Alemite 585-A1 User manual

Service Guide
Alemite, LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright ©2009 by Alemite, LLC
This document contains confidential information that is the property of Alemite, LLC
670966 and is not to be copied, used, or disclosed to others without express written permission. Revision (9-09)
SER 585-A1
585-A1 585-B1
585-C1 585-D1
585
585-1
-E1 585-F1
Description
These model guns are designed to dispense
petroleum-based greases (up to NLGI 2) for general
lubrication applications. A 36-inch (0.91 meter) long
high-pressure whip hose, heavy-duty grease coupler,
1-hour fast charger, and molded carrying case are
included.
The guns use a 14.4 V motor with three stages of gear
reduction. A crank and yoke mechanism drives a
reciprocating piston pump. The motor is powered by a
rechargeable 14.4 Volt / 1900 mAh battery pack.
Each model gun is designed for 3-way loading;
cartridge, suction, and loader pump (requires optional
loader fitting 322610). The guns are spring-primed and
include an air bleed valve to aid priming.
Optional Accessories
Shoulder
Strap Tool B ag
Mobile Battery
Charger
(12 Vdc to 14.4 Vdc)
Loader
Fitting
339812 340057 340916 322610
Cordless Grease Gun
Specifications
Maximum
Pressure Flow Rate Delivery Capacity when
Fully Charged
Grease Cylinder Capacity Hose Assembly
Weight
(Empty)
Bulk Cartridge
Size
Pressure
Rating Length
psi bar Oz./Min. Gms/Min. Cartridges Ounces Gms Ounces psi bar Inches Meters Lbs Kg
10,000 690 5.6 160 17 16 454 14 10,000 690 36 0.91 7 3.2
Gun Model Battery Pack
Quantity Battery Pack Charger
585-A1 1 120 Vac / 60 Hz
(North / South America)
585-B1 2
585-C1 1 230 Vac / 50 Hz
(Europe / Middle East)
585-D1 2
585-E1 1 230 V
None
ac / 50 Hz
(Great Britain / Africa / Hong Kong)
585-F1 2
585-1* 1
*Base unit of above models
Includes Battery Charger
and Carrying Case
Figure 1 Cordless Grease Gun Models 585-A1 - 585-F1
Español...........Página 9
Français ..........Page 17
Español.................................Página 9
Français .................................Page 17
Deutsch................................. Seite 25
Italiano................................Pagina 33
Sound pressure (LpA) 76 dB(A), uncertainty (K) 3 dB(A)
Acoustic power (LWA) 87 dB(A), uncertainty (K) 3 dB(A)
Vibration emission value (ah) 0.7 m/s2, uncertainty (K) 1.5 m/s2

2
Revision (9-09)Alemite, LLC
SER 585-A1 Cordless Grease Gun
Figure 2 Cordless Grease Gun Models 585-A1 - 585-F1 - Exploded View

