Cooper Tools CLECO 136 Series Installation and operating instructions
1
Operation & Service Manual
823090 2/01
136 Bandsaw
(Lock-Off Lever)Inline
Handle:
L
136
Bandsaw
Tool Type:
B
VariableV
Speed:
136
Series:
LVB
NORTH AMERICA EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper PowerTools GmbH & Co.
Postfach 30
D-73461 Westhausen
2
Safety Recommendations
For your safety and the safety of others, read and understand the
safety recommendations before operating this saw.
Always wear protective equipment.
Caution: Faceshields do not provide unlimited protection against
flyingparticlesandarenottobeconsideredaseyeprotection.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,OccupationalandEducationalEyeandFaceProtection.This
standard is available from the American National Standards Insti-
tute, 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, reflective surfaces, pro-
cess noises, and resonant structures can substantially contribute
to the sound level experienced by the operator. Proper hearing con-
servation measures, including annual audiograms and training 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, Occupational Noise Expo-
sure,andAmericanNationalStandardsInstitute,ANSIS12.6,Hear-
ing Protectors.
Other protective clothing should be worn as required, unless it cre-
ates a greater hazard. Do not wear loose fitting clothing or any jew-
elry. Gloves can be caught in the the rotating blade causing severe
injury. Avoid inhaling dust resulting from the operation of this saw.
Wear approved respirator or mask if ventilation is inadequate. Res-
pirators should be selected, fitted, used and maintained in accor-
dancewithOccupationalSafetyandHealthAdministrationand other
applicable regulations.
This saw is designed to operate on 90 psig (6.2 bar) max. air pres-
sure. Installation of a filter-regulator-lubricator in air supply line is
highly recommended. Before tool is connected to air supply, check
throttle for proper operation, i.e., throttle moves freely and returns
to closed position. Clear air hose of accumulated dust and mois-
ture. Be careful not to endanger adjacent personnel. Before remov-
ing tool from service or changing blades, 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. A self-relieving valve is recommended for this purpose.
Work Environment. Work areas should be kept clean and free
from clutter. Visitors should be kept away from work area. The air
hose should be suspended or placed to prevent damage to the
hose or inadvertent tripping to workers. An improperly placed hose
can be hooked by a vehicle or worker pulling the saw out of the
user’s hands or causing a loss of balance. After use the saw should
be disconnected properly and stored.
Safe Use. Keep both hands on the saw and away from the cutting
area while the blade is rotating. Blades should be kept sharp. Mate-
rialstobe cut must be securely held topreventmovement.Be aware
that end pieces may fall after being cut, and care must be exer-
cised. Never use liquid coolants or cutting oils on the blade or band
mechanism. Damage may occur to the blade guides and pulley
tires. When cutting conduit or pipe, be certain that live electrical
wires and explosive and/or harmful gases or liquids are not present.
Some individuals may be susceptible to disorders of the hands and
arms when performing tasks consisting of highly repetitive motions
and/or exposure to extended vibration. Cumulative trauma disor-
ders such as carpal tunnel syndrome and tendonitis may be caused
or aggravated by repetitious, forceful exertions of the hands and
arms.Vibrationmay contribute to a condition called Raynaud’sSyn-
drome. These disorders develop gradually over periods of weeks,
months, and years. It is presently unknown to what extent
exposureorders develop gradually over periods of weeks, months,
and years. It is presently unknown to what extent exposure to vibra-
tions or repetitive motions may contribute to the disorders. Heredi-
tary factors, vasculatory or circulatory problems, 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 tin-
gling,numbness, blanching of fingers, clumsinessorweakened 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
determined that the symptoms are job related or aggravated by
CAUTION!
Personal hearing protection is
recommended when operating
or working near this tool.
CAUTION!
Personal hearing protection is
recommended when operating
or working near this tool.
WARNING
!
Wear respirator where
necessary.
Electrical and/or explosive hazard. Be
certain that the object being cut does not
contain electrical wires or gases.
WARNING
!
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.
3
Safety Recommendations
movements and postures dictated by the job design, it may be nec-
essaryfor the employer to take steps topreventfurtheroccurrences.
