ECHNICAL INFORMATION
PRODUCT
P 1/ 11
T
Models No.
Description
BCG140 / BCG180 (LXGC01*1)
L
Cordless Caulking Gun
*1 Model number for North and Central American countries
H
W
CONCEPT AND MAIN APPLICATIONS
Model BCG140 and BCG180 are Cordless Caulking Guns
powered by 14.4V/18V Li-ion battery.
(The image above is BCG180
with 300ml size holder and Battery BL1815.)
They are compatible with the following sealants by changing
Holder and Piston:
• 300ml/ 600ml cartridge
• Sausage pack
• Bulk sealant
Their other main features are:
• Compact and lightweight design
• High work efficiency
• Variable speed control by dial and trigger switch
for constant bead of sealant
Dimensions: mm (")
Model No.
Length (L) 404 (15-7/8)*2, 538 (21-1/4)*3
Width (W) 108 (4-1/4)
BCG140
BCG180
Height (H) 264 (10-3/8)*4/ 281 (11-1/8)*5
*2 with 300ml size holder
*3 with 600ml size holder
*4 with 1.3Ah Li-ion battery of BL1415 or BL1815
*5 with 3.0Ah Li-ion battery of BL1430 or BL1830
• Anti-drip function that stops excess sealant from oozing out
just upon release of the switch trigger
Specification
Specification
Standard equipment
Holder for 300ml type model
Model
BCG140
BCG180
Holder for 600ml type model
Holder joint for 300ml type model
Holder joint for 600ml type model
Piston for cartridge
Piston for sausage pack
Piston for bulk sealant
Rubber ring for sausage pack
Rubber ring for bulk sealant
Nozzle for sausage pack
Cell
Li-ion
Voltage: V
14.4
18
Battery Capacity: Ah
1.3/ 3.0
19/ 44
1.3 (1.5*5)/ 3.0
24 (27*5)/ 54
Energy capacity: Wh
Charging time: min.
Max output: W
15, 22 with DC18RC
130 150
Max pushing force: N (lbs)
5,000 (1,100)
No load speed: mm/sec. (in/min.)
0 - 28 (0 - 66)
Nozzle for bulk sealant
Plastic carrying case or Tool bag
(for some countries only)
300ml holder model
600ml holder model
300ml holder model
600ml holder model
by trigger
214 (8-3/4)
Stroke length:
mm (")
350 (13-3/4)
Note: The standard equipment
for the tool shown above
may vary by country.
Cartridge
Compatible
sealant size
Cartridge, Sausage pack, Bulk sealant
Yes
Yes
Variable speed control
by dial
Optional accessories
Li-ion battery BL1415 (for BCG140)
Li-ion battery BL1430 (for BCG140)
Li-ion battery BL1815 (for BCG180)
Li-ion battery BL1830 (for BCG180)
Fast charger DC18RC
Charger DC18SD
Charger DC24SC
Automotive charger DC18SE
Holder sets
Continuous run time (approx.) on
a single full battery charge with
300ml cartridge: cartridge quantity
180/ 410
210/ 500
Anti-drip function
Overload protection function
Rubberized soft grip
Trigger lock
Yes
Yes
Yes
Yes
Yes
LED job light
Weight according to
2.1/ 2.2 (4.6/ 4.9)*6, 2.1/ 2.3 (4.7/ 5.1)*6,
Pistons
EPTA-Procedure 01/2003: kg (lbs)
2.5/ 2.6 (5.4/ 5.8)*7 2.5/ 2.7 (5.5/ 6.0)*7
Rubber rings
Nozzles
Rubber seal
*5 for some countries only
*6 with 300ml size holder
*7 with 600ml size holder
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P 2/ 11
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS
Code No.
