Harbor Freight Tools Caulking Gun 94849 User Manual

4.8 V Cordless  
Caulking gun kit  
Model 94849  
set up and operating instruCtions  
Diagrams within this manual may not be drawn proportionally.  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
distributed exclusively by Harbor Freight tools®.  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
read this material before using this product.  
Failure to do so can result in serious injury.  
saVe tHis Manual.  
Copyright© 2006 by Harbor Freight Tools®. All rights reserved. No portion of this  
manual or any artwork contained herein may be reproduced in any shape or form  
without the express written consent of Harbor Freight Tools.  
For technical questions or replacement parts, please call 1-800-444-3353.  
Cover revised 07i  
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7. use eye and ear protection. Always wear ANSI-approved impact safety  
goggles and full face shield. Wear an ANSI-approved dust mask or respirator  
when working around metal, wood, and chemical dusts and mists.  
8. do not overreach. Keep proper footing and balance at all times. Do not  
reach over or across running machines.  
9. Maintain tools with care. Keep tools maintained and clean for better  
and safer performance. Follow instructions for lubricating and changing  
accessories. Inspect tool cords periodically and, if damaged, have them  
repaired by an authorized technician. The handles must be kept clean, dry,  
and free from oil and grease at all times.  
10. disconnect power. Unplug Battery Charger when not in use.  
11. remove adjusting keys and wrenches. Check that keys and adjusting  
wrenches are removed from the tool or machine work surface before using  
the tool.  
12. avoid unintentional starting. Be sure the switch is in the Off position when  
not in use. Do not carry any tool with your finger on the trigger, whether the  
battery is installed or not.  
13. stay alert. Watch what you are doing, use common sense. Do not operate  
any tool when you are tired.  
14. Check for damaged parts. Before using any tool, any part that appears  
damaged should be carefully checked to determine that it will operate  
properly and perform its intended function. Check for alignment and binding  
of moving parts; any broken parts or mounting fixtures; and any other  
condition that may affect proper operation. Any part that is damaged should  
be properly repaired or replaced by a qualified technician.  
15. guard against electric shock. Prevent body contact with grounded  
surfaces such as pipes, radiators, ranges, and refrigerator enclosures.  
16. replacement parts and accessories. When servicing, use only identical  
replacement parts. Use of any other parts will void the warranty. Only use  
accessories intended for use with this tool. Approved accessories are  
available from Harbor Freight Tools.  
17. Do not operate tool if under the influence of alcohol or drugs. Read  
warning labels on prescriptions to determine if your judgment or reflexes are  
impaired while taking drugs. If there is any doubt, do not operate the tool.  
18. Maintenance. For your safety, service and maintenance should be  
performed regularly by a qualified technician.  
SKU 94849  
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Page 3  
using the Battery Charger  
note: Battery will not reach full charge the first time it is charged. Allow several  
cycles (operation followed by recharging) before the Battery will become fully  
charged.  
note: Performance of the charger may vary depending on variations in local line  
voltage. Extension cord usage may also affect tool performance.  
note: During recharging, the Battery will become slightly warm to the touch.  
This is normal and not a cause for concern. Do not keep the Battery or  
charger in an environment of extreme heat or cold. They will work best at  
room temperature.  
Battery temperature Warning:  
Warning: Battery explosion may cause serious personal or property injury in-  
cluding death. Charge the Battery only within a 50° to 100° F. temperature range.  
Lower temperatures may inhibit charging. Higher temperatures increase chance  
of battery failure, including explosion.  
Always allow a battery that is warm from use to cool before charging.  
Battery Charger safety:  
1. Charge the Battery only with the included charger. Use of other chargers  
may cause battery failure including explosion.  
2. Ensure that the Battery Charger is connected only to a 120 VAC, 60 Hz  
power supply that includes a circuit breaker.  
Cordless tool safety:  
1. Before inserting the Battery Pack into the tool, check to be sure that the  
Trigger operates properly, and returns to the OFF position when released.  
2. Use only fully charged Battery Pack specifically designed for this tool. Insert  
the Battery Pack into the handle. Ensure that the Battery Lock is engaged  
securely holding the Battery Pack in place.  
Warning: the warnings, cautions, and instructions discussed in this instruction  
manual cannot cover all possible conditions and situations that may occur.  
it must be understood by the operator that common sense and caution are  
factors which cannot be built into this product, but must be supplied by the  
operator.  
SKU 94849  
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Page 4  
unpacking  
When unpacking, check to make sure that the product is intact and undamaged,  
and all accessories listed below are included.  
Cordless Caulk Gun  
4.8 VDC Rechargeable Battery  
Larger Diameter Caulk Tube  
Recharging Base and Power Supply  
(4) Caulk Tube Screw Caps  
If any parts are missing or broken, please call Harbor Freight Tools at the number  
on the cover of this manual.  
