004-2, EN61000-4-4, EN61000-4-5, EN61000-4-6 and EN61000-4-11
for Battery Chargers; in accordance with the provisions of the
regulations 73/23/EEC, 93/68/EEC, 89/336/EEC.
2nd November 2004
Signed by: S.Doyle
DECLARATION OF CONFORMITY
Report Number E181557
2nd November 2004
Signed by: S.Doyle
DECLARATION OF CONFORMITY
N20215
Battery Charger examined in accordance
with AS/NZS 3350.2.29:2001
Macnaught Pty Ltd
Signed by: S.Doyle
N10097
2nd November 2004
7
TROUBLE SHOOTING GUIDE
TROUBLE
Gun fails to deliver the correct
grease pressure
REMEDY
CAUSE
a) Dirt under the outlet check valve balls
b) Battery is flat or under charged
c) Damaged piston o’ring
Gun does not operate when the
trigger is pressed
c) Replace head assembly
a) Battery is flat or undercharged
a) Re-charge the battery
b) Fault in the electric motor
b) Replace handle assembly
c) Replace handle assembly
d) Replace handle assembly
c) Fault in the wiring
d) Damaged trigger / switch
No grease delivery
a) Clean any dirt or contamination from the
pressure relief valve and piston check valves
b) Re-charge the battery
a) Air in the system
b) Viscosity of the grease is too high
c) Oil seperation of the grease has
occured (now too thick for the the gun to
work correctly)
d) Battery is flat or under charged
a) Bleed the system (refer to = How to
install a cartridge, items 7,8,9)
b) Change grease to NLGI no2
consistancy
c) Clean out the hardened grease and
remove the seperated grease from the
cartridge or fit a new cartridge of grease
d) Re-charge the battery
SPECIFICATIONS
Accuracy
Battery Voltage
Battery Capacity
Rec. Grease Type
Est. Battery Life
Output
Maximum Pressure
Wetted Components
Weight
Minimum Temp
Maximum Temp
Dimensions
+ / - 1% of Reading
12 Volt NiCad
1300 mAh
up to and including NLGI no2
* approximately 4 grease cartridges.
* 100g (3.52oz) per minute at free flow
34,500kPa / 5,000psi / 345 Bar
Aluminium, Nitrile Rubber, Mild Steel
3kg (6.6 lbs)
0 deg C / 32 deg F
50 deg C / 122 deg F
38cm (15") long x 30.5cm (12.5") high x 7.2cm (2.8") wide
* Subject to operating conditions
macnaught warranty
Macnaught Pty Ltd
PO Box 90 Arncliffe NSW 2205 Australia
Telephone (02) 9567 0401
Facsimile (02) 9597 7773
Email: [email protected]
Web: www.macnaught.com.au
1. Macnaught Pty Ltd (“Macnaught”) warrants that all products manufactured by Macnaught and/or supplied by
Macnaught under the “Macnaught” brand, excluding M-Series positive displacement meters (“Meters”) and components subject to wear, will be free from any defects caused by faulty materials or workmanship (“Warranty”) for a
period of 5 years from the date of purchase of the product.
2. For products (excluding Meters) which carry the “Macnaught design ”endorsement, an additional Warranty period
of 5 years applies to all mechanical components (excluding electronic and electrical components), giving a total
Warranty period of 10 years.
3. For Meters, the Warranty period is 12 months from the date of purchase of the product.
4. For components contained in all products which are usually subject to wear from normal operation of the products
(such as o-rings, seals, springs, hoses and batteries), the Warranty period is 12 months from the date of purchase
of the relevant product.
5. For products and components which are not manufactured by Macnaught and are supplied by Macnaught under
a brand name other than “Macnaught”, the Warranty period is the longer of 12 months from the date of purchase
of the relevant product and the period of the manufacturer’s warranty.
6. The warranties contained in clauses 1, 2, 3, 4 and 5 above are conditional on the purchaser, during the relevant
Warranty period:
a. delivering to Macnaught a detailed notice setting out full details of any defect in any product and
details of the date and place of purchase (together with copies of purchase receipts and/or
other supporting documents), and
b. at the purchaser’s own cost, returning the defective product to the nearest
authorised Macnaught service centre.
7. Subject to compliance by the purchaser with clause 6, Macnaught shall, at its option, repair or replace any product
or component found defective by its inspection by reason of faulty materials or workmanship of Macnaught.
8. This Warranty does not cover the failure of products, parts or components which, in the sole judgment of the
Macnaught, arises other than from faulty materials or workmanship of Macnaught, including misuse, abrasion,
corrosion, negligence, accident, substitution of non-Macnaught parts, unauthorised modification, improper use,
storage or handling, faulty installation or tampering by the purchaser or any third party.
9. If Macnaught’s inspection discloses no defect in material or workmanship, repair or replacement and return (at
Macnaught’s sole option) will be made at customary charges, which will be advised to the purchaser.
10. Macnaught’s liability and the purchaser’s rights under this Warranty shall be limited to the repair or replacement
of defective products or components and particular, shall not extend to any direct, special, indirect or consequential
damage or losses of any other warranties.
11. The foregoing Warranty supersedes, voids and is in lieu of any other warranties.
This Warranty does not form part of, nor does it constitute, a contract between Macnaught and the end-user or
purchaser. It is additional to any warranty given by the seller of the products. This Warranty does not exclude, limit,
restrict or modify the non-excludable rights or remedies conferred upon the end-user or purchaser, or the nonexcludable duties or liabilities imposed on the seller or Macnaught, by Part V, Division 2, 2A, and Part VA of the Trade
Act1974 (Commonwealth) or other rights conferred on the end-user or purchaser or duties or liabilities imposed upon
Macnaught.
8
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