Operation & Service Manual
823006
2/01
15G Series Horizontal Grinders
15
G
L
-
XXX
-
X
X
X
Guard:
25
Series:
2 1/2
3 In.
4 In.
15
3
4
Grinder:
Terminations:
Throttle Terminations:
3T
3/8-24
L
Lever
Wheel Type:
Type 1 Wheel
RPM:
W
90
140
180
120
NORTH AMERICA
EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper Power Tools GmbH & Co.
Postfach 30
D-73461 Westhausen
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Safety Recommendations
The guard must be securely attached to the grinder with all
bolts, nuts and lockwashers in place and torqued to 30 to
• Improper mounting
• Imbalance
40 in. lbs.
• Improper shipment or storage
• Exposure to water, solvents, high humidity,
freezing and extreme temperatures
• Mismatched speed ratings
• Age
Warning and Instruction Label
202595 & 202596
1
6
3
5
4
Abrasive wheels known to have been subjected to any
of the above conditions can burst violently. Never use
an abrasive wheel known to have been subjected to
any of the above conditions.
869974
WARNING TAG
Thespeedratingandwarningsarerollstampedonhousing CHECK FLANGE
and should be replaced for legibility in the event or damage.
WARNING
!
Warning tags and warning labels should be maintained.
Warning tags and warning labels are available from the
manufacturer.
On Type 1 wheel
grinders, the driv-
ingflangesmustbe
the relieved-type,
free of nicks and
burrsorotherflaws
that might create
stress concentra-
tions on the grind-
GRINDING
FACE
Extreme caution should
be exercised not to use
excessive side pressure.
Excessive side pressure
can break the wheel and
result in severe injury.
Blotter
Relieved flanges
minimum 1/3 dia.
of wheel dia.
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
TYPE 1
WHEEL
Guard not
shown for
clarity.
Do not grind with
side of Type 1 wheel.
ing
wheel.
Spindlesshouldbe
frequent. Checking free speed after the removal of each checked for damage or abuse. Blotters must be used and
worn wheel and before mounting a new wheel is highly be at least as large in diameter as the flanges. Diameters
recommended.
ofbothdrivingflangeandouterflangemustbeidenticaland
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
INSPECT THE GRINDING WHEEL!
Check the maximum safe RPM marked on the wheel. ANSI B186.1. (See page 6)
Never use a wheel rated below the actual tool speed.
Inspect the wheel for cracks or chips, water stains, or signs Select Type 1 wheels with proper hole size and speed
of abuse or improper storage. Cracked, chipped or faulty rating. Never adapt wheels with an oversize hole to fit the
grinding wheels are dangerous and must not be used. spindle.
They must be destroyed rather than risk their use by
someone who may not notice that they are damaged.
ABRASIVE WHEEL MOUNTING & 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 blotter faces to drive the wheel.
!
WARNING
Fragments from an abrasive wheel
can cause serious injury or death.
Do not operate without proper
wheel guard in place.
Overtightening can cause wheel
!
CAUTION
breakage.
Causes of abrasive wheel failures have been traced to Type 1 Wheel breakage can also occur if:
such factors as:
• Outer flange is left off
• Outer flange is reversed
• Dropping, bumping, or abuse (careless handling
of the grinder or wheel)
• A washer is used in place of proper flange
• Outer flange and driving flange are of unequal
diameters
• No wheel blotters are used
3
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Safety Recommendations
Before beginning operations or after before it becomes a debilitating injury. Any user suffering
mounting a wheel, the tool must be run prolonged symptoms of tingling, numbness, blanching of
for one (1) minute in a protected enclo- fingers, clumsiness or weakened grip, nocturnal pain in the
sure to check the integrity or the wheel. hand, or any other disorder of the shoulders, arms, wrists,
During this time or any other time, no or fingers is advised to consult a physician. If it is deter-
one should stand in front of or in line of mined that the symptoms are job related or aggravated by
the wheel. When starting work with a movements and postures dictated by the job design, it may
cold wheel, apply it gradually to the be necessary for the employer to take steps to prevent
workpiece until the wheel becomes further occurrences. These steps might include, but are not
Cleco
MODEL
SERIAL NO.
CAUTION
warm.
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.
STEEL
DRUM
DO NOT CONTINUE TO USE A GRINDER IF:
The following suggestions will help reduce or moderate the
effects of repetitive work motions and/or extended vibration
exposure:
• It is not equipped with the proper wheel guard
• The speed rating of the wheel is less than the
speed of the grinder
• Use a minimum hand grip force consistent with
proper control and safe operation
• Keep body and hands warm and dry (cold weather is
reported tobeamajorfactorcontributingtoRaynaud's
Syndrome)
• Avoid anything that inhibits blood circulation
—Smoking Tobacco (another contributing
factor)
• It starts to vibrate
• You sense any changes in tool speed or an
unusual increase in noise output that would
indicate the tool is running at excessive speed.