Figure 1  
6-Speed Selector  
Cordless Caulk Gun  
4.8 VDC Rechargeable Battery  
Locking Button  
Gate  
Caulk Tube Screw  
Trigger  
Recharging Base and  
Power Supply  
SKU 94849  
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Page 5  
07j  
Working with the rechargeable Battery  
Charging the Battery:  
1.  
Batteries are normally shipped with low or no charge to prevent potential problems  
during shipment. Before use, you must charge your new Battery. Charge time is ap-  
proximately 7-9 hours.  
2.  
3.  
Plug the battery charger into a 120 VAC, 60 Hz power outlet.  
Insert the Battery into the charger by aligning the rib on the Battery with the groove  
in the charger. Press the Battery into place. The Red LED will illuminate indicating  
that a Battery is charging.  
4.  
The Red LED will remain on while the Battery charges. The Battery Charger will not  
automatically turn off when the Battery is fully charged. The charging indicator light  
will remain on until the Battery Charger is disconnected from the electrical outlet.  
Recharging the Battery more than 9 hours can cause damage to the Battery cells.  
5.  
6.  
When the Battery is fully charged, remove the charged battery from the charger, and  
unplug the charger from its power source. Put the charger away for safekeeping. Do  
not leave the Battery in the charger indefinitely.  
Always dispose of or recycle used batteries properly. Contact your local Hazardous  
Waste Authority for proper battery disposal guidelines.  
Installing the Battery:  
1.  
Slide the Battery into the base of the handle. Caution: Do not press the battery  
into the handle if it is not properly  
aligned, as this may damage the  
body of the tool, and will not secure  
the battery.  
2.  
Be sure the Battery is properly in-  
stalled before using the tool.  
Using the Battery Locks and Remov-  
ing the Battery:  
1.  
After placing the Battery in the tool,  
the battery locks on the side of the  
Battery engage to prevent the battery  
from coming out accidentally.  
2.  
To remove the Battery, depress the  
locks and remove the Battery by pull-  
ing straight out.  
REV 08f  
SKU 94849  
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Page 6  
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about Caulk, adhesives and Fillers  
Selecting the right caulk:  
This tool may be used to apply several different types of material that are packaged in  
a cartridge. In addition to caulk, this tool may be used to apply various adhesives, fillers and  
similar materials. No caulk or other material is supplied with this tool.  
Caulk is a semi-viscous material used to fill holes and gaps in seams of building materials.  
Some types of caulk are also useful as adhesives. There are three basic types of caulk:  
1.  
Latex caulk is a water soluble material useful for indoor uses, such as painting  
preparation and texturing under paint. Latex caulk is not waterproof and should not  
be used outdoors or in applications near water, such as baths and kitchens. It has  
low adhesive strength. Its main advantages include usefulness in paint preparation,  
low price and water cleanup.  
2.  
Silicone caulk is ideal for outdoor uses such as around doors and windows and for  
applications around water such as baths and kitchens. Silicone caulk has moderate  
to high adhesive strength. Silicone caulk is not water soluble, so care must be used  
during application to prevent need for cleanup. Check the product package for the  
manufacturer’s recommended solvent. Use any chemical solvents carefully, follow-  
ing manufacturer’s directions.  
3.  
Combination caulk is a mixture of silicone and latex. It may be cleaned up with  
water, yet offers good water resistance after curing. It is ideal for use in protected  
outdoor areas, such as under flashing around doors and windows, or for caulking  
outdoors prior to painting. It is also useful for indoor paint preparation where a more  
durable caulk is desired. It has low to moderate adhesive strength.  
adhesives are glues which are packaged in cartridges and may be applied with this tool.  
1.  
Silicone caulk may be considered an adhesive because of its moderate to high  
adhesive strength. Silicone Caulk is an ideal material for installing laminate counter  
tops in kitchens, baths and laundry rooms. While the counter top should be screwed  
in place from underneath, the side splashes may be glued in place using only  
silicone caulk. All seams, including contact edges with the wall should be caulked. It  
is good practice to apply a line of caulk under the counter edge and splashes before  
installation, and to apply caulk to the seam after installation. In this way the seam is  
filled and is water tight.  
2.  
3.  
Panel adhesive is sold under various brand names. It is ideal for gluing wall panels  
and other large flat surfaces. Some panel adhesive will damage plastic, such as  
fiber reinforced panels or plastic trim edges. If using plastic materials be sure to use  
an adhesive labeled for use with plastic.  
Construction adhesive is a high tack material used to fill gaps and increase  
holding power of joints made during construction. There are many different kinds  
designed for use with paneling, foam board, pressure treated wood, etc. Be sure to  
select the proper adhesive for your particular application.  
