Cleco 136 Operation & Service Manual

823209 2/01 136 Reciprocating Saw Spade Handle: X 136 Tool Type: Reciprocating R Variable V Speed: 136 Series: X V R NORTH AMERICA EUROPE CooperTools P.O. Box 1410 Lexington, SC 29071 Cooper Power Tools GmbH & Co. Postfach 30 D-73461 Westhausen

safety recommendations before operating this saw. Always wear protective equipment. Caution: Faceshields do not provide unlimited protection against flying particles and are not to be considered as eye protection. ANSI Z87.1 states that separate eyewear shall be used. For additional information on eye protection, refer to Federal OSHA Regulations, 29 CFR, Section 1910.133, Eye and Face Protection, and ANSI Z87.1, Occupational and Educational Eye and Face Protection. This standard is available from the American National Standards 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, and American National Standards Institute, ANSI S12.6, 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- dance with Occupational Safety and Health Administration and 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- rials to be cut must be securely held to prevent movement. 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. Vibration may contribute to a condition called Raynaud’s Syn- 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, clumsiness or weakened grip, nocturnal pain in the hand, or any other disorder of the shoulders, arms, wrists, or fingers is advised to consult a physician. If it is determined that the symptoms are job related or aggravated by WARNING ! Impact resistant eye protection must be worn while 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.

essary 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 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 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 available 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 ! 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. 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

When the blade is properly positioned: the hole in the blade shank will align with the hole (B) Fig. 2, in the backside of blade clamp. Fig. 2 3. Firmly tighten clamp screw. 4. To remove blade, loosen blade clamp three to four turns and pull blade from clamp. PIVOTING GUIDE SHOE The shoe (A) Fig. 3, serves as a rest while making a cut. It is pivoted so the saw may be gradually raised to a position perpendicular to the work as the saw is moved toward the operator. Do not operate the saw with the guide shoe removed. Fig. 3 READ SAFETY RECOMMENDATIONS BEFORE CONNECTING TOOL. OPERATING INSTRUCTIONS The Cleco reciprocating saw is designed to operate on 90 psig (6.2 bar) maximum air pressure, using a 5/16" (8mm) x 8' whip hose. If additional length is required, the next larger hose size may be connected to the 8' whip hose. The Cleco reciprocating saw is designed for cutting wood up to 12" thick, metal up to 3/4" thick and various other materials, such as plastics, fiberglass, hard rubber, etc. The handle, gear housing, intermedi- ate plate, blade and pivoting guide shoe may be made live if the blade cuts into live wiring. To prevent accidental electrical shock, all electricity to material being cut must be completly shut off. STARTING AND STOPPING SAW Connect air supply. Depress throttle lever to start saw. Releasing throttle lever will stop saw. SELECTING THE BLADE For best performance, longer blade life, and smoother cut, select the proper blade for the job. A wide assortment of blades are available. When cutting metal always select a blade which will allow at least three teeth to be engaged in the thickness of ma- terial. INSTALLING THE BLADE Turn off air and bleed air hose before installing or removing blades. 1. Use hex wrench to loosen blade clamp screw (A) Fig. 1, by turning counterclockwise three to four turns. Fig. 1 WARNING ! WARNING ! CAUTION !

STARTING WORK Consult the Blade Selector Charts for the blade best suited for the material to be cut. For greatest economy, use the shortest blade suitable for the thickness of the material to be cut. Be sure the material to be cut is rigid. Small work pieces should be securely clamped in a bench vise or to a work table. As the work progresses in scroll or curved cut-out pieces, the material may be adjusted to accommodate the movement of the saw. If the work is large enough, it may be hand held across saw horses. The saw cuts freely with only slight feed pressure. Forcing the saw will not make it cut faster. SAWING WOOD The saw is used much the same as a hand saw in that it is moved toward the operator during the cutting operation. However, since the blade cuts on the up-stroke instead of the down-stroke as in the case of the hand saw, the good or finish side of the work should face down during the cut- ting operation. PLUNGE CUTS The saw can be used for plunge cutting wood, plywood, wallboard, and plastic materials. DO NOT attempt to plunge cut metal. Clearly mark line of cut on the work. Grasp front housing with one hand and rear handle with the other hand. To start cut, rest saw on shoe bracket, align blade with the marked line of cut, (blade NOT touching work), as shown in Fig. 4. Start saw. Using bracket as a pivot point, roll saw forward by raising rear handle, as shown in Fig. 5. When blade has cut through the work, continue raising the rear handle until saw is perpendicular to the work surface. Keep saw in this position and move blade along line of cut. SAWING METAL When cutting angle, H-beam, I-beam, channel, etc., start the cut on the surface where the greatest number of teeth will contact the work. To make a pocket cut, drill a starting hole first. To extend blade life, cutting oil can be applied to the work surface along the line of the cut. Fig. 4 Fig. 5 MAINTENANCE KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air. Remove build up of grime resulting from working green or sappy wood. The rubber boot may be cleaned with a soft damp cloth. NEVER use solvents, as they could pos- sibly dissolve or otherwise damage the material. LUBRICATION An automatic in-line filter-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 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.

