warning - Apex Power Tools
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1. Driving Flange 5 8 11 204129 7 Lock Washer A Wheel Guard f Retainer Bolt Wheel Guard CAUTION LABEL Retainer Bolt Nut 202409 Wheel Guard 7 204131 Wheel Blotters oun pair RTE Both Sides Type 1 Wheel Relieved Flanges 1 3 Dia of Wheel a Flange Dias Egual ter FI Clean no nicks or burrs Outer Flange 5 8 11 204130 Spindle End Nut 5 8 11 843846 ACCESSORIES FOR 15GL RA GRINDER DEPRESSED CENTER WHEEL GRINDING 843851 SPACER IF REOUIRED 849269 ADAPTOR KIT 7 8 PLAIN HOLE WHEELS 865986 7 WHEEL GUARD SPIRAL COOL RUBBER SANDING PAD 849848 5 SPIRAL RUBBER PAD 849913 7 SPIRAL RUBBER PAD 849259 PAD NUT 849834 SPANNER WRENCH 843851 SPACERS 2 REQUIRED OPERATING AND SERVICE INSTRUCTIONS READ SAFETY RECOMMENDATIONS BEFORE CON NECTING TOOL The 15GL RA Series Grinders are designed to operate on 90 psig 6 2 bar maximum air pressure using a 3 8 hose up to 8 in length If additional length is required the next larger hose size may be connectied to the 8 whip hose LUBRICATION An automatic in line filter regulator lubricator is recom mended as it increases tool life and keeps the tool in sustained operation The in line lubricator should be regu larly checked and filled with a good g2. 861161T 864382 864383 865524 865644 865647 865648 865649 865650 865651 865652 865664 865665 865685 865696 Handle Positloning Spacer 005 Handle Positloning Spacer 010 Lower Spindle Bearing Spindle Gear Key Upper Spindle Bearing Flange Set Screw Grease Fitting Driving Gear Bearing Bevel Gear Set Driving Flange Flange Key Handle Positioning Spacer 015 Bearing Shield Gear Spacer 001 Gear Spacer 002 Gear Spacer 003 881393 865986 204131 Felt Ring Retalner Ring Spindle Retalner Nut Exhaust Deflector Bearlng Spacer Spindle 5 8 11 Right Angle Housing Incl 843589 Dead Handle The complete Right Angle Head can be purchased as a subassembly 5 8 11 Spindle Code No 861199 Number of Spacers required is variable Additions to parts list for 7 Type 1 Wheel 204129 7 Type 1 Driving Flange 1 204130 7 Type 1 Outer Flange 1 PARTS NOT SHOWN 7 Depressed Center Wheel Guard 7 Type 1 Wheel Guard t NOTE 861161 Includes both Gears 15GL RA MOTOR amp GOVERNOR Part No 867082 867083 867084 865691 867086 864232 865693 865661 865657 847095 865663 867388 865686 gt 865687 These parts 864821 are included in governor 867388 subassembly Govenor center No 865687 govenor weights No 865663 and Pins No 867388 should be checked 864236 periodically for wear and SERVICE INSTRUCTI
3. 865644 JA 865647 001 613674 005 865648 002 613685 010 865649 003 015 865665 N 84477 E i AS 861161 294 204129 864382 865650 Type 1 7 Wheel Type 27 SERVICE INSTRUCTIONS FOR RIGHT ANGLE HEAD DISASSEMBLY The bearing spacer No 865665 handle positioning spac ers No 865524 and driving pinion with attached bearing No 844773 may be removed from the rear of the angle head No 865696 Loosen the set screw No 843518 and remove the spindle flange No 864382 Unscrewing the spindle retainer nut No 865652 Left Hand Threads will allow the spindle with attached components to be removed from the angle head Using a suitable bearing puller the bearings and driven gear may be removed from the spindle REASSEMBLY The right angle head is reassembled in the reverse order of disassembly All parts should be cleaned and inspected for wear or damage All bearings and gears should receive a generous amount of Keystone 122 C5X grease For proper spacing on the right angle gears remove spacers until tooth interference is felt then adda 001 gear spacer No 865647 Lever positioning spacers Nos 613674 613675 and 865524 are used to position the backhead in relationship to the right angle head PARTS LIST 15GL RA RIGHT ANGLE HEAD PART NO NAME OF PART PART NO NAME OF PART Qty 613674 613675 619499 842240 842517 843518 843589 844773
