Cleco 15GEL Series Operation & Service Manual

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Operation & Service Manual

823069

4/01

15GEL & NGEL Series
Horizontal Grinders

Throttle Terminations:

Third

Generation:

Lever

Extended

Nose Terminations:

Grinder:

Governor Option:

Non-Governed

Governed

Series:

Wheel Type:

Extensions:

Standard

6" Extension

RPM:

120

140

180

Collet

Plug

Type 1 Wheel

5/16

1/4

3/16

Terminations:

XXX

6mm

3/8

1/2-13

5/8-11

3/8-24

2 1/2

4 In.

3 In.

Guard:

NORTH AMERICA

For additional product information visit our website at http://www.clecotools.com

EUROPE

CooperTools
P.O. Box 1410
Lexington, SC 29071

Cooper Power Tools GmbH & Co.
Postfach 30
D-73461 Westhausen

Safety Recommendations

For your safety and the safety of others, read and understand the
safety recommendations before operating any grinder.

Always wear protective equipment and clothing.

Caution: Facesh-
ields do not pro-
vide unlimited pro-
tection against fly-
ing particles and
are not to be con-
sidered 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.

Hearing protection
is recommended in
high noise areas
(above 85 dBA).
Close proximity of
additional tools, re-
flective surfaces,

process noises, and resonant structures can substantially contrib-
ute to the sound level experienced by the operator. Proper hearing
conservation measures, including annual audiograms and train-
ing in the use and fit of hearing protection devices may be
necessary. For additional information on hearing protection, refer
to Federal OSHA Regulations, 29 CFR, Section 1910.95, Occu-
pational Noise Exposure, and American National Standards Insti-
tute, ANSI S12.6, Hearing Protectors.

• Gloves and other protective clothing should be worn as
required, unless they create a greater hazard.

• Do not wear loose fitting clothing, or clothing that may
restrict movement, become entangled or in any way
interfere with the safe operation of the grinder.

Grinding or other
use of this tool may
produce hazard-
ous fumes and/or
dust. To avoid ad-
verse health ef-
fects utilize ad-

equate ventilation and/or a respirator. Respirators should be
selected, fitted, used and maintained in accordance with Occupa-
tional Safety and Health Administration and other applicable
regulations. Read the material safety data sheet on 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-lubricator in the air supply line is
highly recommended.

Never use the air hose for supporting, lifting, or lowering the tool.
Use a safety line or cable on the tool when working in elevated
areas.

Before the tool is connected to air supply, check throttle for proper
operation, i.e., throttle moves freely and returns to closed position.
Being careful not endanger adjacent personnel, 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 accesso-
ries, make sure air line is shut off and drained of air. This will
prevent tool from operating if throttle is accidently engaged. Do not
use tool to drain residual air from air line, instead use of a self-
relieving valve located near tool is highly recommended.

The wheel guard is
designed to prevent
serious injury to the
operator in the
event of wheel fail-
ure 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.

Cone and plug wheels less than 3" in diameter and 5" in length are
generally used for internal grinding or operations where the work
piece offers protection. On internal grinding operations where the
workpiece offers protection to the operator, wheel guards are not
required.

The guard must be securely attached to the grinder with all bolts,
nuts, and lockwashers in place and torqued to 30 - 40 in-lbs.

The speed rating and warning information on the tool should
be maintained or replaced for legibility in the event of dam-
age. Before mounting a grinding wheel, after all tool repairs, and
whenever a grinder is issued for use, check the free speed of the
tool with a tachometer to make sure actual free speed at 90 psig
(6.2 bar) does not exceed rated free speed stamped on tool.
Grinders in use on the job must be checked at least once every 20
hours of operation, or once a week, whichever is most frequent.
Checking the free speed after the removal of each worn wheel and
before mounting a new wheel is highly recommended.

WARNING

Fragments from an abrasive wheel
can cause serious injury or death.
Do not operate without proper
wheel guard in place.

OVER

CAUTION

Personal hearing protection is

recommended when operating

or working near this tool.

