ASTRO ONYX 408 User manual

1 YEAR LIMITED WARRANTY
408
FLEX HEAD
REVERSIBLE HD
CUT OFF TOOL
• Astro Pneumatic Tool Co. warrants our products to the original user against defective material or workmanship for a
period of 1 year from the date of 1st use. Astro reserves the right to determine whether the product failed because of
defective material, workmanship or other causes and to charge back for missing parts. Astro Pneumatic Tool Co., at its
discretion, will repair products covered under this warranty free of charge. The original user is to return the product
(with the exceptions listed below) with the distributor’s name, address, adequate proof of date of purchase or a copy of
warranty card, and a short note explaining the problem. Failures caused by accident, alteration, or misuse are not
covered by this warranty.
• Astro Pneumatic Tool Co. or its authorized service representatives must perform all warranty repairs. Any repair to the
product by unauthorized service representatives voids this warranty. The rights under this warranty are limited to the
original user and may not be transferred to subsequent owners.
• This warranty is in lieu of all other warranties, expressed or implied, including warranties of merchantability and fitness
for a particular purpose. Some states do not allow the exclusion of limitations of incidental or consequential damages
so the above limitations may not apply to you.
WARNING
Study, understand and follow all instructions provided with this product.
Read these instructions carefully before installing, operating, servicing or
repairing this tool. Keep these instructions in a safe accessible place.
PLEASE DO NOT RETURN ANY PRODUCT WITHOUT CALLING 1-800-221-9705 FOR INSTRUCTIONS
911

02
Flex Head Reversible HD Cut Off Tool408
INTENDED USE OF THE TOOL
The 408 cut off tool is designed to be used with standard 3" cut-off wheels that are meant for
16,000rpm or above to cut sheet metals and other thin metal materials. Do not use this tool outside of
the designed intent. Never modify the tool for any other purpose or use.
BEFORE USE
Before use, check the parts diagram and part number listing on page 6 to make sure all parts are
included. If any parts are missing or damaged, please call your distributor.
SPECIFICATIONS:
PRODUCT INFORMATION
• Flex-head design allows for setting the
tool 25° forward or backward for
clearance
• Forward and reverse dial, you choose
where the sparks are thrown
• 0.8 horsepower motor, designed for full
throttle heavy-duty applications
CAUTION: TO HELP PREVENT PERSONAL INJURY.
• Use of this product can expose you to chemicals including ethylene glycol, gasoline vapors and
engine exhaust, which are known to the State of California to cause cancer, birth defects, or
reproductive harm. For more information, visit www.P65Warnings.ca.gov. Always wear ANSI
approved safety equipment, safety glasses and clothing when using this product.
Study, understand, and follow all instructions provided with this product. Failure to read and follow
all warnings and operating instructions may result in damages and serious injury or death.
• Always wear ANSI approved goggles when using this product. (Users and Bystanders).
• Never use this tool for any application other than for which it was designed.
• Only use accessories designed for this tool.
• Never alter or modify this tool in any way.
• Improper operation and/or maintenance of the tool, modification of the tool, or use of the tool with
accessories not designed for it could result in serious injury or death.
• Always select the correct accessories of the correct size and design for the job that you are
attempting to perform.
• Always work in a clean, safe, well-lit, organized and adequately equipped area.
• Do not begin repairs without assurance that vehicle is in secure position, and will not move during repair.
• Users of this tool should review the chemical composition of the work surface and any products used
in conjunction with this tool for any such chemicals prior to engaging in any activity that creates dust
and/or microscopic particles.
• Users should obtain the Material Safety Data Sheets for all identified chemicals, either from the
manufacturer or their employer, and proceed to study, understand, and follow all instructions and
warnings for exposure to such chemicals.
• Some examples of these chemicals are: lead from lead based paints; crystalline silica from bricks,
cement and other masonry products; and arsenic and chromium from chemically treated lumber. A
listing of the chemicals can be obtained at www.oehha.ca.gov under Propoisition 65.
• In order to reduce their exposure to such chemicals, users should always:
- work in well-ventilated areas.
WARNING
- wear appropriate safety equipment and clothes that are
specifically designed to filter out microscopic particles.
Wheel Size: 3" (75mm)
Free Speed: 16,000 RPM
Overall Length: 9.6" (243.84 mm)
Net Weight: 2.9 lbs. (1.315 kgs)
Air Consumption: 5.3 CFM
Power: 0.8 HP
Air Inlet Thread NPT: 1/4"
Air Pressure: 90 PSI (6.2 Bar)