• You notice excessive end play in the spindle
• You hear any unusual sound from the grinder
—Cold Temperatures
RETURNTHETOOLTOTHETOOLCRIBFORSERVICE
—Certain Drugs
Avoid
Avoid
OK
Avoid
Avoid
OK
IMMEDIATELY!
Some individu-
als may be sus-
WARNING
!
ceptible to dis-
orders of the
Repetitive work motions and/or vibration
may cause injury to hands and arms.
Neutral
Neutral
Ulnar Deviation
Extension
Flexion
Radial Deviation
Use minimum hand grip force consistent
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.
hands
and
armswhenper-
forming tasks
consisting of
highlyrepetitive
motions and/or
• 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
• Stressful postures should be avoided — select a tool
appropriate for the job and work location
• Avoid highly repetitive movements of hands and
wrists, and continuous vibration exposure (after
each period of operation, exercise to increase blood
circulation)
Avoid repeated bending of wrists and hands.
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
• Use quality abrasive wheels
• Keep tool well maintained and replace worn parts
vibrations or repetitive motions may contribute to the disor- Work gloves with vibration reducing liners and wrist sup-
ders. Hereditary factors, vasculatory or circulatory prob- ports are available from some manufacturers of industrial
lems, exposure to cold and dampness, diet, smoking and work gloves. Tool wraps and grips are also available from
work practices are thought to contribute to the conditions. a number of different manufacturers. These gloves, wraps,
Any tool operator should be aware of the following warning and wrist supports are designed to reduce and moderate
signs and symptoms so that a problem can be addressed the effects of extended vibration exposure and repetitive
4
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Safety Recommendations
wrist trauma. Since they vary widely in design, material, when the grinder is running and contribute to the vibration.
thickness, vibration reduction, and wrist support qualities, Rotor blades that are worn or chipped can lock up motor
it is recommended that the glove, tool wrap, or wrist support andresultingrindingwheelspinoffandshouldbereplaced.
manufacturer be consulted for items designed for your Rotor blades should be checked periodically and replaced
specific application. WARNING! Proper fit of gloves is if they measure less than 7/32" (5.5mm) at either end.
important. Improperly fitted gloves may restrict blood
flow to the fingers and can substantially reduce grip
strength.
Must be replaced if
7/32" (5.6mm) or less
at either end.
USE QUALITY ABRASIVE WHEELS
Proper repair procedures and the use of original Cleco
The primary source of vibration when using a portable service parts and bearings rather than substitutes will
grinder is an abrasive wheel that is out of balance, out of return the tool to factory specifications of precision and
round, untrue, or possibly any combination of all three.
balance, and minimize vibration.
The use of quality abrasive wheels which are well bal- The governor should be checked periodically to be sure the
anced, round, and true is highly recommended as they governor mechanism is clean, in good operating condition,
have been found to significantly reduce vibration. Some and functioning properly.
abrasive wheels lose their balance, roundness, and true-
ness as they wear from use. Because of the abusive nature PROPER LUBRICATION
of the vibration caused by out of balance, out of round, and
untrue condition of some abrasive wheels, it is felt that An automatic in-line filter-regulator-lubricator is recom-
these wheels are more susceptible to failure. Excessive mended as it increases tool life and keeps the tool in
vibration may signal eminent wheel failure. Flat spotting of sustained operation. The in-line lubricator should be regu-
the abrasive wheel, caused by grinding the wheel to a stop larly checked and filled with a good grade of 10W machine
after the power has been shut off can result in changes to oil. Proper adjustment of the in-line lubricator is performed
the balance and shape of the wheel. Be sure the grinding by placing a sheet of paper next to the exhaust ports and
wheelhasstoppedbeforesettingthetooldown. Setthetool holding the throttle open approximately 30 seconds. The
in a tool rest or tool holder when not in use.
lubricator is properly set when a light stain of oil collects on
the paper. Excessive amounts of oil should be avoided.
WIRE BRUSHES
STORAGE
If a grinder is used for wire brushing applications the same
problems of balance, roundness, and trueness as experi- In the event that it becomes necessary to store the tool for
enced with abrasive wheels prevail. Use quality wire an extended period of time (overnight, weekend, etc.), it
brushes. Wire brushes must be kept clean and stored should receive a generous amount of lubrication at that
properly to prevent bending, damage and corrosion. Ex- time and run for several seconds to distribute the oil before
cessive bending of wires during brushing causes breakage disconnecting from the air supply. This will reduce the
and flying wires. Wear full face protection, use guard and possibility of corrosion and displace any water that may be
exercise caution.
trapped in the tool. Water trapped in the tool could cause
the governor to freeze and malfunction if tool is exposed to
freezing temperatures.
