Cooper Bussmann 15G User's Manual
Contents
1. e Mismatched speed ratings e Age Abrasive wheels known to have been subjected to any ofthe above conditions can burst violently Never use an abrasive wheel known to have been subjected to any of the above conditions CHECK FLANGE WARNING y GRINDING On Au l nie Extreme caution should FACE grin ers the driv be exercised not to use PEN ingflanges mustbe excessive side pressure mp Excessive side pressure Y S can break the wheeland J the relieved type Relieved flanges free of nicks and minimum 1 3 dia result in severe injury 7 of wheel d a burrs or other flaws TYPE 1 that might create Guard not WHEEL stress concentra eed Do not grind with tions on the grind gt side of Type 1 wheel ING wheel Spindles shouldbe checked for damage or abuse Blotters must be used and be at least as large in diameter as the flanges Diameters of both driving flange and outer flange must be identical and both must measure at least one third the diameter of the grinding wheel mounted between them Both flanges must be properly relieved as per ANSI Safety Code B7 1 and ANSI B186 1 See page 6 Select Type 1 wheels with proper hole size and speed rating Never adapt wheels with an oversize hole to fit the spindle ABRASIVE WHEEL MOUNTING amp BEGINNING GRIND ING OPERATION The spindle end nut should be tightened firmly against the outer flange of Type 1 wheels to assure the necessary friction against the blotter2. Pin Driving Flange Exhaust Deflector Retainer Ring Rotor Collar Front Rotor Bearing Outer Flange Dust Seal Arbor Collar Grip Ring Governor Weight Moa a a o e id Y a Ki iii i 865686 865687 865693 865694 865695 865697 865786 865787 865988 865990 865991 867082 867083 867084 867085 867086 867388 Governor Spider Governor Center Front Bearing Plate Rotor Exhaust Deflector Front Bearing Retainer Wheel Guard 3 Wheel Guard 2 1 2 Wheel Guard 4 Driving Flange 4 Outer Flange 4 Governor Spring See Chart Governor Spring See Chart Governor Spring See Chart Governor Spring See Chart Governor Adjustment Screw Governor Weight Pin Pee eo onan apa an panini i These parts can be purchased as a subassembly using number 861176 15G HANDLE 202105 ES 06 869855 Ae e 865698 ES L 863093 ane ee ee 841552 864530 202337 864375 847710 844304 864387 832595 864531 847808 SERVICE INSTRUCTIONS FOR 15G HANDLE DISASSEMBLY To disassemble the lever throttle handle unscrew the throttle valve cap 864531 This will allow the complete throttle valve assembly to be removed from the handle The oiler body on the handle may be removed from the front of the handle with the aid of spreaders REASSEMBLY The handle is reassembled in the reverse order of disas sembly All parts should be inspected for damage or wear Should a t
3. 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 ateitherend 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 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 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 wat
4. 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 Be careful not endanger adjacent person nel clear air hose of accumulated dust and moisture 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 to 40 in lbs Warning and Instruction Label 202595 amp 202596 alt 869974 WARNING TAG The speed rating and warnings are roll stamped on housing and should be replaced for legibility in the event or damage Warning tags and warning labels
5. NOT OVERTIGHTEN SPINDLE END NUT GREATER THAN ACTUAL FREE RUNNING TOOL SPEED e FLANGES MUST BE AT LEAST 1 3 DIAMETER e CHECK TOOL SPEED WITH TACHOMETER BEFORE OF WHEEL EVERY WHEEL CHANGE AVOID INHALING DUST RESULTING FROM READ THE MANUFACTURER S OPERATING INSTRUCTIONS THE GRINDING OPERATION STRUCTIONS BEFORE USING THIS ALWAYS USE EYE AND HEARING PROTECTION er N 202596 2025 TYPE 1 PROPER GRINDING WHEEL MOUNTING T 1 Wheel C it Model Wheel Te Wheal Proper Recessed Flanges Dia _ Thickness Wheel Guard m Flange Diameters a 116 12 Retainer Bolt Wheel f Identical 7 15GL 180 15GL 140 2 2 2 2 15GL 120 2 4 1 16 1 2 N 15GL 90 2 4 1 16 1 2 Blotters Use Only Wheels With Speed 1 rs Rating Above Tool Speed Spindle 1 58 Ja End Nut mee Recessed Flanges a Avoid Side Loads Flange Diameters ace Identical Face OPERATING AND SERVICE INSTRUCTIONS READ SAFETY RECOMMENDATIONS BEFORE CON NECTING TOOL The 15G 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