• The tool shall not be used in potentially explosive atmospheres.
• Disconnect the air hose before changing or adjusting any inserted tools.
• Before using tool, please confirm all couplings and plugs are fixed securely. An air hose that is under
pressure may lash out when disconnected and could lead to serious injuries.
• Prevent loose clothes, long hair or any other personal accessories from coming close to moving
parts to reduce the risk of being caught, trapped or drawn into the rotating spindle.
• Excessive high air pressure that exceeds the maximum pressure may cause injuries to user.
• Exposure to strong vibration for extended time may cause harm to operator.
• Be aware of the rotation direction before starting the tool to reduce hazardous situations due to
unexpected rotation direction.
• WATCH YOUR STEP! Leaving excess hose unattended near working area or walk path could
result in injury or death.
• Wearing eye/face protection could reduce the danger to person from high speed splinters being
emitted from the tool or work surface.
• Wearing correct breathing protection will help avoid inhaling dust or debris from work process that
can be harmful to your health.
• High sound levels can cause permanent hearing loss. Use hearing protection while operating tool.
• Due to the material being processed, there may be a risk of explosion or fire. Be aware of work
surface dangers prior to beginning work.
• There is a risk of being cut due to high speed rotation. Do not touch high speed rotating disc.
• This power tool is not insulated. If contact is made with an electric current, injury may occur.
• Dust created by sanding, sawing, grinding, drilling and other related activities may expose the user to
dust and/or microscopic particles that may contain chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
03
Flex Head Reversible HD Cut Off Tool408
MAINTENANCE INSTRUCTION
LUBRICATION:
Before connection of the hose, apply 4 to 5 drops
of a good quality air tool oil at the air inlet.
After 3 to 4 hours of operation, oiling may be
necessary again.
TIGHTNESS OF PARTS:
Regularly check whether all connection parts are
fastened securely. Follow this procedure daily
before beginning work.
DISPOSAL:
Follow national legislation of waste disposal.
STORAGE:
Avoid storing the tool in a location subject to high
humidity. If the tool is left unused, the residual
moisture inside the tool can cause rust. Before
storing and after operation, oil the tool at the air
inlet with a good quality air tool oil and run it for a
short period.
ORDERING SERVICE PART:
For further operational and handling information
or for replacement of parts and components,
contact the sales agent from where you purchased
the tool, or the service division of our company,
phone number 800-221-9705.
* When ordering parts and components, give
each part number, name, and quantities.
WARNING

Pitch Pipe Back
Toward Air Receiver
Oil and Water Extractor should be at least 25 ft. from the compressor.
Further if possible.
Oil and Water
Extractor
PIPE SIZE, I.D. (Inches)
04
Flex Head Reversible HD Cut Off Tool408
SUGGESTED AIR LINE CONNECTION
The oil and water extractor should not be mounted on or near the air compressor.
The temperature of air is greatly increased during compression. As the air cools down to room
temperature, in the air line, on its way to the Air Power Tool, the moisture contained in it condenses.
Thus, for maximum effectiveness, the oil and water extractor should be mounted at some point in the
air supply system where the temperature of the compressed air in the line is likely to be lowest.
Air lines must be properly drained daily. Each low point in an air line acts as a water trap. Such points
should be fitted with an easily accessible drain. See diagram below. Pitch all air lines back towards the
compressor so that condensed moisture will flow back into the air receiver where it can be drained off.
Drain daily.
Install Drain
at Each Low Point
COMPRESSOR UNIT
Drain Daily
Drain Daily
Drain Daily
25 FEET OR MORE
Air Flow
(CFM)
10
20
30
40
50
70
50
1/2"
3/4"
3/4"
1"
1"
1"
100
3/4"
3/4"
3/4"
1"
1"
1"
150
3/4"
3/4"
1"
1"
1"
1-1/4"
200
3/4"
1"
1"
1"
1-1/4"
Length of Pipe (feet)

