Makita BCG180, CG140 User Manual

T

ECHNICAL INFORMATION

PRODUCT

P 1/ 11

Models No.

Description

BCG140 / BCG180 (LXGC01*

Cordless Caulking Gun

*

1 Model number for North and Central American countries

CONCEPT AND MAIN APPLICATIONS

Model BCG140 and BCG180 are Cordless Caulking Guns
powered by 14.4V/18V Li-ion battery.

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

• Anti-drip function that stops excess sealant from oozing out
just upon release of the switch trigger

Specification

Specification

Cell Li-ion

Voltage: V

Battery

Max output: W

Max pushing force: N (lbs) 5,000 (1,100)

No load speed: mm/sec. (in/min.)

Stroke length:
mm (")

Compatible
sealant size

Variable speed control

Continuous run time (approx.) on
a single full battery charge with
300ml cartridge: cartridge quantity

Anti-drip function Yes

Overload protection function

Rubberized soft grip

Trigger lock

LED job light
Weight according to

EPTA-Procedure 01/2003: kg (lbs)

*5 for some countries only
*6 with 300ml size holder
*7 with 600ml size holder

Capacity: Ah

Energy capacity: Wh

Charging time: min.

300ml holder model 214 (8-3/4)

600ml holder model 350 (13-3/4)

300ml holder model Cartridge

600ml holder model Cartridge, Sausage pack, Bulk sealant

Model

by trigger

by dial Yes

BCG140 BCG180

14.4 18

1.3/ 3.0

19/ 44 24 (27*5)/ 54

15, 22 with DC18RC

130 150

0 - 28 (0 - 66)

Yes

180/ 410 210/ 500

Yes

Yes

Yes

Yes

2.1/ 2.2 (4.6/ 4.9)*6,

2.5/ 2.6 (5.4/ 5.8)*7

1)

(The image above is BCG180
with 300ml size holder and Battery BL1815.)

Model No.

Length (L)

Width (W)

Height (H)

*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

1.3 (1.5*

2.1/ 2.3 (4.7/ 5.1)*6,

2.5/ 2.7 (5.5/ 6.0)*7

5)/ 3.0

L

W

Dimensions: mm (")

BCG140 BCG180

404 (15-7/8)*

264 (10-3/8)*4/ 281 (11-1/8)*5

2, 538 (21-1/4)*3

108 (4-1/4)

Standard equipment

Holder for 300ml type model
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
Nozzle for bulk sealant
Plastic carrying case or Tool bag

(for some countries only)

Note: The standard equipment
for the tool shown above
may vary by country.

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
Pistons
Rubber rings
Nozzles
Rubber seal

H

P 2/ 11

Repair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

Code No. Description Use for

1R026 Bearing Setting Pipe 16-8.2 removing Spur gear 10
1R027
1R029
1R031
1R258 V Block 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.

Bearing Setting Pipe 18-10.2 holding Carrier A complete when mounting 9 pcs. of Pin 3
Bearing Setting Pipe 23-15.2
Bearing Setting Pipe 28-20.2

removing Ball bearing 6803LLU
separating Spur gear 10 from Ball bearing 6806LLU

Item No.

28

32

39

41

42

43

Fig. 1

Description AmountPortion to lubricate

Carrier A complete Pin (shaft) portion for accepting Spur gear 19B

Spur gear 9C complete Drum portion where Spur gear 10 contacts

Spur gear 19A

Spur gear 9B complete

Spur gear 19A

Teeth portion

a: Pin (shaft) portion for accepting Spur gear 19A

b: Drum portion approx. 1.0 g

Teeth portion

Gear Assembly

Gear housing cover

41

39

Gear housing

Spur gear 10

Internal gear 48

Spacer

28

Plate 23

42

43

a

b

Flat washer 12

approx. 1.5 gInternal gear 48 Teeth portion

a little

a little

a little

approx. 1.0 g

approx. 1.0 g

32

Spur gear 19B

Repair

[3] DISASSEMBLY/ASSEMBLY

[3] -1. Rack Complete

DISASSEMBLING

Disassemble Rack complete as drawn in Fig. 2.

Fig. 2

P 3/ 11

1. Disassemble Holder complete
by turning counterclockwise.

Holder A or B complete Piston A, B or C complete Rack 42 or 64 complete

ASSEMBLING

Assemble by reversing the disassembly procedure. (Refer to Fig. 2)

2. Disassemble Piston complete by
unscrewing M3x18 Pan head screw.

M3x18 Pan head screw

3. Pull out Rack complete.

[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.

M5x16
Pan head
screw (4 pcs.)

Holder joint A or B complete

6. Separate drive section (Motor complete and
Gear assembly) from Housing (L) complete.
And disconnect receptacles from DC motor.

Plate

Housing (L) complete

2. Loosen 9 pcs. of 3x16 Tapping screw, and
remove Housing (R) complete.

Housing (R)
complete

Gear assembly

Motor
complete

Compression
spring 6

Receptacles

Note: Hold Compression spring 6 with your finger,
or it will come off.

