DROPSA K000455 Operating instructions

POWER LIGHT
Battery operated high
performance grease gun
User and
Maintenance Manual
Warranty Information
INDEX
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. PRODUCT IDENTIFICATION
4. TECHNICAL CHARACTERISTICS
5. PUMP COMPONENTS
6. UNPACKING AND INSTALLING
7. OPERATING INSTRUCTIONS
8. TROUBLESHOOTING
9. MAINTENANCE PROCEDURE
10. DISPOSAL
11. ORDERING INFORMATION
12. HANDLING AND TRANSPORTATION
13. OPERATING HAZARDS
14. WARRANTY
15. DISTRIBUTORS
http://www.dropsa.com
Manual drawn up in accordance with EC Directive 06/42
C2222II - WK 37/12

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1. INTRODUCTION
This operation and maintenance manual refers to the POWER LIGHT lubrication pump, and includes essential information
regarding correct operating and safety procedures design to ensure safe and reliable operation of the unit.
You can obtain the latest release of this document by contacting a Dropsa sales office or distributor or by visiting us on the
World Wide Web at http://www.dropsa.com.
It is important that this document is read and maintained in a place that anyone operating the POWER LIGHT is able to consult it
if necessary.
2. GENERAL DESCRIPTION
POWER LIGHT is suitable for lubricating machines, vehicles and equipment with commercial lubricants. The power supply for the
low voltage electric motor comes from a 14.4V battery. As a protection against overload the gun is fitted with a pressure relief
valve.
The rotary movement of the electronic motor is converted into a stroke movement of high pressure feed piston through a
planetary reduction gear box and an eccentric. The unit will feed as long as the switch on the handle is actuated.
Battery powered high performance grease gun set in a sturdy plastic case, suitable for 400g grease cartridge to DIN 1284 or 500
cc of loose grease.
Complete with:
-14.4 Volt battery ;
-Charger fast charge function;
-750mm high pressure armoured hose with a 4 jaw hydraulic gripper nozzle.
3. PRODUCT IDENTIFICATION
On the side of the pump there is a label that indicates
part number of the product, operating voltage and
basic characteristics.
Any other use, or modifications or changes to unit are only allowed after discussion with the manufacturer.
The safety instructions must always be complied with.

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4. TECHNICAL CHARACTERISTICS
BATTERY GREASE GUN CHARACTERISTICS
Tensione di lavoro Working voltage
14.4V
Pressione di lavoro Working pressure
ca. 400 bar
Flow rate
ca. 100 cc/min
Thread for connection nozzle
R1/8”
Working temperature
da -18 a + 50 °C
Lubrificants
NLGI 000 up to 2 (DIN 51818).
Not be used pastes without lubricating properties
(with abrasive components) and silicon pastes
BATTERY CHARACTERISTICS
Power
14.4 V
Delivery
1500 mAh
BATTERY CHARGER CHARACTERISTICS
Primary voltage
230 V, 50 Hz,35 W
Secondary voltage
14.5 V 1500 mA
Loading time
1 hour
WHEIGHT
Case included
5,4 kg
Gun with battery and grease case
3,1 kg
5. COMPONENTS
Battery
charger
Grease gun
Battery