SKU 94849  
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Page 7  
Fillers:  
Fillers are designed to fill large gaps and provide a flexible and waterproof joint  
between large surfaces. Typical uses include around chimneys, masonry joints and  
sections of concrete. Fillers are often sold in larger sized cartridges. To reduce cost,  
joints are often partially filled with “caulk rod” or sand before being topped with filler.  
How to apply caulk, adhesive or fillers:  
1.  
Select the proper caulk, adhesive or filler for your application. Have the correct  
clean up materials ready, including scrapers, rags and solvent.  
2.  
Prepare your work materials before applying caulk. Your project should have been  
test fitted or assembled. Have clamps or any other needed tools available. Caulk,  
adhesive or fillers are a final step in construction. They are not designed to be  
removed once applied.  
3.  
If using caulk in a seam, apply painter’s tape along both sides of all seams before  
applying the caulk. Leave a very small space, usually less than 1/8” between the  
edge of the painter’s tape and the seam. This is the amount of caulk that will be vis-  
ible on completion of the job.  
If using caulk, next apply a small bead of caulk along the seam for no more than a  
few feet. Using a spreader, rub along the seam to smooth the caulk into the seam.  
Excess caulk will be on the tape. Using the spreader, rub excess caulk from the  
tape into the seam. Continue until all seams have been filled.  
Before the caulk has dried, remove all painter’s tape from the project, and dispose  
of it properly. Using painter’s tape will result in a neat, consistent seam with little or  
no clean up required.  
4.  
If using adhesive, test fit your work materials before applying the adhesive.  
If adhesive will be applied to seams or edges of your work material, apply painter’s  
tape to all edges to prevent squeeze-out from getting on the surface.  
Apply the adhesive to the work materials where they will be joined. Apply plenty of  
adhesive in a spiral or zigzag pattern and along all edges.  
If edge trim is being used, install it now. Press the workpiece into place. If neces-  
sary, brads, nails, screws, clamps or bracing may be used to hold the workpiece in  
place until the adhesive dries.  
5.  
If using fillers, secure the proper filler for the job at hand.  
Remove any dirt, water or debris from the seam before starting work. Compressed  
air may be used for this.  
If filling a vertical seam such as in a cement wall, insert caulk rod as needed in the  
seam. If filling a horizontal seam, such as a concrete floor, insert caulk rod or sand  
as needed.  
Caulk rod is a foam rope-like product that is available in various diameters. Select  
the proper caulk rod for your application. If using sand, be sure it is clean dry sand.  
Caulk rod and sand are used to reduce the amount of filler needed for a given job.  
However, filling usually requires a lot of material. This is why fillers are often sold in  
larger cartridges. It is a good idea to buy more than you think you will need.  
When applying caulk rod or sand, leave enough open space in the seam for the filler to  
adhere to both sides of the joint and be thick enough to form a strong seal.  
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Page 8  
Start at one end of the seam, and apply a heavy bead of the filler continuously until  
you reach the other end. The filler must adhere to both sides of the seam and form  
a heavy, continuous bead of material.  
operation  
Testing your Cordless Caulking Gun  
note: Follow the procedure below to test the operation of your Caulking Gun before using  
it for the first time.  
1.  
2.  
Install a charged battery as discussed on page 6.  
Set the 6-speed Selector (11) at position 3, or above, when first running the Caulk-  
ing Gun. Once the motor is running, any of the 6 speeds can be selected.  
3.  
While holding the caulking gun in your right hand, push the Locking Button (7) in.  
(If you are holding the gun in your right hand, the Locking Button (7) will be next to  
your thumb. Push it in until it pops out on the opposite side of the gun housing). Test  
the operation of the tool by squeezing the trigger. The Plunger (46) should move  
forward. See the Figure 1 on page 5.  
4.  
To retract the Plunger (46), push the Locking Button (7) back in until it protrudes  
from the left side of the housing. Using your finger, push the Plunger (46) all the way  
back to it’s starting location.  
Installing a cartridge and using your Cordless Caulking Gun  
1.  
Cut off the tip of a standard 10.5 oz. cartridge (not included) to open it. Pull down  
the Gate at the end of the Cartridge Holder (43), and slide the cartridge, base end  
first, into the Cartridge Holder and onto the Plunger (46). Press the Gate back into  
place. Make sure the Plunger (47) is completely retracted before doing this.  
2.  
3.  
Apply the tip of the cartridge to the work material. Squeeze the Trigger (15) to begin  
applying material, and move the tip of the cartridge along the seam. Move the 6-  
Speed Selector (11) to adjust the rate the material is being applied.  