3
Cordless Grease Gun SER 585-A1
Item
No. Part No. Description Qty
Repair Kits
Notes
3 9 3 7 9 5 - 6 B a l l C h e ck
393757 Bleed Valve
1Screw,M3x6 6
2 Cover, Head 1
3Yoke 1
4Pin,Roll 2
5Piston 1
6 Ring, Retaining 2
7 Washer, 0.24 " ID x 0.67 " OD 1
8Bearing,Roller 1
9Washer,0.24"
ID x 0.59 " OD 1
10 Gear Assembly, Output 1
11 Screw, M5 x 15 3
12 Washer, Lock 3
13 Holder Assembly, Bearing 1
14 Bearing, Needle 1
15 Holster 1
16 Head 1
17 Gear, Internal 1
18 Spring, Trigger 1
19 Trigger 1
20 Cover, Housing, Right 1
21 Cover, Housing, Left 1
22 Screw 4
23 393795-17 Motor Assembly (with Sun Gear) 1 Includes Items 24 & 25
24 Protector, Thermal 1
25 Contact Assembly, Battery 1
26 Mount, Motor 1
27 Screw, M3 x 16 5
28 Washer, 6kcoL
29 Washer 1
30 Gear, Planet (First Stage) 3
31 Gear, Sun (Second Stage) 1
32 Gear, Planet (Second Stage) 3
33 Gear, Output Pinion 1
34 Bearing, Ball 1
35 393795-5 Switch 1
36 339820 Cylinder Assembly, Grease 1
37 340912 Battery Pack, 14.4 V 1 Models 585-A1, -C1, -E1
2 Models 585-B1, -D1, -F1
38 336523 Gasket 1
39 Washer, Lock 8
40 Screw 8
41 Plug, Check 1
42 Gasket (Copper) 1
43 Spring, Check 1
44 Ball, Check, 3/8 " Diameter 1
45 Plug 1
46 O-Ring 1
47 Spring, Bleed Valve 1
48 Valve, Bleed 1
49 Seal, Piston 1
50 340067 Hose Assembly, Grease 1 Never Substitute
51 Bearing, Ball 2
52 Ring, Internal Retaining 1
53 Bearing, Needle 1
54 308730 Coupler,
55 Insert, Coupler (Rubber)
Grease 1
1
56
340913 Charger Assembly, Battery (120 Vac / 60 Hz) 1 Models 585-A1, -B1
340914 Charger Assembly, Battery (230 Vac / 50 Hz) 1 Models 585-C1, -D1
340915 Charger Assembly, Battery (230 Vac / 50 Hz) 1 Models 585-E1, -F1
57 Case, Carrying 1
Legend:
Part numbers left blank are not available separately.
Alemite, LLC Revision (9-09)
Optional
C 6304-B Coupler, Grease
1

SER 585-A1 Cordless Grease Gun
Revision (9-09) Alemite, LLC
General Safety Rules
WARNING
Read all instructions: Failure to follow all instructions listed below may result in electric shock,
fire and/or serious injury. The term "power tool'' in all of the warnings listed below refers to your
mains operated (corded) power tool or battery operated (cordless) power tool.
Save all warnings and instructions for future reference.
Work Area
•
••
•Keep work area clean and well lit. Cluttered and dark areas invite accidents.
•
••
•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.
•
••
•Keep children and bystanders away while operating a power tool. Distractions can cause
you to lose control.
Electrical Safety
•
••
•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.
•
••
•Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
•
••
•Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
•
••
•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.
•
••
•When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use
of a cord suitable for outdoor use reduces the risk of electric shock.
•
••
•If operating a power tool in a damp location is unavoidable, use a residual current
device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
Personal Safety
•
••
•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.
•
••
•Use personal protective equipment. Always wear 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.
•
••
•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 energising power tools that have the switch on invites accidents.
•
••
•Remove any adjusting key or wrench before turning the power tool on. A wrench or a key
left attached to a rotating part of the power tool may result in personal injury.
•
••
•Do not overreach. Keep proper footing and balance at all times. This enables better control
of the power tool in unexpected situations.
•
••
•Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
•
••
•If devices are provided for the connection of dust extraction and collection facilities,
ensure these are connected and properly used. Use of these devices can reduce dust related
hazards.
4

Cordless Grease Gun SER 585-A1
Alemite, LLC 5 Revision (9-09)
General Safety Rules (Continued)
WARNING
Read all instructions: Failure to follow all instructions listed below may result in electric shock,
fire and/or serious injury. The term "power tool'' in all of the warnings listed below refers to
your mains operated (corded) power tool or battery operated (cordless) power tool.
SAVE THESE INSTRUCTIONS.
Power Tool Use and Care
•
••
•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.
•
••
•Do not use the power tool if the switch does not turn it on and off. Any power tool that can
not be controlled with the switch is dangerous and must be repaired.
•
••
•Disconnect the plug from the power source before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally.
•
••
•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.
•
••
•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.
•
••
•Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
•
••
•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.
Battery Tool Use and Care
•
••
•Ensure the switch is in the off position before inserting battery pack. Inserting the battery
pack into power tools that have the switch on invites accidents.
•
••
•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.
•
••
•Use power tools only with specifically designated battery packs. Use of any other battery
packs may create a risk of injury and fire.
•
••
•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.
•
••
•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.
•
••
•Disconnect battery pack from gun before changing accessories, storing gun or
unscrewing grease cylinder from the gun.
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.
5