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6. UNPACKING AND INSTALLING
6.1 UNPACKING
Once a suitable installation position has been identified, unpack the pump and prepare for installation. It is important to inspect
the pump to ensure that there has been no damage during transportation. The packaging material used does not require any
special disposal procedures. You should refer to you regional requirements.
7. OPERATING INSTRUCTIONS
Before using for the first time the battery must be charged up. A charging time of around 1 hour is sufficient for further use.
Before charging ensure that the mains voltage –complies with the details on the rating plate of the charger.
To charge take the battery out of the handle and plug into the charger.
The charging process is started by pressing the SET button on the charger.
The red ON LED indicates that the battery is being charged.
The green OFF LED indicates that the charging process has ended.
7.1 FILLING WITH GREASE CARTRIDGES:
Only use standardised (DIN 1284) 400g grease cartridges.
7.2 FILLING WITH A FILLER UNIT:
Attach the filler nipple on the gun to the filler unit. When filling keep the grease gun presser downwards.
Next push the piston rod completely into the tube body of the grease container again
After filling bleed the air from the grease gun by slightly opening the filler nipple or the grease container ( 1- 1½ turns), until
bubble-free grease comes out.
The grease gun is now ready for use
Operate the START switch until grease comes out of the nozzle.
If the max. Working pressure of ca.400 bar is exceeded, the pressure relief valve will open and let the grease escape. Abort
the lubrication process and cure the reason for the high build up of pressure. For instance be the lubrication nipple, the
lubrication pipe or the bearing could be damaged or blocked.
The temperature of the battery increases during use. Before charging the battery, first let it cool to room temperature, as
otherwise it will not be charged up.
7.3 Performance diagrams

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8. TROUBLESHOOTING
Below is a trouble shooting table to show possible problems and solutions.
If you are in any doubt about the correct solution to fixing a problem, do not dismantle parts of the Bravo but contact an
Authorized Dropsa Sales and Service Point for technical assistance.
TROUBLESHOOTING TABLE
PROBLEM
POSSIBLE CAUSE
REMEDIAL ACTION
The motor will not run
The battery is flat or defective.
The wiring to the motor is defective
Charge or replace the battery.
Remove the battery, disassemble the
handle and check for loos
connections.
Pressure relief valve opens when
grease is being delivered
Lubricating nipple defective or
blocked.
Lubricating pipe defective or blocked
Bearing point defective or blocked
Check affected parts and if necessary
clean or replace
Unit not pumping grease
The grease gun container is empty.
The grease feed is interrupted
Check the level in the grease
container.
Bleed out the air
The unit continually breaks of
delivery of grease
Due filling with loose grease there is
air trapped in the grease
Empty the grease gun container and
bleed the air out of the refilled gun
The battery is not taking a charge
No ,mains voltage to charger.
Battery defective or worn out
Check whether the cosket is alive
Replace the battery.
9. MAINTENANCE PROCEDURE
The battery powered high performance grease gun requires no maintenance.
Make a regular check on the pressurised components (high pressure hose) and also on the live parts (charger) for possible
damage. Defective parts must be replaced with genuine spares without delay.
10. DISPOSAL
During maintenance or disposal of the machine care should be taken to properly dispose of environmentally sensitive items such
as oils or other lubricants. Refer to local regulations in force in your area. When disposing of this unit, it is important to ensure
that the identification label and all the other relative documents are also destroyed.
11. ORDERING INFORMATION
DESCRIPTION
PART NUMBER
GREASE GUN
K000455
12. HANDLING AND TRANSPORTATION
Prior to shipping, the equipment is carefully packed in cardboard package. During transportation and storage, always maintain
the pump the right way up as indicated on the box. On receipt check that package has not been damaged. Then storage the
machine in a dry location.