Release the Trigger (15) to stop applying material. Attach on of the Calking Tube  
Screw Caps to the end of the cartridge when finished. Remove the cartridge form  
the Cartridge Holder (43), see paragraph below.  
Caution: DO NOT leave the cartridge in the Cordless Caulking Gun when you are fin-  
ished using it. The material in the cartridge could harden; making it very difficult or impos-  
sible to remove it from the Caulking Gun.  
Removing the cartridge from your Cordless Caulking Gun  
Push the Locking Button (7) back in until it protrudes from the left side of the hous-  
ing. Firmly press the cartridge in, as far as it will go, toward the handle. Swing the  
Gate open. Pull the cartridge from the Cartridge Holder (43). Swing the Gate to it’s  
closed position. See the Parts List and Assembly Diagram on pages 11 and 12.  
REV 07j, 08f, 08g  
SKU 94849  
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Page 9  
troubleshooting  
Tool will not operate or operates slowly:  
1.  
2.  
Battery may need to be charged. Recharge the Battery.  
Too great a load is being placed on the tool. Try a slower speed on the 6-Speed  
Selector. The caulk may be dried up in the tube, or the tip may be plugged. Check  
condition of cartridge and caulk, replace if necessary.  
Battery loses charge quickly:  
A new Battery will not hold a charge as long as older ones. Completely deplete and  
recharge Battery Pack several times to extend its charge life.  
Caulk squirts out back of cartridge:  
The caulk may be dried up in the tube, or the tip may be plugged. Check condition  
of cartridge and caulk, replace if necessary.  
The trigger is locked in place and won’t move:  
The Locking Button (7) may be in the wrong position. Push it in, and try squeezing  
the trigger again. See Figure 1 page 5.  
Maintenance  
1.  
Keep your tool clean and dry. Wipe dirt and grease from it if it becomes dirty. Re-  
move any excess caulk, adhesive or filler while it is still wet. Do not use solvents on  
the plastic parts of this tool.  
2.  
3.  
4.  
Do not allow your tool, Battery or Charger to become wet.  
Do not leave Battery in Charger unattended for long periods of time.  
When not in use, remove the Battery and store both Tool and Battery in a dry, se-  
cure location.  
SKU 94849  
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Page 10  
07j  
parts list  
part description  
QtY.  
part description  
32 Bronze Axle  
33 Gear Axle  
34 Inner Gear  
35 Star Gear  
36 Gear Tray  
37 Bearing  
38 Gear  
39 Bronze Bushing  
40 Gear  
41 Wave Washer  
42 Washer  
43 Cartridge Holder  
44 Clamp  
45 Screw M 3 x 8  
46 Plunger  
47 Screw ST 4.2 x 13  
48 Washer  
49 Rack  
50 Pin  
51 Spring  
52 Pin  
53 Gear Bushing  
54 Spring  
55 Clutch Pin  
56 Clutch Pin  
57 Pin  
QtY.  
1
1
1
6
1
1
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
2
3
4
5
6
7
8
9
Screw ST 2.9 x 15  
4
1
1
1
4
1
1
5
1
4
1
1
1
1
1
2
2
2
1
1
6
1
1
2
1
1
1
1
1
1
1
Screw ST 2.9 x 8  
Right Housing  
Battery Terminal  
Screw ST 2.9 x 18  
Battery  
Locking Button  
Screw ST 2.6 x 9.5  
PCB  
10 Screw ST 2.6 x 9.5  
11 6-Speed Selector  
12 Strap  
13 Left Housing  
14 Spring  
15 Trigger  
16 Spring  
17 Gear  
18 Bronze Axle  
19 Gear Box  
20 Gear Tray  
21 Star Gear  
22 Gear Tray  
23 Washer  
24 Screw M 3 x 8  
25 Gear Housing  
26 Motor Gear  
27 Motor  
58 Switch  
59 Bracket  
60 Switch  
61 Screw ST 2.6 x 16  
62 Screw ST 2.6 x 19  
28 Screw ST 2.9 x 6.5  
29 Main Body  
30 Bushing Case  
31 Gear Tray  
note: Some parts are listed and shown for illustration purposes only and are not available  
individually as replacement parts.  
SKU 94849  
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Page 11  
assembly drawing  
please read tHe FolloWing CareFullY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A  
REFERENCE TOOLONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKESANY REPRESENTATION  
OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE  
PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE  
MANUFACTURERAND/OR DISTRIBUTOR EXPRESSLY STATES THATALLREPAIRSAND PARTS REPLACEMENTS  
SHOULD BE UNDERTAKEN BY CERTIFIEDAND LICENSED TECHNICIANSAND NOT BYTHE BUYER. THE BUYER  
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT  
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT  
PARTS THERETO.  
REV 08g  
SKU 94849  
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Page 12  

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