4. exhaust ports and holding the throttle open approximately 30 seconds The lubricator is properly set when a light stain of oil collects on the paper Excessive amounts of oil should be avoided STORAGE In the event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it should receive a generous amount of lubrication at that time and run for several seconds to distribute the oil before disconnecting from the air supply This will reduce the possibility of corrosion and displace any water that may be trapped in the tool Water trapped in the tool could cause the governor to freeze and malfunction if tool is exposed to freezing temperatures Note Water in the air system increases tool maintenance costs and can cause the tool to malfunction when it is stored and or operated in freezing conditions This information is a compilation of general safety practices obtained from various sources available at the date of production However our company does not represent that every acceptable safety practice is offered herein or that abnormal or unusual circumstances may not warrant or require additional procedures Your work may require additional specific safety procedures Follow these proce dures as required by your company For more information see the latest edition of ANSI B186 1 Safety Code for Portable Air Tools and ANSI B7 1 Safety Requirements for the Use Care and Protection of Abr
5. of tingling numbness blanching of fingers clumsiness or weakened grip nocturnal pain inthe hand or any other disorder of the shoulders arms wrists or fingers is advised to consult a physician If it is deter mined that the symptoms are job related or aggravated by movements and postures dictated by the job design it may be necessary for the employer to take steps to prevent further occurrences These steps might include but are not limited to repositioning the workpiece or redesigning the workstation reassigning workers to other jobs rotating jobs changing work pace and or changing the type of tool used so as to minimize stress on the operator Some tasks may require more than one type of tool to obtain the optimum operator tool task relationship The following suggestions will help reduce or moderate the effects of repetitive work motions and or extended vibration exposure e Use a minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry cold weather is reported to be amajor factor contributing to Raynaud s Syndrome e Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hyperextended or turned side to side e Avoid anything that inhibits blood circulation Smoking Tobacco another contributing factor Cold Temperatures Certain Drugs Avoid OK Avoid Avoid 7 Flexion Avoid OK Z 74 R
6. they have been found to significantly reduce vibration Some abrasive wheels lose their balance roundness and true ness as they wear from use Because of the abusive nature of the vibration caused by out of balance out of round and untrue condition of some abrasive wheels it is felt that these wheels are more susceptible to failure Excessive vibration may signal eminent wheel failure Flat spotting of the abrasive wheel caused by grinding the wheel to a stop after the power has been shut off can result in changes to the balance and shape of the wheel Be sure the grinding wheel has stopped before setting the tool down Set the tool in a tool rest or tool holder when not in use EE a a U MNES Safety Recommendations WIRE BRUSHES If a grinder is used for wire brushing applications the same problems of balance roundness and trueness as experi enced with abrasive wheels prevail Use quality wire brushes Wire brushes must be kept clean and stored properly to prevent bending damage and corrosion Excessive bend ing of wires during brushing causes breakage and flying wires Wear full face protection use guard and exercise caution USE A PREVENTIVE MAINTENANCE PROGRAM Tool abuse or poor maintenance procedures can amplify and contribute to the vibration produced by the abrasive wheel A preventive maintenance program featuring sched uled periodic inspections and proper maintenance is the best way to assure safety in your po