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:
•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 con-
tributing to Raynaud’s Syndrome)
•Avoid anything that inhibits blood circulation
—Smoking Tobacco (another contribut
ing factor)
—Cold Temperatures
—Certain Drugs
•Tasks should be performed in such a manner
that the wrists are maintained in a neutral posi
tion, which is not flexed, hyperextended, or
turned side to side
•Stressful postures should be avoided —se-
lect a tool appropriate for the job and work lo
cation
•Avoid highly repetitive movements of hands and
wrists, and continuous vibration exposure (af-
ter each period of operation, exercise to in-
crease blood circulation)
•Keep tool well maintained and replace worn
parts (a preventative maintanance program
with scheduled inspections is highly recom-
mended)
This information is a compilation of general safety practices ob-
tained 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 cir-
cumstances may not warrant or require additional procedures. Your
workmay require additional specific safetyprocedures.Follow these
procedures as required by your company. For more information,
see the latest edition of ANSI B186.1, Safety Code for Portable Air
Toolsavailable from the American National Standards Institute, Inc.,
11 West 42nd Street, New York, NY 10036.
Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation
Avoid Avoid Avoid
OK Avoid OK
OVER
CAUTION!
Personalhearing protection is
recommendedwhen operating
orworking near this tool.
WARNING!
Impactresistant eye protection
mustbe worn while operating
orworking 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.
SAFETY
INSTRUCTIONS
1. Use eye and hearing protection.
2. Keep hands away from cutting
area.
3. Turn off air when not in use, when
changing or adjusting blades, or
servicing.
4. Secure work. Use clamps or vise
to hold work.
5. Stay clear of end pieces that may
fall after being cut off.
6. Keep blades sharp.
204203
204204
Electrical and/or explosive hazard. Be
certain that the object being cut does not
contain electrical wires or gases.
WARNING
!
204203 204204 204737
4
WHICH BLADE TO USE
In general, select a blade which will allow at least two teeth
to be engaged in the material thickness. The thinner or the
harder the material, the finer the blade teeth. The thicker or
thesofterthe material,thecoarser thebladeteeth. Hi-speed
steel blades stay sharp longer than alloy steel blades. Due
to the many materials that can be cut, operator's experi-
encewill determinewhich bladewill havethe longestlife for
any specific operation.
USE OF LUBRICANTS
NEVERUSE LIQUIDCOOLANT WITHYOUR BANDSAW.
Damage to the blade guide bearings or rubber tires on the
pulleys may result.
Bandsaw lube wax is available and recommended when
cuttingaluminum,brassandthick materials.Castironshould
be cut dry.
With the saw running, apply the wax momentarily to both
sides of the blade. Reapply wax intermittently as needed.
EXERCISE EXTREME CARE TO PREVENT HANDS
FROM CONTACTING THE BLADE.
After prolonged cutting, the wax will cling to the pulleys of
your band saw. This does not affect the operation of the
machine.All that isnecessary isto disconnect themachine
from the air supply and wipe the wax from the pulleys.
TO CHANGE SAW BLADES
DISCONNECT SAW FROM AIR SUPPLY.
TOREMOVEBLADE -Turnhandle (A),Fig. 2,clockwise to
release tension on the saw blade. Remove the blade, first
from the pulleys and then from the blade guide.
Fig 2.
READ SAFETY RECOMMENDATIONS
BEFORE CONNECTING TOOL.
OPERATING INSTRUCTIONS
TheClecobandsawisdesignedtooperateon90psig (6.2
bar)maximumairpressure,usinga 5/16"(8mm)x8' whip
hose. If additional length is required, the next larger hose
size may be connected to the 8' whip hose.
TO START AND STOP SAW
Connect air supply. Push the lock-off device foward
(A),Fig.1,and depressthe throttle lever (B),Fig.1, tostart
the saw. Releasing throttle lever will stop saw.
Fig. 1
LUBRICATION
An automatic in-line filter-lubricator is recommended as it
increases tool life and keeps the tool in sustained opera-
tion.Thein-linelubricatorshouldberegularlycheckedand
filled with a good grade of 10W machine oil. Proper
adjustmentofthein-linelubricatorisperformed 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
Inthe eventthat itbecomesnecessary tostore thetool 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.
