Cooper Bussmann Grinder 15G Series User Manual

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  
 
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
 
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
 
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
 
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
 
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
 
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
 
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
 
NOTES  
10  
 
NOTES  
11  
 
CooperTools  
670 Industrial Drive  
Lexington, SC 29072  
Phone: (803) 359-1200  
Fax: (803) 359-2013  
 

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