Lincoln Guardian G121 User manual

Model G121 & G122
Guardian 12v Battery Operated Grease Gun
Series “A”
Note: Extra battery only included on Model G122
Form 402106
JUNE - 2006
G121
G122

Page Number - 2
Model G121 & G122
Guardian 12v Battery Operated Grease Gun
Form 402106
Safety
Read and carefully observe these operating instructions before
unpacking and operating grease gun. Operate this tool only
after safety instructions and this operation manual are fully
understood.
Never operate this tool in explosive atmospheres. Electric
power tools can emit sparks that may ignite flammable
liquids, dust, or fumes.
Extreme pressure may cause nozzle extension or whip
hose to burst. Use only Lincoln approved high pressure
hose and follow the whip hose instructions and warnings.
Models and Components
Sales Models Hose Battery Charger
G121 1230* G915 G920
G122 1230* G915 (2ea) G920
*Lincoln brand
Grease gun can develop high pressure – up to 4,000 PSI
(276 Bar). Use safety glasses and gloves for protection
during operation.
Keep hands clear of the exposed rubber portion of hose.
Do not use battery charger in damp or wet locations.
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 battery terminals together
may cause sparks, burns, or fire.
Use only accessories that are recommended for use with
the Guardian Battery Operated Grease gun. Only acces-
sories that are capable of 4,000 psi (476 bar) Working
Pressure should be used.
PERSONAL SAFETY
1. Use only Lincoln branded 1218, 1224, 1230 or 1236 outlet
whip hoses. Grease injection injuries are a very serious
injury. Hold the hose only in the area of the spring guard.
2. Avoid accidental starting. Be sure switch is not depressed
when inserting battery pack.
3. Do not bend the hose so that it becomes kinked.
4. Replace the hose at the first sign of wear, kink or damage
to the outside jacket.
General Description
The Guardian Battery Operated Grease Gun was developed
for the purpose of manual lubrication of grease points and in-
cludes a pressure relief valve (Item 1 in diagram) to protect the
electric motor from excessive pressure (4000 PSI or 276 Bar)
and to identify a blocked bearing, fitting or lubrication line.
Appropriate Use
This grease tool was designed to pump and dispense lubricant
using 12.0 volt battery power. The maximum specification
ratings should not be exceeded. Any other use not in accor-
dance with instructions will result in loss of claim for warranty
or liability.
Specifications
Operating Power, Volt 12.0
Maximum Operating Pressure, PSIG (bar) 4,000 (276)
Grease Reservoir Capacity, oz. (cm³) 14.5 (411)
Lubricant (Grease) Up to NLGI #2
Weight, Lbs. (Kg) 7.8 (3.5)
Accessories:
Battery Model G915
Output, VDC 12.0
Capacity, mAh 1300
Battery Charger Model G920
Charge time 1 Hour
Input, VAC 120 V, 60 Hz
Outlet Hose Model 1230*
Hose Pressure Rating, psi (Bar) 7,500 (517)
Length of the Hose, In (mm) 30 (760)

Page Number - 3
Model G121 & G122
Guardian 12v Battery Operated Grease Gun
Form 402106
Figure 1
Pressure Relief Valve
Prevents motor overload if operating pressure exceeds 4,000 PSIG (276 bar). Grease flowing from the valve indicates a stuck
or clogged fitting. Correct the blockage and reattached grease gun.
USE AND CARE
Do not continue to hold down trigger if grease gun is stalled.
This could damage the motor or cause fire.
OPERATION
Prime the grease gun after each refill or grease cartridge
change. Prime the gun before using it to lubricate grease
points.
To prime, operate the gun until grease flows from the hose. Air
pockets in the cartridge lubricant will cause the gun to lose its
prime.
Installing Grease Cartridge
1. Visually check the follower seal lip direction before load-
ing a new cartridge. The follower seal lip must be directed
toward the follower handle or rear side for cartridge loading.
(Note: To change the direction of the follower seal, unscrew
tube cap from grease tube assembly and pull on the handle
to remove follower seal from tube. Flip the follower seal
over and re-assemble)
2. Pull back on the follower handle and latch the follower rod
groove into the slot on the tube cap.
3. Remove the cap from the grease cartridge and insert car-
tridge into the container tube.
4. Remove the pull tab from grease cartridge and screw
grease tube assembly into pump assembly.
5. Release follower rod from slot. Purge air from pump. See
air purging instructions.
Removing Empty Grease Cartridge
1. Pull back on the follower handle until the follower rod is fully
extended and latch the follower rod groove into the slot on
the tube cap.
2. Unscrew the grease tube assembly from the power-head.
3. Carefully release the follower handle to eject the empty
cartridge from container tube.
TO CONVERT GUN TO ALLOW
FILLING FROM BULK CONTAINER
OR FILLER PUMP
1. Unscrew the grease tube assembly cap from the grease
tube assembly. Pull on the follower handle to extract the
follower and spring from the grease tube assembly.
2. Flip the follower lip from the rear to the front side.
(Note: The follower resembles a cup. When the gun is as-
sembled for use with bulk lubricant, the cup opens toward
the pump assembly)
3. Reassemble follower into grease tube assembly and posi-
tion the follower handle so that the grease tube assembly
cap can be retightened onto the container tube. Tighten
grease tube assembly back onto the pump head.
Ball Check
Assembly
Pressure
Relief Valve