6. eas 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 e 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 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 adeguate 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 lifting or
7. er 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 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 Abra sive Wheels available from the American National Stan dards Institute Inc 11 West 42nd street New York NY 10036 TYPE 1 WHEEL GUARD MOUNTING Wheel Guard Wheel Guard Retainer Bolt Wheel Dia Part No Torque to 30 to 40 in Ibs 2 1 2 62mm 865787 KAS asker 3 75mm 865786 m Recessed Flanges Driving allem 105958 Wheel Dia Part No a i 2 1 2 62mm 3 75mm 865653 Wheel 4 100mm 865990 Blotters 844280 H i O Spindle End Nut 842970 Recessed Flanges Outer 865661 Driving Flange Key Wheel Dia Part No Driving Flange 2 1 2 62mm 3 75mm 865659 Grip Ring 4 100mm 865991 Wheel Guard Flange dia should be minimum Retainer Bolt Nut of 1 3 wheel dia CAUTION LABELS 2 Required 202595 and 202596 DO NOTREMOVE TIIS GUARD IT IS FOR e DO NOT USE WHEELS THAT HAVE BEEN DROPPED THEY ARE USE THIS GUARD ONLY WITH TYPE 1 PAMAGED QR IMFROPERLYSTOREDN WHEELS USE ONLY WHEELS WITH SPEED RATING EQUAL TO OR DO
8. faces to drive the wheel A CAUTION Type 1 Wheel breakage can also occur if e Outer flange is left off e Outer flange is reversed A washer is used in place of proper flange e Outer flange and driving flange are of unequal diameters e No wheel blotters are used Overtightening can cause wheel breakage Safety Recommendations mounting a wheel the tool must be run for one 1 minute in a protected enclo sure 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 I Before beginning operations or after 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 lt 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 excessive 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 A WARNING Repetitive work motions and or vibration may cause injury to hands and arms Use minimum hand grip force consistent Some individu als may be sus ceptible to dis orders of the hands and arms when per forming tasks consisting of highly repetit
9. gt Operation amp Service Manual COOPER Tools 823006 2 01 Cleco 15G Series Horizontal Grinders Series je 25 2 1 2 A 3 3 In Grinder 4 4 In Terminations Throttle Terminations 3T 3 8 24 L Lever RPM Wheel Type 90 140 W Type 1 Wheel 120 180 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 WARNING Impact resistant eye protection must be worn while operating or working near this tool CIO Caution Faceshields do not provide unlimited protection against flying particles and are notto 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 CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is recommended in high noise ar
10. heel 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 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 Ex cessive bending 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 portable 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
11. hrottle valve bushing need replacing be sure to align air ports Air screens should be cleaned and replaced if torn PARTS LIST 15G HANDLE PART NO NAME OF PART PART NO NAME OF PART 202105 202106 202337 832595 841552 843590 844304 844311 _ Toggle Lock Off Lever Throttle Valve Throttle Valve Spring Inlet Bushing Oiler Valve O Ring 7 32 x 11 32 O Ring 9 16 x 3 4 845409 Toggle Pin 847710 O Ring 1 2 x 5 8 PES ND a QTY 847808 863093 864375 864387 864530 864531 865698 865701 869855 Throttle Lever Pin O Ring 1 x 1 1 8 Throttle Valve Seal Oil Fill Plug Valve Bushing Valve Cap Oiler Body Incl 843590 Backhead Incl 864530 Toggle Spring The complete handle assembly can be purchased using Part No 201019 The lock off lever can be purchased as a subassembly using Part No 861992 COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www clecotools com