WARNING

Impact resistant eye protection

must be worn while operating

or working near this tool.

Read Operating Instructions carefully. Follow

the Safety Recommendations for your safety

and the safety of others.

Hearing protection is recommended in high noise

areas (above 85 dBA). Close proximity of other

tools, reflective surfaces, process noises, and

resonant structures can substantially contribute

to the sound level experienced by the user.

WARNING

Repetitive work motions and/or vibration

can cause injury to hands and arms.

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.

Avoid repeated bending of wrists and hands.

Do not remove this tag until

the operator of this tool has

read these safety precautions.

869974

WARNING TAG
(or 203266 Plug

Wheel Grinder or

869590 6" Extended

Spindle Grinder)

Warning Labels

202406 & 202407

Cleco

MODEL

SERIAL NO.

CAUTION

Personal hearing protection is
recommended when operating
or working near this tool.

WARNING

Impact resistant eye protection
must be worn while operating
or working near this tool.

WARNING

Wear respirator where
necessary.

Safety Recommendations

INSPECT THE GRINDING WHEEL!
Fragments from a grinding wheel that

breaks or comes apart while rotating can cause serious injury
or even death. Inspect grinding wheel. Check the maximum safe
RPM marked on wheel or package. Never use wheels rated at or
below actual tool speed. Cracked, chipped or faulty grinding
wheels are dangerous. Suspect wheels should not be used and
should be disposed of. Look for cracks, chips, water stains, or
signs of abuse or improper storage. Causes of grinding wheel
failures have been traced to such factors as:

• Dropping, bumping, or abuse (careless handling of the

grinder)

• Improper mounting
• Imbalance
• Improper shipment or storage, or age
• Mismatched speed ratings
• Exposure to water, solvents, high humidity, freezing, and
extreme temperatures

Wheels known to have been subjected to any of the condi-
tions above can burst violently and should be destroyed
rather than risk their use by someone who may not notice that
they are damaged.

CHECK FLANGE
A Type 1 wheel grinder's driving flanges must be
relieved, free of nicks and burrs that might cause
stress concentrations on the wheel which can
cause cracks. Blotters must be used and be as
large in diameter as the flanges. Diameters of
driving and outer flange must be equal and meas-
ure at least 1/3 dia. of the wheel. If flanges are
less than 1/3 dia. of wheel, do not use grinder or
select proper wheel. Spindle should be checked for damage or
abuse. Spindle end nut must be tightened firmly against outer
flange to insure necessary friction against blotters to drive wheel.
Caution: Overtightening can cause wheel breakage. Type 1
breakage can also occur if:

• Outer flange is left off
• Outer flange is reversed
• A washer is used in place of either flange
• Outer and driving flange are different diameters
• Blotters are not used
• Wheel is side loaded (Grind on periphery only!)

Threaded hole cone/
plug wheel flanges
should be flat, at least
1/3 the diameter of
the wheel, and not re-
lieved (relieved
flanges can pull the
threaded insert out of
the wheel). Always
use a blotter as large
as the driving flange.
Do not use spacers
between the cone/plug wheel and the driving flange. The grinder
spindle must not bottom out in hole or threads of cone/plug wheel.

BEGINNING GRINDING OPERATION
Before using or after mounting a wheel, tool must be run for one
minute in a protected enclosure to check the integrity of the wheel.
During this time or any other time, no one should stand in front or
in line of the wheel. When starting work with a cold wheel, apply
it gradually to the workpiece until it becomes warm. Do not
continue to use a grinder if:

• It is not equipped with proper wheel guard
• It starts to vibrate
• You sense changes in tool speed or an
unusual increase in noise that would in-
dicate tool is running at excessive speed
• You notice excessive end play in spindle
• You hear any unusual sound from grinder

RETURN THE TOOL TO THE TOOL CRIB
FOR SERVICE IMMEDIATELY!