1R026
1R027
1R029
1R031
1R258
Description
Bearing Setting Pipe 16-8.2
Bearing Setting Pipe 18-10.2
Bearing Setting Pipe 23-15.2
Bearing Setting Pipe 28-20.2
V Block
Use for
removing Spur gear 10
holding Carrier A complete when mounting 9 pcs. of Pin 3
removing Ball bearing 6803LLU
separating Spur gear 10 from Ball bearing 6806LLU
setting Ball bearing 6806LLU when removing Spur gear 10
[2] LUBRICATION
Apply Seal lubricant No.101 to the following portions designated with the black triangle to protect
parts and product from unusual abrasion.
Item No.
Description
Portion to lubricate
Amount
approx. 1.5 g
a little
Internal gear 48
Teeth portion
28
32
39
41
Carrier A complete
Spur gear 9C complete
Spur gear 19A
Pin (shaft) portion for accepting Spur gear 19B
Drum portion where Spur gear 10 contacts
Teeth portion
a little
a little
a: Pin (shaft) portion for accepting Spur gear 19A
b: Drum portion
approx. 1.0 g
approx. 1.0 g
approx. 1.0 g
Spur gear 9B complete
Spur gear 19A
42
43
Teeth portion
Fig. 1
Gear Assembly
Gear housing cover
43
42
41
39
a
b
Flat washer 12
Gear housing
Spur gear 10
Internal gear 48
Spacer
Plate 23
28
32
Spur gear 19B
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P 3/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -1. Rack Complete
DISASSEMBLING
Disassemble Rack complete as drawn in Fig. 2.
Fig. 2
1. Disassemble Holder complete
by turning counterclockwise.
2. Disassemble Piston complete by
unscrewing M3x18 Pan head screw.
3. Pull out Rack complete.
M3x18 Pan head screw
Holder A or B complete
ASSEMBLING
Piston A, B or C complete
Rack 42 or 64 complete
Assemble by reversing the disassembly procedure. (Refer to Fig. 2)
[3] -2. Motor Complete, Gear Assembly
(1) Disassemble the drive section (Gear assembly, Motor complete) as drawn in Fig. 3.
Fig. 3
1. Loosen M5x16 Pan head screws, and remove Plate
and Holder joint.
2. Loosen 9 pcs. of 3x16 Tapping screw, and
remove Housing (R) complete.
M5x16
Plate
Pan head
screw (4 pcs.)
Housing (R)
complete
Gear assembly
Motor
Holder joint A or B complete
complete
Compression
spring 6
6. Separate drive section (Motor complete and
Gear assembly) from Housing (L) complete.
And disconnect receptacles from DC motor.
Housing (L) complete
Receptacles
Note: Hold Compression spring 6 with your finger,
or it will come off.
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P 4/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Motor Complete, Gear Assembly (cont.)
DISASSEMBLING
(2) Remove Motor complete from Gear assembly as drawn in Fig. 4.
Fig. 4
3. Remove Motor complete from
Gear assembly by loosening
three 3x16 Tapping screws.
1. Remove Synchro belt
4-176.
2. Remove Spur gear 9A complete from
Gear assembly by levering up with
Slotted screwdrivers.
Note: Spur gear 9A complete is assembled
at the factory, so do not disassemble it.
Synchro belt 4-176
Spur gear 9A complete
Motor complete
Gear assembly
Slotted screwdrivers
(3) Disassemble component parts of Gear assembly from Gear housing as drawn in Fig. 5.
Fig. 5
1. Remove Flat washer 12, Spur gear 19A (6 pcs.),
Spur gear 9B complete and Internal gear 48 from
Gear housing as shown below.
2. Remove Stop ring E-4 from
Spur gear 9C complete.
Internal gear 48
Spur gear 19A (6 pcs.)
Flat washer 12
Gear housing
Flat
washer 5
Flat washer 5
Spur gear 9C
complete
Stop ring E-4
Spur gear 9B complete
3. Remove the following pars as shown below.
Spacer with
Oil seal 30
Flat washer 5
Carrier A complete
Pin 3 ( 9 pcs.)