12. ich indicates a brinelled condition Pack both rotor bearings with a good grade of No 2 Moly 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 longer than the rotor The rotor in this tool must be set by means of the rotor collar 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 an rotor collar 0015 larger than this dimension Governor center 865687 governor weights 865663 and governor pins No 867388 should be checked periodically for wear and replaced if excessively worn PARTS LIST 15G MOTOR 8 GOVERNOR PARTNO NAME OF PARTS PARTNO NAME OF PARTS 812164 842970 844280 847095 864232 864234 864236 864735 864821 865653 865655 865657 865658 865659 865660 865661 865663 Cylinder Pin Key Arbor Nut Rear Rotor Bearing Rear Bearing Plate Rotor Blades Cylinder O Ring Safety Lock
13. ive motions and or exposure to extended vibration Cumulative trauma disor ders such as carpal tunnel syndrome 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 periods of weeks months and years It is presently unknown to what extent exposure to vibrations or repetitive motions may contribute to the disor ders Hereditary factors vasculatory or circulatory prob lems exposure to cold and dampness diet smoking and work practices are thought to contribute to the conditions Any tool operator should be aware of the following warning signs and symptoms so that a problem can be addressed with proper control and safe operation Keep body and hands warm and dry Avoid anything that inhibits blood circulation Avoid continuous vibration exposure Keep wrists straight Avoid repeated bending of wrists and hands before it becomes a debilitating injury Any user suffering prolonged symptoms of tingling numbness blanching of fingers clumsiness or weakened grip nocturnal pain in the 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 occur
14. larger hose size may be connected 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 grade 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 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 model remove the retainer ring driving flange exhaust deflector retainer ring exhaust deflector and unscrew the front bearing retainer No 865697 left hand threads The motor assembly may now be slipped out the front of the backhead REASSEMBLY If the tool has been completely disassembled assemble the various subassemblies per their instructions After assembly of the complete tool the R P M mustbe checked To change the R P M settting on the 15G the governor will have to be removed left hand threads and the governor adju
15. rences 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 e Keep body and hands warm and dry cold weather is reported to be a major factor contributing to Raynaud s Syndrome e Avoid anything that inhibits blood circulation Smoking Tobacco another contributing factor Cold Temperatures Certain Drugs Avoid OK Avoid Avoid OK Avoid Sh 74 92 Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation 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 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 Wo
16. rk 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 Safety Recommendations 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 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 w
17. should be maintained 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 Exposure to water solvents high humidity freezing and extreme temperatures
18. sting screw rotated clockwise to decrease the speed and counter clockwise to increase the speed Check speed of tool before mounting wheel Mount wheel guard before mounting wheel 15G MOTOR amp GOVERNOR RPM 9000 Part No 867082 865663 867388 12000 842970 8656994 867083 14000 867084 lt y 18000 867085 mi D 867086 864234 AN mie 4 A Jo 865660 865697 fa AA These parts e d 864821 are included in governor subassembly a AA DAS lm 865657 I ie AJO 865658 864236 865786 865659 865988 865991 865653 865990 SERVICE INSTRUCTIONS FOR 15G MOTOR 8 GOVERNOR DISASSEMBLY Clamp the cylinder 864236 lightly in a soft jawed vise and tap the rotor 865694 out of the front rotor bearing 865658 This will allow the front rotor bearing front bearing plate 865693 rotor collar 865657 cylinder and rotor blades 864234 to be removed from the rotor Clamp the rotor in the vise and unscrew the governor left hand threads The governor adjusting screw 867086 may now be removed from the rear of the rotor REASSEMBLY The motor is reassembled in the reverse order of disassembly Wash all parts thoroughly ina solvent and visually inspect for damage or wear Check bearings for wear which can be detected by excessive end play orroughness ofthe bearings wh
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