CHANGING THE WHEEL:
Disconnect the tool from the air source. Place one of the supplied wrenches on the drive shaft,
interlocking the flat sides. Place the other wrenches on the hex bolt head at the end of the shaft. While
holding the wrench on the shaft, turn the hex bolt counter-clockwise. Remove the hex bolt while
holding the flange. To reinstall the wheel, align the lower drive flange and drive shaft. Then center the
wheel on the drive shaft. Place the upper flange on the wheel and thread the hex bolt into the drive
shaft. Place one supplied wrenches on the drive shaft and the other on the hex bolt head. While firmly
holding the lower wrenches, turn the upper wrench clock-wise to tighten.
This tool is equipped with a 360˚ swiveling exhaust port. Use this function to direct air away from your
face and/or debris around the work area.
POSITIONING THE FLEX HEAD:
Disconnect the tool from air source. Firmly grasp the tool with one hand below the knurled lock sleeve.
With the thumb and forefinger of that hand push the lock sleeve outward. With the other hand, you may
now choose from three positions of the wheel end (25˚ upward, 25˚ downward, and standard-straight
operation).
ROTATING THE GUARD :
Disconnect the tool from air source. Firmly grasp the tool with one hand, and with other, gently pull the
guard in an outward direction. You may now rotate the guard to the desired position. Always keep the
guard in a position to direct debris away from you and others.
REVERSING MOTOR ROTATION:
Disconnect the tool from air source. On side Opposite of the throttle is a black knob. You may choose
from F=Forward or R=Reverse. Turn the downward to switch direction.
05
Flex Head Reversible HD Cut Off Tool408
OPERATING INSTRUCTIONS
Always turn off the air supply, drain the hose of air pressure and detach tool from air supply before
installing, removing or adjusting any accessory or attachment to this tool, or before performing any
maintenance.
DO NOT place this tool on the ground or work surface with air source attached, while not in use. The
trigger could be accidentally engaged. This could result in damage to the tool and/or other incidental
items and/or serious injury to the user or bystanders.
NOTE: THE BOTTOM DRIVE FLANGE HAS A SLOT IN IT THAT MUST ALWAYS BE
ALIGNED WITH THE WITH FLAT SIDES OF THE DRIVE SHAFT. FAILURE TO DO SO
COULD CAUSE THE DISC LOOSENS DURING OPERATION, LEADING TO THE
POSSIBILITY OF CAUSING DAMAGE AND /OR INJURY.

Call 1.800.221.9705 for questions concerning performance of the product or other inquiries.
PARTS LIST
Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
408-01
408-02
408-03
408-04
408-05
408-06
408-07
408-08
408-09
408-10
408-11
408-12
408-13
408-14
408-15
408-16
408-17
408-18
408-19
House
Spring Pin
Air Inlet
Throttle Lever
Valve Shaft
Bushing
Screw
Spring
Muffler
Exhaust Diffuser
O-Ring
Knob
O-Ring
Rear End Plate
Rotor
Vane
O-Ring
Cylinder
Front End Plate
Index Part No. Description
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
2
1
1
Qty
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
408-20
408-21
408-22
408-23
408-24
408-25
408-26
408-27
408-28
408-29
408-30
408-31
408-32
408-33
408-34
408-35
408-36
408-37
408-38
O-Ring
O-Ring
Spring Pin
Ball Bearing
Spring Pin
Ball Bearing
Steel Ball
Retaining Ring
O-Ring
Needle Bearing
Pin
Spring
Spacer Ring
Clamp Nut
Socket Joint
Flex Spacer
Screw
Inverted Retaining Ring
Screw
Index Part No. Description
1
1
1
1
2
1
2
2
2
2
1
1
1
1
1
2
2
1
2
Qty
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
408-39
408-40
408-41
408-42
408-43
408-44
408-45
408-46
408-47
408-48
408-49
408-50
408-51
408-52
408-53
408-54
408-55
408CW3
Spring Pin
Washer
Power Shaft
Flex Shaft
Spanner
Screw
Lock Sleeve
Spring
Clamp Nut
Bushing
Drive Shaft
Drive Flange
Flange
Grip
Guard
Safety Bar
Spring
3" 1/32" Cut-Off Wheel
Index Part No. Description
1
4
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
06
Flex Head Reversible HD Cut Off Tool408
PARTS BREAKDOWN