Gear housing
Spur gear 9C
complete
Carrier B
Internal gear 48
Plate 23
Spur gear 19B ( 3 pcs.)
Note: Pin 3 comes off easily,
so be careful not to lose them.
Note: Spur gear 10 and Ball bearings
still remain in Gear case
in this step.
4. Remove Oil seal 30 from the groove
on Spacer with a slotted screwdriver.
Oil seal 30
Spacer
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P 5/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Motor Complete, Gear Assembly (cont.)
DISASSEMBLING
(4) Remove Spur gear 10 and Ball bearings from Gear housing as drawn in Fig. 6.
Fig. 6
2. Spur gear 10 is removed together with
Ball bearing 6806LLU.
1. Set 1R026 on Spur gear 10 and press 1R026 with
arbor press to remove Spur gear 10.
Spur gear 10
Ball bearing 6806LLU
Arbor press
Spur gear 10
1R026
Magnet
Note: Be sure to prevent foreign materials
from sticking to Magnet because it has
strong magnetic force.
3. Set Ball bearing 6806LLU
with Spur gear 10 into 1R258.
4. Set 1R031 onto Spur gear 10 and
press the gear with Arbor press.
5. Spur gear 10 is removed
from Ball bearing 6806LLU.
Ball bearing 6806LLU
with Spur gear 10
Ball bearing 6806LLU
1R031
1R258
Spur gear 10
(5) Ball bearing 6803LLU still remains in Gear housing in the step of Fig. 6. This ball bearing can be removed
as drawn in Fig. 7.
Fig. 7
1. Set 1R029 on Ball bearing 6803LLU and
press the bearing with Arbor press to remove it.
2. The component parts of Spur gear 10 section
are removed as shown below.
Ball bearing 6803LLU,
removed in the left
Ball bearing
6803LLU
1R029
Ball bearing 6806LLU,
removed in Fig. 6
Spur gear 10,
removed in Fig. 6
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P 6/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Motor Complete, Gear Assembly (cont.)
ASSEMBLING
(1) Assemble Ball bearing 6803LLU to Gear housing. Refer to the drawing on the left in Fig. 7.
(2) Mount Ball bearing 6806LLU to Spur gear 10. Refer to the drawing on the bottom in Fig. 6.
(3) Assemble the Spur gear 10 section to Gear housing. Refer to the drawing on the upper right in Fig. 6.
(4) Mount Oil seal 30 to Spacer. Refer to the drawing on the bottom in Fig. 5.
(5) Assemble Plate 23, Spacer, Internal gear 48 and Spur gear 9C complete to Gear housing as drawn in Fig. 8.
Fig. 8
Note: Assemble Spacer with the convex side
of it facing to Internal gear 48.
Gear housing
Spacer
Oil seal 30
Spur gear 9C
complete
Internal gear 48
Plate 23
(6) Assemble the parts on the Flat washer 5 side to Gear housing as drawn in Fig. 9.
Fig. 9
2. While holding Internal gear 48
with your fingers, assemble Gear housing
to Carrier A complete section.
1. Set Carrier A complete on 1R027, and
assemble Carrier B and 9 pcs. of Pin 3.
Pin 3 (9 pcs.)
Carrier B
Carrier A complete
1R027
Gear housing
< Note for Assembling of Pin 3 >
Do not lubricate on Pin 3.
And, be careful that Pin 3 easily falls off.
3. Assemble Spur gear 19B to the Pins of Carrier A complete.
And then, mount Flat washer 5 to Gear housing.
4. Assemble Stop ring E-4 to the shaft
on Spur gear 9C complete.
Spur gear 9C complete
Flat washer 5
Spur gear 19B
( 3 pcs.)
Stop ring E-4
Pins of Carrier
A complete
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P 7/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Motor Complete, Gear Assembly (cont.)
ASSEMBLING
(7) Assemble the parts on the Flat washer 12 side to Gear housing as drawn in Fig. 10.