6
Specific Safety Rules
WARNING
The gun can develop high pressure up to
10,000 psi (690 bar). Rupture of components can
inject grease into skin and eyes, causing serious
injury and possible amputation. If injured, seek
immediate medical attention.
Do not operate without proper safety protection,
gloves, and goggles. Hold hose at spring guard
only. Do not use if hose is damaged or worn.
Inspect hose before each use. Use only Alemite
340067 Grease Whip Hose.
This gun uses lubricants, that may be flammable
and poisonous if ingested. Do not use gun near
open flame or other fire hazards. Read all
warnings on lubricants before using this gun.
Use ear protection to reduce the risk of induced
hearing loss.
Disconnect battery pack from gun before changing
accessories or storing the gun.
Loading and Priming the Gun
NOTE: Refer to Figure 2 for component
identification on the following procedures.
Cartridge Loading
1. Unscrew Grease Cylinder (36) from the gun.
2. Pull the follower rod and engage the groove in the
follower rod with the slot in the Grease Cylinder cap.
3. Remove the plastic cap from the cartridge.
4. Apply a film of grease to the exposed inside surface of
the cartridge.
NOTE: This is only necessary for a virgin
gun.
5. Insert the cartridge into the Grease Cylinder.
• Remove the tabbed seal from the cartridge.
6. Screw the Grease Cylinder onto the gun.
7. Disengage the follower rod from the slot in the Grease
Cylinder cap.
• Push the follower rod into the Grease Cylinder.
Suction Loading
1. Unscrew Grease Cylinder (36) from gun.
2. Insert the head of the Grease Cylinder below the
surface of the grease.
3. Slowly pull the follower rod outward from the Grease
Cylinder cap until the groove is visible.
4. Engage the groove in the follower rod with the slot in
the Grease Cylinder’s cap.
5. Screw the Grease Cylinder onto the gun.
6. Disengage the follower rod from the slot in the Grease
Cylinder cap.
• Push the follower rod into the Grease Cylinder.
Loader Pump
WARNING
The gun can be equipped with an optional
low-pressure Loader Fitting. Do not substitute with
a high-pressure grease fitting. Personal injury can
occur due to excessive pressure.
The use of a grease fitting will void the warranty.
CAUTION
The Loader Fitting on the gun must mate with the
loader coupler. The pump may not operate if the
components are not compatible.
1. Pull the follower rod and engage the follower by
rotating the rod.
2. Seat the Loader Fitting into the loader coupler.
• Push down to hold the coupler valve open.
3. Operate the pump and view the movement of the
follower rod.
4. Discontinue pump operation once the groove on the
follower rod is visible.
5. Disengage follower rod from follower and push into
the Grease Cylinder.
SER 585-A1 Cordless Grease Gun
Revision (9-09) Alemite, LLC
Warning! To reduce the risk of injury, the
user must read the instruction manual.
Separate collection. This product must not be
disposed of with normal household waste.