Some individuals
may be susceptible
to disorders of the
hands and arms
when performing
tasks consisting of
highly repetitive mo-
tions and/or expo-
sure to extended vi-
bration. Cumulative

trauma disorders 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 disorders. Hereditary factors, vasculatory or
circulatory problems,

WARNING

1/3 Dia.

of wheel

Relieved Flange

TYPE 1

GRINDING

FACE

WARNING

Extreme caution should
be exercised not to use
excessive side pressure.
Excessive side pressure
can break the wheel and
result in severe injury.

Guard not

shown for

clarity.

TYPE 1

WHEEL

Blotter

Relieved flanges

minimum 1/3 dia.

of wheel dia.

Do not grind with

side of Type 1 wheel.

Cleco

MODEL
SERIAL NO.

CAUTION

STEEL
DRUM

5"(127mm)

MAX

3"(76mm)

MAX

DIA.

PROPER CONE /PLUG

WHEEL MOUNTING

Cone/Plug Wheel

Unrelieved

Driving Flange

Blotter

Grinder spindle

should be shorter

than depth of hole.

Must not bottom out

Repetitive work motions and/or vibration
may cause injury to hands and arms.

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.

WARNING

Avoid repeated bending of wrists and hands.

Safety Recommendations

exposure to cold and dampness, diet, smoking and work practices
are thought to contribute to the conditions.

Tool operators should be aware of the following warning signs and
symptoms so that a problem can be addressed 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 physi-
cian. If it is determined 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 proper selection of the correct type of grinder is an important
ergonomic consideration. Each application should be carefully
considered and the tool chosen that will minimize the stresses on
the operator that can lead to the onset of cumulative trauma
disorders. Some tasks require more than one type of tool to obtain
the optimum operator/tool/task relationship. Cleco offers a com-
plete selection of tools including vertical, straight, angle, and
extended grinders that make possible the correct ergonomic
match of the operator, tool, and task.

The following suggestions will help reduce or moderate the effects
of repetitive work motions and/or extended vibration exposure:

• 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 a major factor contributing to Raynaud's
Syndrome)
• Avoid anything that inhibits blood circulation
—Smoking Tobacco (another contributing factor)
—Cold Temperatures
—Certain Drugs

• 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)

• Use quality abrasive wheels (the primary source of vi-
bration when using a grinder is a wheel that is out of

balance, out of round, untrue, or possibly any combina-

tion of all three)
• Keep tool well maintained and replace worn parts (a
preventive maintanance program with scheduled inspec-
tions is highly recommended)

Work gloves with vibration reducing liners and wrist supports 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 vibra-
tion exposure and repetitive wrist trauma. Since they vary widely
in design, material, thickness, vibration reduction, and wrist sup-
port qualities, it is 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 impor-
tant. 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 balanced,
round, and true is highly recommended as they have been found
to significantly reduce vibration. Some abrasive wheels lose their
balance, roundness, and trueness as they wear from use. Be-
cause 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 suseptible to failure.
Excessive vibration may signal eminent wheel failure. Out of
balance abrasive wheels are dangerous. 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 experienced
with abrasive wheels prevail. Use quality wire brushes.

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 scheduled periodic
inspections and proper maintenance is the best way to assure
safety in your portable grinding operations. 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

Extension

Neutral

Flexion

Radial Deviation

Neutral

Ulnar Deviation

Avoid

when the grinder is running and contribute to the vibration. Rotor
blades that are worn or chipped can lock up the motor and damage
motor components. Rotor blades should be checked periodically
and replaced if they measure less than 7/32" (5.6mm) 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.

PROPER LUBRICATION
An automatic in-line filter-regulator-lubricator is recommended as
it increases tool life and keeps the tool in sustained operation. The
in-line lubricator should be regularly checked and filled with a good
grade of 10W machine oil. Proper adjustment of in-line lubricator
is performed by placing a sheet of paper next to exhaust ports and
holding throttle open approximately 30 seconds. Lubricator is
properly set when a light stain of oil collects on paper. Excessive
amounts of oil should be avoided.