7. ONS FOR 15G RA MOTOR 8 GOVERNOR replaced when necessary DISASSEMBLY Remove the retainer ring No 865661 and clamp the cylinder No 864236 in a soft jawed vise with the splined end of the rotor facing upward Using a soft mallet tap the rotor No 865691 out of the front rotor bearing No 865658 This will allow the front rotor bearing front bearing plate No 865693 rotor collar No 865657 cylinder and rotor blades No 864234 to be removed from the rotor Lightly clamp the rotor in the vise and unscrew the governor Left Hand Threads The governor adjusting screw No 867086 may now be removed from the rear of the rotor by using a long series 3 32 Hex wrench No 867027 from the front of the rotor REASSEMBLY The motor is reassembled in the reverse order of disassembly Wash all parts thoroughly in solvent and visually inspect for damage or wear Check bearings for wear which can be detected by excessive end play or roughness of the bearings which indicates a brinelled condition Pack both rotor bearings with a good grade of NLGI 2 EP grease Particular attention should be paid to the governor assembly replacing any of its parts that show wear or damage It is recommended that new rotor blades be installed at each repair cycle If not replaced the used ones must measure a minimum of 7 32 5 5mm at both ends Failure of these parts could cause damage to more expensive components Also be sure that the blades are no l
8. a sive Wheels available from the American National Stan dards Institute Inc 11 West 42nd Street New York NY 10036 TYPE 27 WHEEL GUARD MOUNTING O 5 8 11 843518 Driving Flange 5 8 11 864382 a Lock Washer i Wheel Guard l k Wheel Guard E Retainer Bolt Retainer Bolt Nut Spacer tr Reguired Wheel Guard Note For wheels with built in disposable adapters Spacer 7 865986 No 843851 may be used to i properly space the wheel within the guard CAUTION LABEL 202408 Adapter Kit Provides proper back 849269 support required for depressed center or raised hub wheels with 7 8 holes Depressed Center Wheel TYPE 27 PROPER GRINDING WHEEL MOUNTING i Spindle Flange Te Flange Set Screw Adapter Nut 3 S m Adapter Spacer t Requires Note For wheels with built in disposable adapters Spacers No 843851 may be used to P rope r properly space the wheel Depressed within the gu p L Wheel Guard ie a Center Wheel TYPE 1 WHEEL GUARD MOUNTING wan g 350 O 3 z 8 2 8 5 8 11 843518
9. adial Deviation Neutral Ulnar Deviation Extension Neutral e Stressful postures should be avoided select a tool appropriate for the job and work location e Avoid highly repetitive movements of hands and wrists and continuous vibration exposure after each period of operation exercise to increase blood circulation e Use quality abrasive wheels e Keep tool well maintained and replace worn parts Work gloves with vibration reducing liners and wrist sup ports are available from some manufacturers of industrial work gloves Tool wraps and grips are also available from a number of different manufacturers These gloves wraps and wrist supports are designed to reduce and moderate the effects of extended vibration exposure and repetitive wrist trauma Since they vary widely in design material thickness vibration reduction and wrist support qualities itis recommended that the glove tool wrap or wrist support manufacturer be consulted for items designed for your specific application WARNING Proper fit of gloves is important Improperly fitted gloves may restrict blood flow to the fingers and can substantially reduce grip strength USE QUALITY ABRASIVE WHEELS The primary source of vibration when using a portable grinder is an abrasive wheel that is out of balance out of round untrue or possibly any combination of all three The use of quality abrasive wheels which are well bal anced round and true is highly recommended as
10. ded in governor assembly 15GL RA HANDLE 202105 v 06 Sy j 869855 n 865698 863093 0 E 7864375 847710 a 864530 20233 OT Pree An 9 WD 0 844304 864387 832595 864531 SERVICE INSTRUCTIONS FOR 15GL RA HANDLE DISASSEMBLY REASSEMBLY To disassemble the lever throttle handle unscrew the The handle is reassembled in the reverse order of disas throttle valve cap No 864531 This will allow the complete sembly All parts should be inspected for damage or wear throttle valve assembly to be removed from the handle Should a throttle valve bushing need replacing be sure that the air ports are aligned Coat throttle valve bushing The oiler body onthe handle may be removedfromthefront with Locktite 271 before pressing into position Air screens of the handle with the aid of spreaders should be cleaned and replaced if torn PARTS LIST 15GL RA HANDLE QTY 202105 Toggle 847808 Throttle Lever Pin 202106 Lock Off Lever 863093 O Ring 1 x 1 1 8 202337 Throttle Valve 864375 Throttle Valve Seal 832595 Throttle Valve Spring 864387 Oil Fill Plug 841552 Inlet Bushing 864530 Valve Bushing 843590 Oiler Valve 864531 Valve Cap 844304 O Ring 7 32 x 11 32 865698 Oiler Body Incl 843590 844311 O Ring 9 16 x 3 4 865701 Backhead Incl 864530 845409 Toggle Pin 869855 Toggle Spring 847710 O Ring 1 2 x 5 8 The complete handle assembly can be purchased
