Cornwell tools Cat820r User manual

CAT820R Rev. 12/18/15

CAT820R

Reversible

Cut-Off Tool

Operating Instructions • Warning Information

• Parts Breakdown

WARNING

Some dust created by power sanding, sawing, grinding, drilling, and other

construction activities contains chemicals known to cause cancer, birth

defects or other reproductive harm. Some examples of these chemicals are:

 

 

products, and

 

Your risk from these exposures varies, depending on how often you do this type

of work. To reduce your exposure to these chemicals: work in a well ventilated

area, and work with approved safety equipment, such as those dust masks that

are specially designed to filter out microscopic particles.

Free Speed .................................18,000 RPM

Horsepower ....................................... 0.7

Air Inlet Size ................................. 1/4" NPT

Recommended Hose Size ........................3/8" I.D.

Maximum Air Pressure ................... 90 psig, 6.2 bar

Average Air Consumption ........................3.6 CFM

Overall Length .................................... 7.6"

Vibration Level.............................. 1.8 m/sec²

Sound Pressure Level ........................... 90 dBA

Weight ...................................... 1.85 Lbs.

Wheel Size .........................................3"

SPECIFICATIONS

RPM OF THE ACCESSORY

MUST EXCEED TOOL RPM

ALWAYS READ

INSTRUCTIONS BEFORE

USING POWER TOOLS

ALWAYS WEAR

SAFETY GOGGLES

ALWAYS WEAR HEARING

PROTECTION

ALWAYS WEAR FACE

PROTECTION

ALWAYS WEAR HAND

PROTECTION

AVOID PROLONGED

EXPOSURE TO VIBRATION





90 PSIG, 6.2 BAR

WARNING

RPMRPMRPM

CAT820R 2 Rev. 12/18/15

FAILURE TO OBSERVE THESE WARNINGS COULD RE SULT IN IN JU RY.

WARNING

THIS INSTRUCTION MANUAL CONTAINS

IMPORTANT SAFETY INFORMATION.

READ THIS INSTRUCTION MANUAL CAREFULLY

AND UNDERSTAND ALL INFORMATION BEFORE

OPERATING THIS TOOL.

• Itistheresponsibilityoftheownertomakesureall

 personnelreadthismanualpriortousingthisairtool.

 Itisalsotheresponsibilityoftheairtoolownerto

 keepthismanualintactandinaconvenientlocation

 foralltoseeandread.Ifthemanualorproductlabels

 arelostornotlegible,contactCornwellforreplacements.

 IftheoperatorisnotfluentinEnglish,theproductand

 safetyinstructionsshallbereadtoanddiscussed

 withtheoperatorintheoperator'snativelanguageby

 thepurchaser/ownerorhisdesignee,makingsure

 thattheoperatorcomprehendsitscontents.

• Alwaysoperate,inspectandmaintainthistoolin

 accordancewithAmericanNationalStandards

 InstituteSafetyCodeofPortableAirTools(ANSIB186.1)

 andanyotherapplicablesafetycodesandregulations.

• Forsafety,topperformanceandmaximumdurability

 ofparts,operatethistoolat90psig:6.2barmaxair

 pressurewith3/8"diameterairsupplyhose.

• Alwayswearimpact-resistanteyeprotectionwhen

 operatingorperformingmaintenanceonthistool

 (usersandbystanders).

• Alwayswearhearingprotectionwhenusingthistool

 (usersandbystanders).Highsoundlevelscancause

 permanenthearingloss.Usehearingprotectionas

 recommendedbyyouremployerorOSHAregulation.

• Alwayswearfaceandhandprotectionwhenoperating

 thistool.

• Keepthetoolinefficientoperatingcondition.

• Operatorsandmaintenancepersonnelmustbe

 physicallyabletohandlethebulk,weightandpower

 ofthistool.

• Airunderpressurecancausesevereinjury.Never

 directairatyourselforothers.Alwaysturnofftheair

 supply,drainhoseofairpressureanddetachtool

 fromairsupplybeforeinstalling,removingor

 adjustinganyaccessoryonthistool,orbefore

 performinganymaintenanceonthistool.Failureto

 dosocouldresultininjury.Whiphosescancause

 seriousinjury.Alwayscheckfordamaged,frayedor

 loosehosesandfittings,andreplaceimmediately.

 Donotusequickdetachcouplingsattool.See

 instructionsforcorrectset-uponpage4.

• Airpoweredtoolscanvibrateduringuse.Vibration,

 repetitivemotionsoruncomfortablepositionsover

 extendedperiodsoftimemaybeharmfultoyour

 handsandarms.Discontinueuseoftoolifdiscomfort,

 tinglingfeelingorpainoccurs.Seekmedicaladvice

 beforeresuminguse.

• Slipping,trippingand/orfallingwhileoperatingairtools

 canbeamajorcauseofseriousinjuryordeath.Beaware

 ofexcesshoseleftonthewalkingorworksurface.

• Keepbodyworkingstancebalancedandfirm.

 Donotoverreachwhenoperatingthetool.

• Anticipateandbealertforsuddenchangesinmotion

 duringstartupandoperationofanypowertool.

• Donotcarrytoolbythehose.Protectthehose

 fromsharpobjectsandheat.

• Toolshaftmaycontinuetorotatebrieflyafterthrottle

 isreleased.Avoiddirectcontactwithaccessories

 duringandafteruse.Gloveswillreducetheriskof

 cutsorburns.

• Keepawayfromrotatingendoftool.Donotwear

 jewelryorlooseclothing.Securelonghair.Scalping

 canoccurifhairisnotkeptawayfromtooland

 accessories.Chokingcanoccurifneckwearisnot

 keptawayfromtoolandaccessories.