TYPE OF MATERIALS
The Cleco bandsaw is designed to cut various types of
material up to 4-3/4" diameter or 4-1/4" x 4-3/4" rectangu-
lar shape.
SELECTING THE BLADE
The Cleco bandsaw requires blades that are .020 thick,
1/2" wide, and 44-7/8" long. NOTE: Blades for stationary
bandsaws areof differentthickness thanabove andWILL
NOTfit theprecision bladeguides on portable band saws.
Therefore, they MUST NOT be used.
A
WARNING
!
WARNING
!
A
B
5
6.RepeatSteps 1through 5asnecessary toachieveproper
tracking.
Fig. 5
HOW TO USE A PORTABLE BANDSAW
1. Verify material to be cut is firmly held to prevent move-
ment.
2. Hold the saw as shown in Fig. 5, with the work stop (A)
contacting the work and blade teeth clear of the work.
3. Turn saw "ON" and lower onto work. Allow weight of saw
to control cutting pressure. Additional pressure will slow
down speed of the blade and reduce cutting efficiency.
4. Hold saw straight in the cut. Any twisting or cocking of
the blade results in shorter blade life.
5. Stay clear of end pieces that may fall after being cut
off.
6. At completion of cut DO NOT allow saw to fall against
work. HOLD SAW SECURELY.
7.Fig.6showsthepropercutting positionfor variousshapes.
Fig. 6
DIRECTION OF BLADE TRAVEL
ON LEFT SIDE OF MACHINE POSITION OF TEETH
ON LEFT SIDE OF MACHINE
LOCKING NUT
TRACKING SCREW
Before installing a blade, clean chips and wax, which may
have accumulated on blade guides and pulley tires.
TOINSTALL BLADE-install bladein bladeguides andthen
position on pulleys. MAKE SURE TEETH ON LEFT SIDE
OF MACHINE POINT TOWARD THE REAR OF THE MA-
CHINE. See Fig. 3.
Fig. 3
Turnhandle (A),Fig. 2, counterclockwise as faras itwill go.
This reinstates tension on saw blade.
Start and stop saw two or three times to seat blade on pul-
leys.
TO ADJUST BLADE TRACKING
This Bandsaw is equipped with an adjustable Blade Track-
ing Mechanism. When properly adjusted, the back edge of
the blade will run lightly against at least one of the back-up
rollers, but will not press heavily against the roller. If the
blade fails to track correctly, adjust as follows:
1. DISCONNECT SAW FROM
POWER SOURCE.
2. Use a 9/|6" wrench to loosen the adjustment locking nut
(see Fig. 4), by turning it counterclockwise, one or two
turns.
Fig. 4
3. Use a flat screwdriver to turn the tracking screw 1/4 turn.
Turning the screw clockwise will move the blade further
up, toward the blade guide rollers. Turning the screw
counterclockwise will move the blade down, away from
the blade guide rollers.
4. Tighten the adjustment Iocking nut.
5. Following the directions in TO START AND STOP SAW,
operate the saw and observe blade tracking.
A
RIGHT WAY
RIGHT WAY WRONG WAY
RIGHT WAY WRONG WAY
WRONG WAY
WARNING
!
CAUTION!
6
MAINTENANCE
Periodically blow out all air passages with dry compressed
air. Remove waxandchipbuildup frompulleytiresand blade
guides.All plastic partsshould be cleanedwith a softdamp
cloth.NEVERuse solventstocleanplastic parts.Theycould
possibly dissolve or otherwise damage the material.
SERVICE AND REPAIRS
All quality tools will eventually require servicing or replace-
ment of parts due to wear from normal use. Repairs should
be made by trained staff familiar with this product or by an
authorized Cleco Service Center. Original factory replace-
ment parts are recommended to maintain factory perfor-
mance specifications. If you have any questions about this
product,pleasecontact yourClecodistributoror salesman.