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13. OPERATING HAZARDS
-The unit must not be operated in potentially explosive areas
-Protect the unit from damage and the effects of heat
-The unit must only be operated with the 14.4V battery originally intended for it.
-The use of a different battery could lead to damage to the unit, or to a risk of fire.
-The battery must only be charged with the charger provided for the purpose.
-Before charging ensure that the mains voltage complies with the details on the rating plate of the charger.
-The ventilation slots on the top and bottom of the charger must not be covered during the charging process.
-Do not charge the battery when the temperature is under 0°C or over 40°C
-Do not charge the battery in damp or wet surroundings
-Only dispose of used batteries properly in accordance with EC Guideline 91/157/EWG. The battery contains rechargeable
NiCd cells.
-The setting of the of the pressure relief valve must never be changed.
-In case of blocking do not continue pressing the START switch. There is a danger of the motor overheating and being
damaged.
-Never point the lubrication hose at people or animals ! Risk of injury!
-Before repair or maintenance work the current supply must be shut off. The battery must be taken out of the handle.
-Leather industrial gloves and also safety glasses must be worn when using the unit
-When lubricating, only hold the high pressure hose in the area of the nozzle
-Do not bend the high pressure hose sharply
-Make a regular check on the pressurised components / high pressure hose) and also on the live parts ( charger) for possible
damage. Defective parts must be replaced with genuine spares without delay.
-The use of accessory components e.g. hoses and connection fittings, which are not supplied by DROPSA, can in some cases
give rise to the risk of accidents. No liability can be accepted for accidents or damage caused by components from other
sources.
-Modifications or charges to the equipment are only allowed after discussion with the marker.
-The safe operation of the equipment is only guaranteed if used in accordance with the directions.
-Maintenance, inspection and repairs must only be carried out by qualified specialist personnel, who have acquainted
themselves with the subject by studying the operating instructions.
WARNING: Non- compliance with the safety instruction can result in danger both to person and to the
environment and the equipment. Non –compliance with the safety instructions can lead to the loss of any claims
for damages. The operator of the equipment must ensure that the contents of the Operating Instructions,
particularly the Safety instructions are know to the operating personal.

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14. WARRANTY
All products manufactured and marketed by Dropsa are warranted to be free of defects in material or workmanship for a period
of at least 12 months from date of delivery. Extended warranty coverage applies as follows:
Complete system installation by Dropsa: 24 Months.
All other components: 12 months from date of installation; if installed 6 months or more after ship date, warranty shall be
maximum of 18 months from ship date.
If a fault develops, notify Dropsa giving:
a complete description of the alleged malfunction
the part number(s)
test record number where available (format xxxxxx-xxxxxx)
date of delivery
date of installation
operating conditions of subject product(s)
We will subsequently review this information and supply you with either servicing data or shipping instruction and returned
materials authorization (RMA) which will have instructions on how to prepare the product for return.
Upon prepaid receipt of subject product to an authorized Dropsa Sales & Service location, we will then either repair or replace
such product(s), at out option, and if determined to be a warranted defect, we will perform such necessary product repairs or
replace such product(s) at our expense.
Dropsa reserves to right to charge an administration fee if the product(s) returned are found to be not defective.
This limited warranty does not cover any products, damages or injuries resulting from misuse, neglect, normal expected wear,
chemically caused corrosion, improper installation or operation contrary to factory recommendation. Nor does it cover
equipment that has been modified, tampered with or altered without authorization.
Consumables and perishable products are excluded from this or any other warranty.
No other extended liabilities are states or implied and this warranty in no event covers incidental or consequential damages,
injuries or costs resulting from any such defective product(s).
The use of Dropsa product(s) implies the acceptance of our warranty conditions. Modifications to our standard warranty must
be in made in writing and approved by Dropsa.

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15. DISTRIBUTORS
Web site: http://www.dropsa.com -E-mail: [e-mail]
BB TECHNICAL SERVICE SRL
Via Roma 13, 23848 Oggiono (LC)
Tel: [phone]
Fax: [phone]
Email: [email protected]
Dropsa Ame
23, Av.des.Morillons
Z.I. des Doucettes
91140 - Garges Les Gonesse
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa (UK) Ltd
Unit 6, Egham Business Village,
Egham,Surrey,TW20 8RB
Tel: [phone] - 431177
Fax: [phone] - 438598
E-mail: [email protected]
Dropsa do Brazil
Rua Sobralia 175,
Sao Paulo, Brazil
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa USA Inc.
6645 Burroughs Ave
48314-2132 Srerling Hts,Mi Us -USA
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa Lubrication Systems
Nr 8 Dongxing Road,
Songjiang Industrial Zone
(Shanghai) Co., Ltd
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa Gmbh
Volmerswerther Strasse 80
40221 Dusseldorf 1, Deutschland
Tel: [phone]
Fax:[phone]
E-mail: [email protected]
Dropsa Australia Pty.
C20/148 Old Pittwater Road
Brookvale, NSW 2100
Tel: [phone]
Fax: [phone]
E-mail: [email protected]