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

P 4/ 11

1. Remove Synchro belt
4-176.

Synchro belt 4-176

(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 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.

Spur gear 9A complete

Slotted screwdrivers

3. Remove Motor complete from
Gear assembly by loosening
three 3x16 Tapping screws.

2. Remove Stop ring E-4 from
Spur gear 9C complete.

Motor complete

Gear assembly

Gear housing

Flat
washer 5

3. Remove the following pars as shown below.

Flat washer 5

Spur gear 19B ( 3 pcs.)

Internal gear 48

Spur gear 19A (6 pcs.)

Spur gear 9B complete

Carrier A complete

Pin 3 ( 9 pcs.)

Carrier B

Note: Pin 3 comes off easily,

so be careful not to lose them.

Flat washer 12

Spacer with
Oil seal 30

Internal gear 48

Plate 23

Flat washer 5

Spur gear 9C
complete

Stop ring E-4

Gear housing

Spur gear 9C
complete

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

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

P 5/ 11

1. Set 1R026 on Spur gear 10 and press 1R026 with
arbor press to remove Spur gear 10.

Spur gear 10

3. Set Ball bearing 6806LLU
with Spur gear 10 into 1R258.

Ball bearing 6806LLU
with Spur gear 10

1R258

4. Set 1R031 onto Spur gear 10 and
press the gear with Arbor press.

Arbor press

1R026

2. Spur gear 10 is removed together with
Ball bearing 6806LLU.

Spur gear 10

Note: Be sure to prevent foreign materials
from sticking to Magnet because it has
strong magnetic force.

5. Spur gear 10 is removed
from Ball bearing 6806LLU.

Ball bearing 6806LLU

1R031

Ball bearing 6806LLU

Magnet

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.

Ball bearing
6803LLU

1R029

2. The component parts of Spur gear 10 section
are removed as shown below.

Ball bearing 6803LLU,
removed in the left

Ball bearing 6806LLU,
removed in Fig. 6

Spur gear 10,
removed in Fig. 6

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.

P 6/ 11

Spacer

Internal gear 48

(6) Assemble the parts on the Flat washer 5 side to Gear housing as drawn in Fig. 9.

Fig. 9

1. Set Carrier A complete on 1R027, and
assemble Carrier B and 9 pcs. of Pin 3.

Oil seal 30

Plate 23

Pin 3 (9 pcs.)

Carrier B

Carrier A complete

1R027

Gear housing

Spur gear 9C
complete

2. While holding Internal gear 48
with your fingers, assemble Gear housing
to Carrier A complete section.

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.

Flat washer 5

Spur gear 19B
( 3 pcs.)

Pins of Carrier
A complete

4. Assemble Stop ring E-4 to the shaft
on Spur gear 9C complete.

Spur gear 9C complete

Stop ring E-4

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

P 7/ 11

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.

Spur gear 19A

Internal gear 48

Spur gear 9C
complete

4. Assemble Motor complete with
three 3x16 Tapping screws.

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.

Spur gear 9B
complete

Spur gear 19A

5. Assemble Spur gear 9A complete and Synchro
belt 4-176.

3. Assemble Flat washer 12
to Gear housing.
And make sure that it fits
to Gear housing.

Flat washer 12

Motor complete

Gear assembly

Spur gear 9A
complete

Synchro belt 4-176

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

P 8/ 11

1. Mount Compression spring 6 to Magnet
in Gear housing.

Compression spring 6

Magnet

3. Gear assembly is pushed by Compression spring 6
toward Sub controller, and it may not be fitted
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.

Rib

2. Fit Compression spring 6 to the rib on
Housing (L) complete with pressing
it toward Magnet.

Compression spring 6

Rib

Magnet

4. Make sure that Compression spring 6
fits inside the space.

Compression
spring 6

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

Circuit diagram

Fig. D-1

Black
Gray

White

Sub controller

P 9/ 11

Color index of lead wires' sheath

Blue

Red

Yellow

Dial

Red point mark

DC Motor

DC motor has to be mounted so
that its Red point mark is located
to Sub controller side.

Warning lamp

Switch

LED Job light

Controller

Terminal

Wiring diagram

Fig. D-2

Gear assembly

Lead wires have to be
fixed within Lead wire
holder.

P 10/ 11

Wiring of DC motor’s Lead wires

(Viewed from Housing (L) side)

Wire connecting
portions

Flag terminal

Red point mark

Flag terminals have to be connected so that
their wire connecting portions are faced
toward Gear assembly side.

DC motor

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)

Wiring diagram

Fig. D-4

Line filter

Put Line filter in this place.
(when using Line filter)

Route Sub controller’s lead wires
(black, white, red, blue) through
this Lead wire holder.

Route Sub controller’s lead wires
(black, white, red, blue) through
this Lead wire holder.

Sub controller

Rib A

Rib B

Connector

P 11/ 11

Wiring in Housing set (L)

(Viewed from Housing (R) side)

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.

Switch

Lead wire holder

Route Controller’s lead wires to
DC Motor (black, red) through
this Lead wire holder.

Rib C

Do not route Connector’s
lead wires on Rib C.

Controller

Terminal