USE A PREVENTIVE MAINTENANCE PROGRAM
Tool abuse or poor maintenance procedures can amplify Note: Water in the air system increases tool maintenance
and contribute to the vibration produced by the abrasive costs and can cause the tool to malfunction when it is
wheel.Apreventivemaintenanceprogramfeaturingsched- stored and/or operated in freezing conditions.
uled periodic inspections and proper maintenance is the
best way to assure safety in your portable grinding opera- Formoreinformation, seethelatesteditionofANSIB186.1,
tions. A well managed program can, for example, detect Safety Code for Portable Air Tools, and ANSI B7.1 Safety
such things as speed variations due to wear, flanges or Requirements for the Use, Care, and Protection of Abra-
spindles that have been damaged from abuse, or bad sive Wheels available from the American National Stan-
bearings damaged by foreign matter or lack of lubrication. dards Institute, Inc., 11 West 42nd street, New York, NY
Problems such as these can affect the wheel trueness 10036.
5
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TYPE 1
WHEEL GUARD MOUNTING
Wheel Guard
Wheel Dia. Part No.
2-1/2"(62mm) 865787
Wheel Guard Retainer Bolt
Torque to 30 to 40 in. lbs.
Lock Washer
Recessed Flanges (Driving)
3"(75mm)
865786
865988
4"(100mm)
Wheel Dia.
Part No.
2-1/2"(62mm), 3"(75mm) 865653
4"(100mm)
865990
Wheel
Blotters
844280
Spindle End Nut
842970
Driving Flange Key
Recessed Flanges (Outer)
865661
Driving Flange
Grip Ring
Wheel Dia.
Part No.
2-1/2"(62mm), 3"(75mm) 865659
4"(100mm)
865991
Wheel Guard
Retainer Bolt Nut
Flange dia. should be minimum
of 1/3 wheel dia.
CAUTION LABELS
(2 Required 202595 and 202596)
!
CAUTION
!
CAUTION
DO NOT REMOVE THIS GUARD Ñ IT IS FOR
YOUR PROTECTION
USE THIS GUARD ONLY WITH TYPE 1
WHEELS
DO NOT USE WHEELS THAT HAVE BEEN DROPPED,
DAMAGED, OR IMPROPERLY STORED Ñ THEY ARE
DANGEROUS
USE ONLY WHEELS WITH SPEED RATING EQUAL TO OR
GREATER THAN ACTUAL FREE RUNNING TOOL SPEED
CHECK TOOL SPEED WITH TACHOMETER BEFORE
EVERY WHEEL CHANGE
DO NOT OVERTIGHTEN SPINDLE END NUT
FLANGES MUST BE AT LEAST 1/3 DIAMETER
OF WHEEL
AVOID INHALING DUST RESULTING FROM
READ THE MANUFACTURER'S OPERATING INSTRUCTIONS
AND SAFETY INSTRUCTIONS BEFORE USING THIS
THE GRINDING OPERATION
ALWAYS USE EYE AND HEARING PROTECTION
202595
GRINDER
202596
TYPE 1
PROPER GRINDING WHEEL MOUNTING
Type 1 Wheel Capacity
Recessed Flanges
Flange Diameters
Proper
Wheel Guard
Retainer Bolt
Model
Wheel
Dia.
Wheel
Thickness
15GL-180 2" - 3" 1/16" - 1/2"
15GL-140 2" - 4" 1/16" - 1/2"
15GL-120 2" - 4" 1/16" - 1/2"
Identical
Wheel
15GL-90
2" - 4" 1/16" - 1/2"
Blotters
Use Only Wheels With Speed
Rating Above Tool Speed
Spindle
End Nut
Avoid Side Loads
Recessed Flanges
Flange Diameters
Identical
Grinding
Face
6
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OPERATING AND SERVICE INSTRUCTIONS
READ SAFETY RECOMMENDATIONS BEFORE CON- DISASSEMBLY
NECTING TOOL.
To disassemble the 15G model, remove the retainer ring,
driving flange, exhaust deflector retainer ring, exhaust
The 15G Series Grinders are designed to operate on 90 deflector, and unscrew the front bearing retainer, No.
psig (6.2 bar) maximum air pressure, using a 3/8" hose up 865697, (left hand threads). The motor assembly may
to 8' in length. If additional length is required, the next now be slipped out the front of the backhead.
larger hose size may be connected to the 8' whip hose.