Page Number - 4
Model G121 & G122
Guardian 12v Battery Operated Grease Gun
Form 402106
TO FILL THE GUN WITH A FILLER PUMP
Thread a filler nipple into the pump head. Engage the follower
rod with the follower by rotating the follower handle. Insert the
filler nipple into a filler pump socket. Operate the filler pump to
fill the container. When the follower rod groove is exposed, the
grease tube assembly is filled. The follower rod will be extended
approximately 8 inches (20 cm). Disengage the follower rod
from the follower by rotating the follower handle. Push the fol-
lower rod into the grease tube assembly.
TO FILL THE GUN FROM BULK CONTAINER
1. Remove pump assembly from grease tube assembly.
2. Pack lubricant into cavity of the pump assembly.
3. Insert the open end of the grease tube assembly into lubri-
cant. Slowly pull the follower handle back while pushing the
grease tube assembly deeper into the lubricant to prevent
air pockets from being pulled into the grease tube assembly.
4. When the follower rod is fully extended, pull it sideways to
latch the rod groove into the keyhole slot in the grease tube
assembly cap.
5. Loosely assemble the pump assembly to the grease tube
assembly. Release the follower rod from the grease tube as-
sembly cap and disengage the follower rod from the follower
by rotating the follower handle. Push the follower rod into the
grease tube assembly.
TO EXPEL AIR POCKETS (Purging Air)
1. Withdraw the follower rod from the grease tube assembly
cap and engage it with the follower by rotating the follower
handle.
2. While exerting force on the follower handle, pull the trigger
in short bursts to operate gun until trapped air is expelled.
Disengage the follower rod from the follower by rotating the
follower handle. Push the follower rod into the grease tube
assembly.
3. If step 2 fails, unscrew the grease tube assembly 1-1/2 turns
from the pump assembly.
4. Exert force on the follower handle until lubricant oozes from
the grease tube assembly and pump assembly interface.
5. Retighten grease tube assembly into the pump assembly.
Disengage the follower rod from the follower by rotating the
follower handle. Push the follower rod into the grease tube
assembly.
CHARGER OPERATION
FIRST TIME CHARGING OF THE BATTERY PACK
Make sure power circuit voltage is the same as that shown
on the charger specification plate before connecting to power
source.
The first battery charge should be for 4 hours before use.
1. Plug the charger into an appropriate outlet before inserting
battery pack.
2. Insert the battery pack into the charger. The red (charging)
light will come on indicating that the charging process has
started.
3. The red light will go out and the green light will come on
indicating the battery is fully charged. When the green light
comes on the battery charger will be in the trickle charge
mode.
4. Keep the battery in the trickle charge mode for a period of 4
hours during the initial charge.
NORMAL CHARGING PROCEDURE
Make sure power circuit voltage is the same as that shown
on the charger specification plate before connecting to power
source.
1. Plug the charger into an appropriate outlet before inserting
battery pack.
2. Insert the battery pack into the charger. The red (charging)
light will come on indicating that the charging process has
started.
3. The red light will go out and the green light will come on
indicating the battery is fully charged. When the green light
comes on the battery charger will be in the trickle charge
mode.
4. The pack is fully charged and may be used at this time.
5. The battery pack trickle charge mode is not recommended
for extended periods of time. Batteries life will be shortened
if left in the charger for extended periods.
6. Disconnect charger from power source when not in use.
CHARGE INDICATORS
The charger is designed to detect certain problems that can
arise with battery packs. Problems are indicated by neither the
red nor the green light illuminating when the battery is placed
in the charger. If this occurs, re-insert battery pack into the
charger. If the problem persists, try a different battery pack to
determine if the charger is O.K. If the new battery pack charges
correctly, then the original pack is defective and should be
returned to a service center or other collection site for recycling.
If the new battery pack elicits the same trouble indication as
the original, have the charger tested at an authorized service
center.
NOTE: As a battery pack approaches the discharged state, you
will notice a sharp drop in tool performance. When the tool is
unable to perform the task at hand, it is time to recharge the
battery pack. Recharging the battery pack before this condition
is reached will reduce the total work life of the battery. Discharg-
ing the battery beyond this point can damage it.
NOTE: Battery temperature will increase during and shortly
after use. The battery may not accept a full charge if it is
charged immediately after use. Allow the battery pack to cool
to room temperature before charging for best results. Longest
life and best performance can be obtained if the battery pack
is charged when the air temperature is between 65°F and 75°F
(18° - 24°C).
CAUTION: Vent slots in top and bottom of charger must not
be obstructed. Do not charge battery when temperature is
BELOW 32°F (0° C) or ABOVE 104°F (40° C). Do not probe
with charging terminal with conductive objects. Danger of
electric shock is possible.

Page Number - 5
Model G121 & G122
Guardian 12v Battery Operated Grease Gun
Form 402106
Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]
Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone [phone]
Fax [phone]
Asia/Pacific:
51 Changi Business Park
Central 2
#09-06 The Signature
Singapore 486066
Phone [phone]
Fax [phone]
© Copyright 2006
Printed in USA
Web site:
www.lincolnindustrial.com
TROUBLESHOOTING:
Condition Possible Cause Corrective Action
Motor fails to run: Battery needs charging. Recharge battery
Grease Gun fails to dispense grease: Grease tube assembly Check that grease tube assembly has grease
is out of grease.
Loss of prime. Repeat priming operation
Ball check is contaminated. Remove ball check plug.
(Item 2 in diagram) Clean contaminates (old grease, paper from
grease tube, etc) from the spring, ball,
and ball seat. Reassemble.
Grease gun continues to lose prime: Air may be trapped in several Empty grease tube assembly, refill and repeat
locations. priming instructions.
Follower may be binding in grease. Check for damaged grease tube and replace.
Battery fails to take a charge: Charger may not have power. Check that receptacle has power.
Battery may be bad. Replace battery.