11. gh noise areas above 85 dBA Close proximity of additional tools reflec tive surfaces process noises and resonant structures can substantially contribute to the sound level experienced by the operator Proper hearing conservation measures in cluding annual audiograms and training in the use and fit of hearing protection devices may be necessary For addi tional information on hearing protection refer to Federal OSHA Regulations 29 CFR Section 1910 95 Occupa tional Noise Exposure and American National Standards Institute ANSI S12 6 Hearing Protectors Gloves and other protective clothing should be worn as required Do not wear clothing that may restrict movement become entangled or in any way interfere with the safe operation of grinders A WARNING Wear respirator where necessary Grinding or other use of this tool may produce hazardous fumes and or dust To avoid adverse health effects utilize adequate ventilation and or a respirator Read the material safety data sheet of any materials involved in the grinding process Cleco grinders are designed to operate on 90 psig 6 2 bar max air pressure If the tool is properly sized and applied higher air pressure is unnecessary Excessive air pressure increases the loads and stresses on the tool parts and may result in breakage Installation of a filter regulator lubrica tor in the air supply line is highly recommended Never use the air hose for supporting
12. gt Operation amp Service Manual COOPER Tools 823038 2 01 Cleco 15 Series Right Angle Grinders Guard Tin Series 7 Terminations Grinder 5T 5 8 11 ae Wheel Type Throttle Terminations YP D Type 27 L Lever W Type 1 Wheel RPM 60 77 Model A Right Angle For additional product information visit our website at http www clecotools com NORTH AMERICA EUROPE CooperTools Cooper Power Tools GmbH amp Co P O Box 1410 Postfach 30 Lexington SC 29071 D 73461 Westhausen Safety Recommendations For your safety and the safety of others read and under stand the safety recommendations before operating any grinder Always wear protective equipment and clothing A WARNING Impact resistant eye protection must be worn while operating or working near this tool Caution Faceshields do not provide unlimited protection against flying particles and are not to be considered as eye protection ANSI Z87 1 states that separate eyewear shall be used For additional information on eye protection refer to Federal OSHA Regulations 29 CFR Section 1910 133 Eye and Face Protection and ANSI Z87 1 Occupational and Educational Eye and Face Protection This standard is available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 A CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is recommended in hi
13. h humidity freezing and extreme temperatures e Mismatched speed ratings e Age Abrasive wheels known to have been subjected to any of the above conditions can burst violently Never operate a right angle grinder without proper wheel guard in place CHECK FLANGE Check the grinder spindle and driving flange for signs of damage or abuse On a vertical grinder the driving flange must be flat unrelieved and free of nicks and burrs The spindle must not be bent and the threads should be free of any damage that might keep an abrasive wheel and its mount from locating centrally or seating properly against the driving flange ABRASIVE WHEEL MOUNTING amp BEGINNING GRIND ING OPERATION Tighten wheels to a minimum of 10 ft Ibs 13 6Nm to prevent wheel spin off Do not over tighten Before beginning operations or after mounting a wheel the tool must be run for one 1 minute in a protected enclosure to check the integrity or the wheel During this time or any other time no one should stand in front of or in line of the wheel When starting work with a cold wheel apply it gradually to the workpiece until the wheel becomes warm DO NOT CONTINUE TO USE A GRINDER IF e It is not equipped with the proper wheel guard e The speed rating of the wheel is less than the speed of the grinder e It starts to vibrate e You sense any changes in tool speed or an unusual increase in noise output that would indicate the tool is running at exces