Safety Recommendations

STORAGE
In the event it becomes necessary to store 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 oil before disconnecting from air supply. This
will reduce corrosion and displace water that may be trapped in
tool. Water trapped in the tool could cause the governor to freeze
and malfunction if tool is exposed to freezing temperatures.

The governor,if so equipped, should be checked periodically to be
sure the governor mechanism is clean, in good operating condi-
tion, and functioning properly.

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 procedures 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 Abrasive
Wheels, available from the American National Standards
Institute, Inc., 11 West 42nd Street, New York, NY 10036.

These safety instructions, operating instructions, and ser-
vice instructions should accompany tool if it is subsequently
sold or ownership is changed.

Must be replaced if
7/32" (5.6mm) or less
at either end.

Spindle End Nut
Wheel Dia. Thread Size Part No.
2-1/2"(62mm)

3/8-24 844280

3"(75mm) 3/8-24 844280
4"(100mm) 3/8-24 844280
4"(100mm) 1/2-13 864575

Wheel

Blotters

Wheel Guard

Nut

CAUTION LABELS

(2 Required 202406 and 202407)

WARNING

Wheel Guard

Wheel Dia. Part No.

2-1/2"(62mm) 202277
3"(75mm) 202278
4"(100mm) 202245

Wheel

Blotters

Recessed Flanges

Flange Diameters

Identical and at least

1/3 dia. of wheel

Spindle
End Nut

Recessed Flanges

Flange Diameters

Identical and at least

1/3 dia. of wheel

Grinding

Face

Proper

Wheel Guard

TYPE 1 WHEEL GUARD MOUNTING

TYPE 1 PROPER GRINDING WHEEL MOUNTING

Lock Washer

Type 1 Wheel Capacity
Model Wheel Wheel
Dia. Thickness
15GEL-180 2" - 3" 1/16" - 1/2"
15GEL-140 2" - 4" 1/16" - 1/2"
15GEL-120 2" - 4" 1/16" - 1/2"
15GEL-90 2" - 4" 1/16" - 1/2"

Flange dia. should be minimum

of 1/3 wheel dia.

Avoid Side Loads

Use Only Wheels With Speed

Rating Above Tool Speed

Outer Flanges (Recessed)
Wheel Dia. Thread Size Part No.
2-1/2"(62mm)

3/8-24 865659

3"(75mm) 3/8-24 865659
4"(100mm) 3/8-24 865991
4"(100mm) 1/2-13 202336

Cleco

MODEL

SERIAL NO.

CAUTION

Cleco

MODEL

SERIAL NO.

CAUTION

DO NOT REMOVE THIS GUARD Ñ IT IS FOR
YOUR PROTECTION

202406

CAUTION

AVOID INHALING DUST RESULTING FROM THE
GRINDING OPERATION
ALWAYS USE EYE AND HEARING PROTECTION
REPETITIVE WORK MOTIONS AND/OR EXPOSURE
TO VIBRATION MAY BE HARMFUL TO YOUR
HANDS AND ARMS

WHEEL

BLOTTERS

RECESSED
FLANGES

FLANGE DIAMETERS
IDENTICAL

PROPER

WHEEL
GUARD

PROPER GRINDING WHEEL MOUNTING

RADIAL WHEEL

USE THIS GUARD ONLY WITH TYPE 1 WHEELS
DO NOT OVERTIGHTEN SPINDLE END NUT
FLANGES MUST BE AT LEAST 1/3 DIAMETER
OF WHEEL

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

202407

CAUTION

CHECK TOOL SPEED WITH TACHOMETER BEFORE EVERY
WHEEL CHANGE
READ THE MANUFACTURER'S OPERATING INSTRUCTIONS
AND SAFETY INSTRUCTIONS BEFORE OPERATING THIS GRINDER
USE EYE AND HEARING PROTECTION
REPETITIVE WORK MOTIONS AND/OR EXPOSURE TO VIBRATION
MAY BE HARMFUL TO YOUR HANDS AND ARMS

5"(127mm)

MAX

3"(76mm)

MAX

DIA.