DISASSEMBLY
BACKHEAD
The backhead 204212, can be separated from the handle
adapter 204206, by removing the retainer pin 204327. To
gainaccesstothispin,carefullyrollthegripsleeve204213,
back over itself beginning at the end adjacent to the handle
adapter,anduntilthepinbecomesvisible.Note:If"O"-rings
844311 and 847272 (2) two, are replaced, do not lubricate.
Forinspectionorreplacementofthethrottlevalveorrelated
parts,unscrewtheinletbushing204220.Theairinletscreen
863598,shouldbewashedinasolventandblownoutinthe
reverse of normal air flow. Replace the screen if clogged or
torn.
HANDLE ADAPTER & UPPER HOUSING
The handle adapter and upper housing 204210 should not
bedisassembledunlessnecessary.Todisassemblehandle
adapter from upper housing remove (3) three hex cap
screws 624820 and pull apart. To remove upper housing
from lower housing, remove (7) seven hex cap screws
204198 and pull apart.
LOWER HOUSING & INTERMEDIATE PLATE
Todisassemblethelowerhousing204211fromtheinterme-
diateplate201655,remove(4)fourhexcapscrews845758
andliftcompleteunitofftheintermediateplate.Thesecond-
arymufflercanberemovedforinspectionandmotorcanbe
pulled out of lower housing. The primary muffler 204214
inside the lower housing can be removed from inside for
inspection.
MOTOR
Use a suitable driver to drive the front rotor shaft out of the
front rotor bearing. After removing the cylinder and rotor
blades,therearrotorshaftmaybedrivenoutoftherearrotor
bearing.
REASSEMBLY
Thetoolisreassembledinthereverseorderofdisassembly.
Washall partsin asolvent andinspect fordamage or wear.
Itisrecommendedthatnewrotorbladesbeinstalledateach
repaircycle.If notreplaced,the used onesmustmeasure a
minimum of 3/16" (4.7mm) at both ends.
Replacebearingsthatareroughorhaveexcessiveendplay.
Install the front rotor bearing in the front bearing plate and
measure the distance from the face of the bearing plate to
the inner race of the bearing with the bearing race loaded
rearward. Select or fit by sanding, a rotor collar .001"
(.025mm)to.002"(.050mm)longerthanthismeasurement.
Installtherotorblades, cylinderrearbearingplate, andrear
bearing on the rotor. After final assembly of the motor unit,
thecylinder shouldbe heldsecurelybut nottightly between
the two plates. The rotor should not rub either plate.
Tighten all joints securely during reassembly. Place a few
drops of 10W machine oil in the air inlet to ensure positive
lubrication of all motor parts as soon as air is applied.
Replace if 3/16"
(4.7mm) or less
at either end.
7
8
Ref.
No.
7
8*
9*
10
11
11A
12
13
14
15
16
17
18
19
20
21
22
23
23*
24
25
26
27
32
36*
Part
No.
203096
201652
201649
204224
204229
204230
204231
204232
204233
204234
204235
204236
204279
204237
204238
204239
204240
204241
201653
204242
204243
204244
204245
204246
201654
Name of Part
Muffler
Pulley Housing Assembly, T2, Incl. 74,
75,76,83,84
Knob Set
Screw
Tension Lever
Tension Shaft
Yoke
Pulley Tire
Bushing
Bearing
PulleyShaft
Pulley
Washer
Work Stop
Screw
Blade Guide Roller
Blade Guide Bearing
Blade Guide Holder
Blade Guide Hardware Package Incl. 20,
21,22,24,25,26,27,52
Pin
Washer
Blade Guide Bearing
Screw
Screw
Yoke Kit, Incl. 14
Ref.
No. Part
No.