Fig. 10
1. Assemble the other Internal
gear 48. And then, mount 3 pcs.
of Spur gear 19A to the three
pins of Spur gear 9C complete.
2. Assemble Spur gear 9B complete.
And then, mount the other 3 pcs. of
Spur gear 19A to the pins of Spur
gear 9B complete.
3. Assemble Flat washer 12
to Gear housing.
And make sure that it fits
to Gear housing.
Spur gear 9B
complete
Flat washer 12
Spur gear 19A
Internal gear 48
Spur gear 19A
Spur gear 9C
complete
4. Assemble Motor complete with
three 3x16 Tapping screws.
5. Assemble Spur gear 9A complete and Synchro
belt 4-176.
Synchro belt 4-176
Spur gear 9A
complete
Motor complete
Gear assembly
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P 8/ 11
Repair
[3] DISASSEMBLY/ASSEMBLY
[3] -2. Motor Complete, Gear Assembly (cont.)
ASSEMBLING
(8) Assemble the driving section (Gear assembly and Motor complete) to Housing (L) complete as drawn in Fig. 11.
Fig. 11
2. Fit Compression spring 6 to the rib on
Housing (L) complete with pressing
it toward Magnet.
1. Mount Compression spring 6 to Magnet
in Gear housing.
Compression spring 6
Compression spring 6
Rib
Magnet
Magnet
3. Gear assembly is pushed by Compression spring 6
toward Sub controller, and it may not be fitted
4. Make sure that Compression spring 6
fits inside the space.
within the rib on Housing (L) complete at the motor
portion. So, push Gear assembly toward the direction
of the black arrow shown below to set it within the rib.
Compression
spring 6
Rib
Sub controller
(9) When replacing the whole Gear assembly, use new Gear assembly as drawn in Fig. 12.
Fig. 12
1. Remove three 3x16 Tapping screws and Gear housing cover from Gear assembly.
2. Assemble Motor complete with Gear housing cover to new Gear assembly
with three 3x16 Tapping screws.
Note: Scrap Removed Gear housing cover and three 3x16 Tapping screws.
Gear housing cover
(the component of Motor complete)
3x16 Tapping screw (3 pcs.)
Main body of
Gear assembly
Motor complete
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P 9/ 11
Circuit diagram
Fig. D-1
Color index of lead wires' sheath
Blue
Black
Gray
Red
White
Yellow
Sub controller
Warning lamp
Dial
Red point mark
DC Motor
Switch
DC motor has to be mounted so
that its Red point mark is located
to Sub controller side.
LED Job light
Controller
Terminal
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P 10/ 11
Wiring diagram
Fig. D-2
Wiring of DC motor’s Lead wires
(Viewed from Housing (L) side)
Wire connecting
portions
Flag terminal
Gear assembly
Red point mark
Flag terminals have to be connected so that
their wire connecting portions are faced
toward Gear assembly side.
DC motor
Lead wires have to be
fixed within Lead wire
holder.
Flag terminal
Fig. D-3
Wiring of Lead wires of Sub Controller
(Viewed from Housing (R) side)
Sub controller
Inner wall
Rib
Lead wires of Sub controller have to be
routed between Ribs and the inner wall of
Housing (L) complete.
Housing set (L)
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P 11/ 11
Wiring diagram
Fig. D-4
Wiring in Housing set (L)
(Viewed from Housing (R) side)
Sub controller
Line filter
Put Line filter in this place.
(when using Line filter)
Route Sub controller’s lead
wires (black, white, red, blue)
and Controller’s lead wires to
DC Motor (black, red)
between Ribs A and B.
Rib A
Rib B
Switch
Route Sub controller’s lead wires
(black, white, red, blue) through
this Lead wire holder.
Lead wire holder
Route Controller’s lead wires to
DC Motor (black, red) through
this Lead wire holder.
Connector
Route Sub controller’s lead wires
(black, white, red, blue) through
this Lead wire holder.
Rib C
Do not route Connector’s
lead wires on Rib C.
Controller
Terminal
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