REASSEMBLY
LUBRICATION
If the tool has been completely disassembled, assemble
An automatic in-line filter- regulator- lubricator is recom- the various subassemblies per their instructions. After
mended as it increases tool life and keeps the tool in assemblyofthecompletetool,theR.P.M.mustbechecked.
sustainedoperation.Thein-linelubricatorshouldberegu-
larlycheckedandfilledwithagoodgradeof10Wmachine To change the R.P.M. settting on the 15G, the governor
oil.Properadjustmentofthein-linelubricatorisperformed will have to be removed (left hand threads) and the
by placing a sheet of paper next to the exhaust ports and governor adjusting screw rotated clockwise to decrease
holding the throttle open approximately 30 seconds. The the speed, and counter-clockwise to increase the speed.
lubricatorisproperlysetwhenalightstainofoilcollectson
the paper. Excessive amounts of oil should be avoided.
Check speed of tool before mounting wheel. Mount wheel
guard before mounting wheel.
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.
7
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15G MOTOR & GOVERNOR
RPM
Part No.
867082
867083
867084
867085
865663
867388
9000
12000
14000
18000
865686
8656994
842970
864821
847095
865687
These parts
are included
in governor
subassembly
867086
864821
864232
865663
864234
867388
812164
865693
865657
865655
865660
865658
865695
864735
864236
865697
865787 2 1/2"
865786 3"
865659 2 1/2", 3"
865991 4"
865661
865988 4"
844280
865653 2 1/2", 3"
865990 4"
SERVICE INSTRUCTIONS FOR 15G MOTOR & GOVERNOR
DISASSEMBLY
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
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, must measure a minimum of 7/32" (5.5mm) at both ends.Failure of
and rotor blades, 864234, to be removed from the rotor. Clamp the rotor these parts could cause damage to more expensive components. Also,
in the vise and unscrew the governor (left hand threads). The governor be sure that the blades are no longer than the rotor.
adjusting screw, 867086, may now be removed from the rear of 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
REASSEMBLY
The motor is reassembled in the reverse order of disassembly. Wash the rotor collar, assemble the front bearing (shield toward backhead)
all parts thoroughly ina solvent and visually inspect for damage or wear. into the front bearing plate. Measure the depth of the inner race from the
Check bearings for wear which can be detected by excessive end play,
face of the bearing plate. Select, or fit by sanding, an rotor collar .0015"
or roughness of the bearings which indicates a brinelled condition. Pack larger than this dimension. Governor center 865687, governor weights
both rotor bearings with a good grade of No. 2 Moly Grease. Particular 865663, and governor pins No. 867388, should be checked periodically
for wear and replaced if excessively worn.
PARTS LIST — 15G MOTOR & GOVERNOR
PART NO. NAME OF PARTS
QTY.
PART NO.
NAME OF PARTS
QTY.
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 Pin *
Driving Flange
Exhaust Deflector Retainer Ring
Rotor Collar
Front Rotor Bearing
Outer Flange
Dust Seal
Arbor Collar Grip Ring
Governor Weight *
1
1
1
1
1
4
1
1
2
1
1
1
1
1
1
1
2
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 *
1
1
1
1
1
4
1
1
2
1
1
1
1
1
1
1
2
*These parts can be purchased as a subassembly using number: 861176
8
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15G HANDLE
202105
202106
869855
869856
847808
843590
841552
865698
863093
847710
864375
202337
864530
844304
844311
843590
865701
864387
832595
864531
SERVICE INSTRUCTIONS FOR 15G HANDLE
REASSEMBLY
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 handle is reassembled in the reverse order of disas-
sembly.Allpartsshouldbeinspectedfordamageorwear.
Should a throttle valve bushing need replacing, be sure to
alignairports.Airscreensshouldbecleanedandreplaced
if torn.
Theoilerbodyonthehandlemayberemovedfromthefront
of the handle with the aid of spreaders.
PARTS LIST — 15G HANDLE
PART NO.
202105
202106
202337
832595
841552
843590
844304
844311
845409
847710
NAME OF PART
Toggle
Lock-Off Lever
Throttle Valve
Throttle Valve Spring
Inlet Bushing
QTY.
PART NO.
847808
863093
864375
864387
864530
864531
865698
865701
869855
NAME OF PART
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
QTY.
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Oiler Valve
"O"-Ring 7/32' x 11/32"
"O"-Ring 9/16" x 3/4"
Toggle Pin
"O"-Ring 1/2" x 5/8"
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.
9
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NOTES
10
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NOTES
11
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CooperTools
670 Industrial Drive
Lexington, SC 29072
Phone: (803) 359-1200
Fax: (803) 359-2013
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