37
38
48
49
52
53
54
55
56
57
58
59
60
61
65
66
74
75
76
80
81
83
84
85
86
87
204247
204248
204249
204250
204251
204252
204253
204254
204255
204256
204257
204258
204259
204260
204261
201655
204262
204263
204264
204265
204266
204267
204268
204269
204270
204271
204272
204204
204203
Screw
Washer
Tension Spring
Screw
Lock Washer
Chain
Driven Sprocket
Screw
Lock Washer
Screw
Washer
Washer
Bearing
Gear & Sprocket
Intermediate Gear
Intermediate Plate Assembly, Incl.60
Needle Bearing
Seal
Bearing
Pin
Washer
Nut,T2
Set-Screw, T2
Retaining Ring, T2
14 Tooth Bi-metal blade
18 Tooth Bi-metal blade
24 Tooth Bi-metal blade
Warning Label
Safety Instruction Label
* Subassemblies
GEAR AND PULLEY HOUSING PARTS LIST
Name of Part
9
Name of Part
3ty.
1
1
1
1
1
1
1
7
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
3
3
1
1
1
1
1
1
4
2
1
1
1
1
1
Qty.Part No.
202105 †
203133 †
203519
203521
203522
203523
203524
204198 *
204206 *
204210 *
204211 *
204212
204213
204214 *
204215 *
204216 *
204217 *
204218
204219
Part No.Name of Part
LOCK-OFF PAWL
LOCK-OFF LEVER
EXHAUST DEFLECTOR
THROTTLE VALVE SPRING
THROTTLE VALVE
THROTTLE VALVE SEAT
THROTTLE VALVE BUSHING
SOCKET CAP SCREW
HANDLE ADAPTER
UPPER HOUSING
LOWER HOUSING
BACKHEAD
GRIP SLEEVE
PRIMARY MUFFLER
SECONDARY MUFFLER
SPACER
WAVY WASHER
THROTTLE VALVE SEAL
FLOW VALVE
PARTS LIST BANDSAW BACKHEAD & HOUSING ASSEMBLIES
204220
204221
204327
619164 *
624820
842305
844306
844308
844309
844311
844312
845409†
845758 *
847272
847808
863598
864271
869855 †
869856 †
INLET BUSHING
THROTTLE PIN
RETAINER PIN
O- RING
CAP SCREW
WASHER, LOCK
O- RING
O- RING
O- RING
O- RING
O- RING
LOCK-OFF LEVER SPRING PIN
ALLEN CAP SCREW
O-RING
LOCK-OFF LEVER PIN
INLET SCREEN
SNAP RING
LOCK-OFF LEVER SPRING
LOCK-OFF LEVER SPRING PIN
The complete Backhead can be purchased as a subassembly using part number: 201656. *Not included in Backhead subassembly.
The complete Lock-off lever can be purchased as a subassembly using part number: 201322. †Included in Lock-off lever subassem-
bly.
847808
203519
204220
203521
203522
844308
203523
203524
204221
842305
204218
204216
204217
845758
204212
204213
847272
844311
204327
863598
204219 864271
844306
845409
869855
624820
204206
844309
844312
204210
619164
204211
204198
204215 204214
202105 203133
TO
INTERMEDIATE
PLATE
INSERT
MOTOR ASSEMBLY HERE
LOCK-OFF LEVER
BACKHEAD
SUB-ASSEMBLY
201656-6
LOCK-OFF LEVER
SUB-ASSEMBLY
201322-5
BANDSAW BACKHEAD &
HOUSING ASSEMBLIES
10
PARTS LIST BANDSAW MOTOR
BANDSAW MOTOR
Part No.
204222
204223
204312
812165
847525
847528
864489
864493
865417
869445
869448
869449
Name of Part
REAR BEARING PLATE
ROTOR
CYLINDER (INCLS. 812165)
CYLINDER PIN
Rotor Collar .124"
Front Rotor Bearing
Rotor Collar .122"
Rotor Collar .126"
Rotor Collar .128"
REAR BEARING
FRONT BEARING PLATE
ROTOR BLADE
Qty.
1
1
1
1
*
1
*
*
*
1
1
4
* ONLY ONE ROTOR COLLAR
REQUIRED.
869445
847528 812165
869449
869448 204222
204312
204223
ROTOR COLLAR
PART NO. SIZE
864489 .122"
847525 .124"
864493 .126"
865417 .128"
11
NOTES
12
CooperTools
670 Industrial Drive
Lexington, SC 29072
Phone: (803) 359-1200
Fax: (803) 359-2013
www.cooperindustries.com
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