7
Priming the Gun
In most cases the gun will prime simply by
operating the Trigger several times.
Should grease fail to appear, air must be bled.
Force Prime
This process manually assists air within the gun to
be bled at the Bleed Valve.
1. Pull the follower rod and engage the follower by
rotating the rod.
2. Depress Bleed Valve (48) and at the same time
push on the follower rod.
Once the air is eliminated, operate the gun several
times.
Once grease appears, disengage the follower rod
from the follower and push into the Grease Cylinder.
Gun Operation
Battery Pack (37) is intentionally shipped with a
low charge.
Charge Battery Pack prior to use.
• Refer to the following section for details.
NOTE: The Battery Pack must be dis-
charged and recharged several times
before achieving a full charge.
CAUTION
Air pockets in the grease can cause the gun
to lose prime. Check for prime after each refill
and before lubrication.
The gun is equipped with a thermal protector to
prevent the motor from overheating. When a
blocked bearing, line, or grease fitting causes
the gun to stall, the thermal protector will stop
and restart the motor every 2 to 3 seconds. For
maximum motor life, avoid operating at stall.
Check Valve Contamination
Should the gun fail, the outlet check may be held
open. Remove Plug (41), clean Ball (44), and the Ball
seat of Head (16).
Battery Pack and Charger Safety Rules
This manual contains important safety and operating
instructions for Battery Pack part number 340912 and Battery
Chargers340913, 340914, 340915.
WARNING
Before using the Battery Charger read all
instructions and cautionary markings on Battery
Charger (55), Battery Pack (37), and products using
the Battery Pack.
To reduce the risk of injury, charge only Nickel-Cad-
mium type rechargeable batteries. Other types of bat-
teries may burst causing injury.
An extension cord should not be used unless abso-
lutely necessary. Use of an improper extension cord
could result in a risk of fire and electric shock. If an
extension cord must be used, make sure it is 16-
gauge. Check to ensure that the pins on the plug of
the extension cord are the same number, size, and
shape as those of the plug on the Charger. Make sure
that the extension cord is properly wired and in good
electrical condition.
Do not incinerate the Battery Pack, even if it is
severely damaged or completely worn out. The Battery
Pack may explode in fire.
CAUTION
Do not expose the Charger to rain, snow, or frost.
To reduce the risk of damage to electric plug and
cord, pull by the plug rather than the cord when
disconnecting the Charger.
Make sure the cord is located so that it will not be
stepped on, tripped over, or otherwise subjected to
damage or stress.
Do not operate the Charger with damaged cord or plug.
Replace immediately.
Cordless Grease Gun SER 585-A1
Alemite, LLC Revision (9-09)

8
CAUTION
Do not operate the Charger if it has received a
sharp blow, been dropped, or otherwise damaged
in any way.
Do not disassemble the Charger.
Do not charge the Battery when the temperature
is below 50° F (10° C) or above 95° F (35° C).
The Charger is designed to operate on standard
household electrical power. Do not attempt to use
it on any other voltage.
Consecutive charging may cause overheating. If
you need to recharge the Battery consecutively,
wait for about 15 minutes to allow the Charger
to cool.
Do not insert foreign material into the hole for the
Battery in the Charger stand.
Do not disassemble the Battery.
Do not Store the gun and Battery assembly
in locations where the temperature may reach or
exceed 104° F (40° C).
Do not short-circuit the Battery.
Do not discharge the Battery beyond normal use
limits. Further discharging (such as placing a
rubber band on the Trigger) can cause a deep
discharge which may result in the polarity
reversal of a cell rendering the Battery useless.
Do not place the Charger in an area of extreme
heat or cold. It works best at normal room
temperature.
Battery Charger Operation
Charge the Battery only with the Charger provided.
After normal usage, 1 hour of charge time is required
to be fully charged. A minimum charge time of 1 to 1-1/2
hours is required to recharge a completely discharged
Battery.
The Battery will become slightly warm to the touch
while charging. This is normal and does not indicate a
problem.
SER 585-A1 Cordless Grease Gun
Revision (9-09)Alemite, LLC
Make sure power circuit voltage is same as that shown
on the charger specifications plate. Press down to ensure
the battery properly engages with the charger’s contacts.
Function of Red and Green Lights
Red and Green Lights Alternate Flashing
Once the charger is powered on, the Red and Green
lights flash alternately for 2 times.
Both Lights Off
No battery
Red Light On
Battery Charging
Green Light On
Battery fully charged
Red Light Flashes
Battery overheating
An overheated battery* in the charger may
cause a flashing red light. To restore the charging,
the battery pack needs to be taken out of the
charger for an approximate 30-minute cool down
prior to the next charging.
* The battery overheating could be attributed
to a reason below:
A. Long continuous running
B. Hot ambient temperature
C. One or more cells are damaged
The Battery contains
rechargeable nickel-cadmium
batteries. These batteries
must be recycled or disposed
of properly. Drop off
expended Battery at your
local replacement battery
retailer or your local
recycling center. Applicable
fees for the collection and recycling ofthese
batteries (in the United States) have beenpaid to the
Rechargeable Battery Recycling Corpo-ration. For
further information call 1-800-822-8837.