PROPER CONE /PLUG WHEEL MOUNTING

Cone/Plug Wheel Driving Flange

(Flat and not relieved)

(3/8-24Ñ202241-6)

(1/2-13Ñ202257-2)

Blotter

To avoid breakage grinder spindle must

be shorter than depth of hole in cone/plug wheel.

Spindle must not bottom out in hole or threads.

Wheel Guard

Bolt (Torque to

30 to 40 in. lbs.)

CAUTION

Flange dia. should be minimum

of 1/3 wheel dia.

Driving Flanges (Recessed)
Wheel Dia. Thread Size Part No.
2-1/2"(62mm)

3/8-24 202240

3"(75mm) 3/8-24 202240
4"(100mm) 3/8-24 202256
4"(100mm) 1/2-13 202256

Wheel must have a speed

(RPM) rating equal to or

higher than tool speed (RPM).

OPERATING INSTRUCTIONS

READ SAFETY RECOMMENDATION BEFORE
CONNECTING TOOL.

The 15GEL 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 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.

SERVICE INSTRUCTIONS

DISASSEMBLY - GENERAL
Remove the tool from the air supply and clamp the flats of
the backhead in a soft-jawed vise and unscrew (left hand
threads) the spindle housing. Remove the motor unit from
the backhead.

DISASSEMBLY - SPINDLE HOUSING
Use a 9/16" six (6) point socket to unscrew splined nut, No.
202236, from the spindle. Remove the spindle from the
front of the spindle housing. Bearing retainer nut, No.
202258, has left hand threads.

DISASSEMBLY - MOTOR UNIT
Use a 3/16" hex wrench to hold the rotor and unscrew (left
hand threads) the governor assembly. Note: Remove the
governor spring at this time to prevent its loss. Use a 9/16"
six (6) point box wrench to unscrew the splined nut, No.
202236. Use a suitable driver to drive the front rotor shaft
out of the front rotor bearing. After removing the cylinder
and rotor blades, the rear rotor shaft may be driven out of
the rear bearing.

DISASSEMBLY- BACKHEADS
Remove the oiler body from the front of the backhead. The
throttle valve on lever throttle backheads may be removed
by unscrewing the valve cap, No. 864531.

Inlet screens should be washed in a solvent and blown out
in the reverse of normal air flow. Replace screens if clogged
or torn.

REASSEMBLY- GENERAL
The tool is reassembled in the reverse order of disassem-
bly. Clean parts in a solvent and inspect for damage or
wear. Replace any bearing that feels rough or has exces-
sive play.

REASSEMBLY- MOTOR
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" (5.6mm) 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.

Assemble the front rotor bearing and front bearing plate and
support the bearing on its outer race. Measure from the face
of the bearing plate to the bearings inner race. Select or fit
by sanding, a rotor collar .0015"(.0038mm) to .0025"
(.076mm) longer than this measurement.

When installing the splined nut, No. 202236, on the rotor,
the undercut end should be toward the bearing. Assemble
the rotor blades (4), cylinder, rear bearing plate, rotor
bearing, RPM adjustment screw (hex toward front of rotor),
governor spring, and governor assembly on the rotor.
Check the governor for smooth operation. Tighten the
splined nut and governor securely.

REASSEMBLY- SPINDLE HOUSING
When installing the two (2) front spindle bearings, No.
202234, the shielded side should be assembled to the rear
of the tool. Bearing spacer, No. 864635, must be in place
between the two (2) bearings. Splined nut, No. 202236,
should be assembled with the undercut end to the rear of
the housing.

FINAL ASSEMBLY - COMPLETE TOOL
Tighten all joints securely and check the free speed (RPM)
of the tool with a dependable tachometer. To adjust the
RPM setting, shut off the air supply and remove (left hand
threads) the extension housing assembly and use gover-
nor adjusting wrench, No. 867027, to adjust the RPM adju-
stment screw. Rotate the screw clockwise (CW) to increase
the RPM setting and counter-clockwise (CCW) to decrease
the RPM setting.