A blade for every type of sawing application; will cut smoothly and easily through wood, metal and composition material. Blades designed for use on Porter-Cable, Cleco and most competive saws. Proper Blade Selection for metal: ALWAYS select a blade where at least three teeth are engaged in the thickness of the metal. Porter-Cable Blades PORTER-CABLE BLADES

(4.7mm) or less at either end. DISASSEMBLY HANDLE Should the throttle valve seal 847426, need replacing, unscrew the throttle valve cap 867753, for removal of the throttle valve and components. The tool is equipped with an air screen for protection of the internal motor parts from foreign material. The air screen located in the inlet bushing may be removed for cleaning and inspection by unscrewing the inlet bushing 867758. If the screen is torn or damaged, the inlet bushing should be replaced. The throttle handle and motor housing, may be removed for cleaning and inspection by unscrewing the two (2) socket head cap screws and nuts after the tool is disassembled to the point that the motor can be removed to allow access to nuts inside motor housing. MOTOR HOUSING & MOTOR The front housing and intermediate plate 204683, must be removed from motor housing to remove motor. Remove four (4) hex cap screws holding the front housing and intermediate plate to motor housing. The motor can be pulled from motor housing. The "O"-rings and mufflers can be removed from motor. 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 rotor bearing. FRONT HOUSING & INTERMEDIATE PLATE To disassemble the front housing 204692, from the inter- mediate plate 204683, remove (4) four hex cap screws and lift complete unit off the intermediate plate. The secondary muffler can be removed for inspection. REASSEMBLY The tool is reassembled in the reverse order of disassem- bly. Inspect all parts for damage or wear. It is recommended that new rotor blades be installed at each repair cycle. If not replaced, the used ones must measure a minimum of 3/16" (4.7mm) at both ends. Replace bearings that are rough or have excessive end play. 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) longer than this measure- ment. Install the rotor blades, cylinder rear bearing plate, and rear bearing on the rotor. After final assembly of the motor unit, the cylinder should be held securely but not tightly between the two plates. The rotor should not rub either plate. Note: Tighten 204727 locknuts holding handle to backhead, to a maximum of 12 ft. lbs. of torque during reassembly. Tighten all screws and nuts 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.

Safety Instruction Label Warning Label Intermediate Plate Bearing Front Housing Bearing Gear Reciprocating Shaft Blade Clamp Blade Clamp Screw Insulator Boot Front Housing Screw Intermediate Plate Plate Drive Shaft Flat Washer Wobble Plate Retaining Ring Part No. 204689 204690 204691 204692 204693 204694 204695 204696 204697 204698 204699 204700 204701 204702 204703* 204704* 204759 Spacer Carrier Tube Assembly Felt Seal Front Housing Felt Seal Shoe & Bracket Assembly Shoe Screw Carrier Tube Screw Plug Retaining Ring Plate Screw Oil Seal Plug O-Ring Wrench Wrench Holder Housing Bolts HOUSING PARTS LIST Name of Part Qty. 1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 2 Qty. 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 4 204675 204703 204704 204675 204701 204676 204688 204689 204676 204687 204676 204698 204688 204685 204678 204702 204690 204691 204680 204699 204681 204694 204695 204696 204679 204677 204682 204683 204684 204693 204700 204686 204692 204697 204759 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 ! * Parts not included in head. The complete head can be purchased using part no. 204738.

PARTS LIST RECIPROCATING SAW MOTOR Part No. 204222 204312 204712 812165 847525 847528 864489 864493 865417 869445 869448 869449 Name of Part Rear Bearing Plate Cylinder (incls. 812165) Rotor 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 204712 ROTOR COLLAR PART NO. SIZE 864489 .122" 847525 .124" 864493 .126" 865417 .128"

Subassembly - 201794 204708 204724 204715 204727 204706 204709 847426 204710 413056 833961 867753 612136 204707 864582 615643 204713 204715 QUANTITY RECIPROCATING SAW HANDLE AND MOTOR HOUSING PARTS LIST Motor Housing Insert Washer Spacer Throttle Valve Motor Housing Plate Throttle Bushing Throttle Pin Muffler Handle Muffler Lock Nut Throttle Valve Spring Socket Head Cap Screw "O"-Ring Lever Stop Pin "O"-Ring 13/16" x 1" Throttle Valve Seal Throttle Lever Pin Throttle Lever "O"-Ring 1-1/8" x 5/16" Throttle Valve Cap Throttle Pin Bushing Inlet Bushing 1 2 2 1 1 1 1 1 3 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 204706 204707 204708 204709 204710 204711* 204713 204714 204715* 204720 204724* 204727 413056 612136 615643 812977 833961 847426 864195 864582 867732 867753 867756 867758 PART NO. NAME OF PART RECIPROCATING SAW HANDLE AND MOTOR HOUSING SUBASSEMBLY The complete handle and motor housing can be purchased as a subassembly using part no. 201794. * Parts not included in handle and motor housing subassembly.

Lexington, SC 29072 Phone: (803) 359-1200 Fax: (803) 359-2013 www.cooperindustries.com