14. lifting or lowering the tool Use a safety line or cable on the tool when working in elevated areas Before tool is connected to air supply check throttle for proper operation i e throttle moves freely and returns to closed position Being careful not to endanger adjacent personnel clear air hose of accumulated dust and mois ture Use protective barriers where necessary hot sparks can burn Barriers also help reduce noise levels Before removing tool from service or changing accessories make sure air line is shut off and drained of air to prevent the tool from operating if the throttle is accidently engaged The use of a self relieving valve for this purpose is highly recom mended A WARNING Do not operate without proper wheel guard in place The wheel guard is designed to prevent serious injury to the operator in the event of wheel failure and must not be modified in any way Any wheel guard that is damaged or bent must be replaced NOTE The grinder must be held so that the opening in the guard is away from the operator Safety Recommendations The guard must be securely attached to the grinder with all bolts nuts and lockwashers in place and torqued to 30 40 in Ibs A 202408 INSTRUCTION O WARNING AND 869974 WARNING TAG The speed rating warning tags and warning labels should be maintained
15. onger than the rotor Must be replaced if 7 32 5 6mm or less at either end The rotor in this tool must be set by means of the rotor collar No 865657 so that when assembled there is 0015 clearance between the front end of the rotor and the face of the front bearing plate To properly set the rotor collar assemble the front bearing shield toward backhead into the front bearing plate Measure the depth of the inner race from the face of the bearing plate Select or fit by sanding a rotor collar 0015 larger than this dimension The governor adjusting screw No 867086 should be inserted in the rotor with the hex toward the splined end of the rotor It may be adjusted from the front of the motor with a long series 3 32 Hex Wrench No 867027 PARTS LIST 15GL RA MOTOR AND GOVERNOR PART NO NAME OF PART PART NO NAME OF PART 812164 847095 864232 864234 864236 864821 865657 865658 865661 865663 Cylinder Pin Rear Rotor Bearing Rear Bearinig Plate Front Rotor Bearing Front Bearing Retainer Governor Weight QTY 865686 865687 865691 865693 867082 867083 867084 867086 867388 Governor Spider Governor Center Rotor Front Bearing Plate Governor Spring See Chart Governor Spring See Chart Governor Spring See Chart Governor Adj Screw Governor Weight Pin xe ae ee ee cere Gee Gee eer The complete governor assembly can be purchased using Part No 861176 parts inclu
16. or replaced for legibility in the event of damage Speed rating warning tags and warning labels are available from the manufacturer Before mounting a wheel after all tool repairs and when ever a grinder is issued for use check the free speed of the grinder with a tachometer to make certain that the actual free speed at 90 psig 6 2 bar does not exceed the rated free speed stamped on the tool Grinders in use on the job must be similarly checked at least once every twenty hours of operation or once every week whichever is more frequent Checking free speed after the removal of each worn wheel and before mounting a new wheel is highly recommended INSPECT THE GRINDING WHEEL Check the maximum safe RPM marked on the wheel Never use a wheel rated below the actual tool speed Inspect the wheel for cracks or chips water stains or signs of abuse or improper storage Cracked chipped or faulty grinding wheels are dangerous and must not be used They must be destroyed rather than risk their use by someone who may not notice that they are damaged WARNING Fragments from an abrasive wheel can cause serious injury or death Do not operate without proper wheel guard in place Causes of abrasive wheel failures have been traced to such factors as e Dropping bumping or abuse careless handling of the grinder or wheel e Improper mounting e Imbalance e Improper shipment or storage e Exposure to water solvents hig