CAUTION: After the grinder is reassembled, be sure to
check the free speed (RPM) for proper speed with a
dependable tachometer before returning the grinder to
service.

Must be replaced if
7/32" (5.6mm) or less
at either end.

PART NO.

202233
202234
202235
202236
202238
202239
202240
202241
202245
202248
202249
202250
202251
202252
202253
202254
202255
202256
202257
202258
202259

NAME OF PART

Collet Spindle
Spindle Bearing
Spline Coupling
Splined Nut
3/8-24 (Type 1) Spindle
6" Extended Cone/Plug Wheel Spindle
3/8-24 Driving Flange (1" O.D.)
3/8-24 Cone/Plug Wheel Driving Flange
4" Wheel Guard
Retainer Ring
Retainer Ring
Spindle Housing
Type 1 Wheel Exhaust Deflector
Cone/Plug Wheel Exhaust Deflector
5/8-11 Cone/Plug Wheel Spindle
Collet Equipped Exhaust Deflector
1/2-13 (Type 1) Spindle
3/8-24 & 1/2-13 Driving Flange (1-3/8" O.D.)
1/2-13 Cone/Plug Wheel Driving Flange
Bearing Retainer Nut
Dust Seal (Felt)

PART NO.

202277
202278
202336
203662
844280
847803
847805
847811
863880
864158
864575
864635
864737
865423
865501
865659
865991
867469
869471

NAME OF PART

2-1/2" Wheel Guard
3" Wheel Guard
1/2-13 Outer Flange (1-3/8" O.D.)
6" Extended Spindle Exhaust Deflector
3/8-24 Spindle End Nut
Nose Piece
3/8" Collet (Opt.)
1/4" Collet (Std.)
"O"-Ring 1-1/4" x 1-3/8"
6MM Collet (Opt.)
1/2-13 Spindle End Nut
Bearing Spacer
"O"-Ring 1-7/8" x 2"
3/16" Collet (Opt.)
5/16" Collet (Opt.)
3/8-24 Outer Flange (1" O.D.)
3/8-24 Outer Flange (1-3/8" O.D.)
Muffler
Rear Spindle Bearing

QTY.

1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

QTY.

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

EXTENSION HOUSING

Collet
Size

Part No.

3/16"

865423

6mm

864158

1/4"

847811

5/16"

865501

3/8"

847805

Wheel Guard
Size

Part No.

2-1/2"

202277

202278

202245

Side Exhaust Deflector
Type Tool Part No.
Type 1 Wheel 202251
Collet 202254
6" Extended Spindle 203662
Cone/Plug

202252

869471

202234

202250

864635

Wrenches
Size

Part No.

9/16" x 11/16"

849837

5/8" x 3/4"

849844

7/8" x 1"

849473

202259

202258

202235

202236

202249

863880

867469

864737

TYPE 1 WHEEL

(For Cone/Plug Wheel Grinding - See Note Below)

CARBIDE BURRS & SMALL MOUNTED WHEELS

CONE/PLUG WHEEL 6" EXTENDED

CONE/PLUG WHEEL DRIVING FLANGE

NOTE: Use this driving flange

in lieu of the Type 1 wheel driving

flange when using cone or plug wheels.

NOTE: SEE PAGE 6

FOR PROPER GRINDING

WHEEL MOUNTING.

When using 4" wheel guard 202245, 1-3/8" O.D. driving flange 202256 and 1-3/8" O.D. outer flange
865991 (3/8-24) or 202336 (1/2-13) must be used.
Fee speed (RPM) of the grinder must not exceed speed (RPM) of the Type 1 wheel.

202233

202253

202239

847803

202236

202238 3/8-24

202255 1/2-13

202241 3/8-24

202257 1/2-13

844280 3/8-24

864575 1/2-13

Type 1 Wheel Outer Flange

Spindle Flange Max.Wheel

Thread

O.D.

Size

Part No.