17. rade of 10W machine oil Proper adjustment of the in line lubricator is performed by placing a sheet of paper next to the exhaust ports and holding the throttle open approximately 30 seconds The lubricator is properly set when a light stain of oil collects on the paper Excessive amounts of oil should be avoided Application of the tool should govern how frequently it is greased It is recommended that the right angle gears receive a generous amount of Keystone 122 C5X grease when the angle head is removed for service Periodic lubrication is recommended through grease fitting in head STORAGE In the event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it should receive a generous amount of lubrication at that time and again when returned to service The tool should be stored in a clean and dry environment DISASSEMBLY To disassemble the 15G RA unscrew the head left hand threads and slip the motor out of the backhead See the following pages for disassembly instructions on the various subasemblies REASSEMBLY If the tool has been completely disassembled assemble the various sub assemblies per their instructions After assembly of the complete tool the R P M must be checked with a reliable tachometer Check R P M without wheel Mount guard before installing abrasive wheel 15GL RA RIGHT ANGLE HEAD 843589 881 aos 865664 i eDC ie 861161 619499
18. rtable grinding opera tions A well managed program can for example detect such things as speed variations due to wear flanges or spindles that have been damaged from abuse or bad bearings damaged by foreign matter or lack of lubrication Problems such as these can affect the wheel trueness when the grinder is running and contribute to the vibration Rotor blades that are worn or chipped can lock up motor and result in grinding wheel spinoff and should be replaced Rotor blades should be checked periodically and replaced if they measure less than 7 32 5 5mm at either end Must be replaced if 7 32 5 6mm or less ______ at either end Proper repair procedures and the use of original Cleco service parts and bearings rather than substitutes will return the tool to factory specifications of precision and balance and minimize vibration The governor should be checked periodically to be sure the governor mechanism is clean in good operating condition and functioning properly If excessively worn govenor cen ter No 865687 weights No 865663 or pins No 867388 should be replaced PROPER LUBRICATION An automatic in line filter regulator lubricator is recom mended as it increases tool life and keeps the tool in sustained operation The in line lubricator should be regu larly checked and filled with a good grade of 10W machine oil Proper adjustment of the in line lubricator is performed by placing a sheet of paper next to the
19. sive speed e You notice excessive end play in the spindle e You hear any unusual sound from the grinder RETURN THE TOOL TO THE TOOL CRIB FOR SERVICE IMMEDIATELY Safety Recommendations WARNING Repetitive work motions and or vibration can cause injury to hands and arms Use minimum hand grip force Keep body and hands warm and dry Avoid anything that inhibits blood curculation Avoid continuous vibration exposure Keep wrists straight Avoid repeated bending of wrists and hands Some individuals may be susceptible to disorders of the hands and arms when performing tasks consisting of highly repetitive motions and or exposure to extended vibration Cumulative trauma disorders such as carpal tunnel syn drome and tendonitis may be caused or aggravated by repetitious forceful exertions of the hands and arms Vibration may contribute to a condition called Raynaud s Syndrome These disorders develop gradually over peri ods of weeks months and years It is presently unknown to what extent exposure to vibrations or repetitive motions may contribute to the disorders Hereditary factors vasculatory or circulatory problems exposure to cold and dampness diet smoking and work practices are thought to contribute to the conditions Any tool operator should be aware ofthe following warning signs and symptoms so that a problem can be addressed before it becomes a debilitating injury Any user suffering prolonged symptoms
20. using Part No 201019 The lock off lever can be purchased as a subassembly using Part No 861992 eet ets NS ee a g COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www clecotools com
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