3/8-24 1" O.D. 3"

865659

3/8-24 1-3/8" O.D.

865991

1/2-13 1-3/8" O.D.

202336

CONE/PLUG WHEEL 5/8-11

CAUTION

Type 1 Wheel Driving Flange

Spindle Flange Max.Wheel

Thread

O.D.

Size

Part No.

3/8-24 1" O.D.

202240

3/8-24 & 1/2-13

1-3/8" O.D.

202256

202248

PART NO.

864821
865663
865686
865687
867082
867083
867084
867085
867086
867388
869055

NAME OF PARTS

Lock Pin
Governor Weight
Governor Spider
Governor Valve
9,000 RPM Governor Spring
12,000 RPM Governor Spring
14,000 RPM Governor Spring
18,000 RPM Governor Spring
RPM Adjustment Screw
Governor Weight Pin
Rear Bearing Plate (Non-Governed)

PART NO.

202246
202247
202321
613002
812164
842870

843444
847095
847525
864232
864234
864236

NAME OF PARTS

Rotor (Governed)
Front Bearing Plate
Rotor (Non-Governed)
Front Rotor Bearing (Governed)
Cylinder Pin
Front Rotor Bearing (Non-Gov-
erned)
Rear Rotor Bearing (Non-Governed)
Rear Rotor Bearing (Governed)
Rotor Collar
Rear Bearing Plate (Governed)
Rotor Blade
Cylinder

QTY.

1
1
1
1
1

1
1
1
1
1
4
1

QTY.

2
2
1
1
1
1
1
1
1
2
1

The Governor can be purchased as a subassembly using number: 861176. Spring not included in Governor subassembly.

MOTOR UNIT

864234

864236

812164

202247

Gov.

613002

Non-Gov.

842870

867086

865663

864821

These parts

are included

in governor

subassembly

865687

864821

867388

865663

865686

867388

847525

Gov.

202246

Non-Gov.

202321

RPM

Part No.

9000

867082

12000

867083

14000

867084

18000

867085

Gov.

864232

Non-Gov.

869055

Gov.

847095

Non-Gov.

843444

OPTIONAL

ROTOR COLLARS

Part No. Size

864487 .120

864488 .121

864489 .122

864490 .123

847525 .124

864492 .125

864493 .126

865416 .127

864417 .128

202076 .129

202187 .130

202188 .131

PART NO.

202103
202104
202105
202106
202322
202337
832595
841552
843590
844304
844311
845409

846664

847272
847767
847710
847808
863093
864375
864387
864530
864531
865698
865701
867008
869489
869712
869855

NAME OF PART

Inlet Bushing
Throttle Valve Pin (Incl. 869712)
Toggle
Lock-Off Lever
Backhead (Incl. 846664)
Throttle Valve
Throttle Valve Spring
Inlet Bushing
Oiler Valve
"O"-Rling 7/32" x 11/32"
"O"-Ring 9/16" x 3/4"
Toggle Pin
Throttle Pin Bushing
"O"-Ring 5/8" x 3/4"
Throttle Valve Spring
"O"-Ring 1/2" x 5/8"
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)
Inlet Screen
Throttle Valve
"O"-Ring 5/64" x 13/64"
Toggle Spring

QTY.

1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

The complete handles can be purchased as a subassembly using these part numbers listed below.
Lock-Off Lever (Governed) - 201019

Lock-Off Lever (Non-Governed) - 201013

The lock-off lever can be purchased as a subassembly using part no. 861992.

HANDLE ASSEMBLIES

869856

869855

865701

847808 841552

844304

832595

864531

843590

844311

202105

202106

843590

865698

863093

864387

864530 202337

864375

847710

202322

845409

869855

847808

LEVER

(GOVERNED)

LEVER

(NON-GOVERNED)

847767

203043

869489

202104

869712

846664

202105

202106

847272

202103

NOTES

CooperTools
670 Industrial Drive
Lexington, SC 29072
Phone: (803) 359-1200
Fax: (803) 359-2013
www.clecotools.com

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