• NotedirectionofrotationBEFOREoperatingtool.

• Use accessories rated at 18,000 RPM or higher.

• Never operate this tool without required disc

cover/guard in place.

• Do not lock, tape or wire the "on/off" safety lever

in the "on" position, as the lever must be free to

return to the "off" position when released.

• Correctcut-offwheelmountingisnecessaryto

 preventinjuryfrombrokenwheels.Donotuse

 chippedorcrackedcut-offwheels.Cut-offwheels

 shouldbeafreefitonthespindletopreventstress

 atthehole.Useonlywheelcollarsthatcomewith

 thetoolformountingthecut-offwheel.Flatwashers

 orotheradaptersmayoverstressthewheel.Tighten

 thewheelonthespindletopreventspinoffwhenthe

 toolisturnedoff.

• Donotuse(ormodify)thetoolforanyotherpurpose

 thanthatforwhichitwasdesignedwithoutconsulting

 themanufacturer'sauthorizedrepresentative.

• Donotlubricatetoolswithflammableorvolatile

 liquidssuchaskerosene,dieselorjetfuel.

• Thistoolisnotinsulatedagainstelectricshock.

• Thistoolmustnotbeusedinexplosiveatmospheres.

• Servicingandrepairsshouldonlybemadebyan

 authorizedservicecenter.

• Donotforcetoolbeyonditsratedcapacity.

• Use accessories recommended by Cornwell Tools.

• Keeptooloutofreachofchildren.

• Donotremoveanylabels.Replaceanydamaged

 labels.

• Thisproductmaycontainoneormorechemicals

 knowntotheStateofCaliforniatocausecancerand

 birthdefectsorotherreproductiveharm.Wash hands

thoroughly after handling.

CAT820R 3 Rev. 12/18/15

PARTS BREAKDOWN - CAT820R

*ReplacementsavailableasCAT820CW(5PK).**Newimprovedpartsasofserialnumber111290001.

Fortoolswithearlierserialnumbers,orderRS820R17Housing,RS820R01Regualator,RS820R38O-RingandRS820R161Pin.

GuardWarnngLabelavailableasRSCAT820RWL.

Ref. # Item # DESCRIPTION QTY

 1 **RS621001 Regulator 1

 2  RS820R02 O-Ring(AS015) 1

 3  RS246002 O-Ring(3.5x1.4) 1

 4  RS820R04 ValveStem 1

 5  RS288302 O-Ring(P10) 1

 6  RS820R06 Regulator 1

 7  RS820R07 AirInlet 1

 8  RS820R08 ExhaustSleeve 1

 9  RS820R09 Silencer 2

 10  RS820R10 HousingCover1

 11  RS820R11 Pin(3.1x16L) 1

 12  RS820R12 SafetyLever 1

 13  RS820R13 Spring 1

 14  RS820R14 Valve 1

 15  RS820R15 Washer(6x13.8x1.6T) 1

 16  RS820R161A Pin(2.8x25.8L) 1

 17 **RS820R17A Housing 1

 18  RS21114 Bearing(626ZZ) 1

 19  RS820R19 Washer(17x33.2x0.8T) 1

 20  RS820R20 RearPlate 1

 21  RS820R21 Muffler 1

 22  RS820R22 RotorBlade 4

Ref. # Item # DESCRIPTION QTY

 23  RS820R23 Rotor 1

 24  RS820R24 Cylinder 1

 25  RS820R25 BearingSpacer 1

 26  RS288323 Pin(2.5x6L) 2

 27  RS820R27 FrontPlate 1

 28  RS10920 Bearing(6000ZZ) 2

 29  RS820R29 Washer(22x33.2x3T) 1

 30  RS820R30 DiscRetainer 1

 31  RS820R31 ClampNut 1

 32  RS820R32 Guard 1

 33  RS20830 Nut 1

 34 *  DiscWheel 1

 35  RS820R35 Washer(9.6x21x1.5T) 1

 36  RS820R36 Nut 1

 37  RS820R37 ScrewwithWasher 1

 38 **RS850XLR60 O-Ring(S16) 1

 39  RS31535 StopSpannerWrench(14mm) 1

 40  RS165051 HexWrench(4mm) 1

 41  RS305A37 StopSpannerWrench(17mm) 1

 42  RS850XLR77 Screw(M4x8L) 1

 43  RS850XLR78 SnapRing(RTW-18) 1

 44  RS850XLR79 Forward/ReverseValve 1

10 11

CAT820R 4 Rev. 12/18/15

Drain Daily

RegulatorOilerQuick CouplerLeader

Hose

Nipple

Do Not Install

Quick Coupling

Here

Nipple

Filter

Air Supply

Whip Hose

AIR SUPPLY

Toolsoperateonawiderangeofairpressures.Itisrecommended

thatairpressuremeasures90psigatthetoolwiththetriggerfully

depressedandnoloadappliedtothetool.Higherpressure(over90

psig;6.2bar)raisesperformancebeyondtheratedcapacityofthe

tool,whichwillshortentoollifeandcouldcauseinjury.

Alwaysuseclean,dryair.Dust,corrosivefumesand/orwaterinthe

air line will cause damage to the tool. Drain water from air lines

andcompressorpriortorunningtool.Cleantheairinletfilterscreen

weekly.Therecommendedhookupprocedurecanbeviewedinthe

abovefigure.

Theairinletusedforconnectingairsupplyhasstandard1/4"NPT.

Linepressureshouldbeincreasedtocompensateforunusuallylong

airhoses(over25feet).Minimumhosediametershouldbe3/8"I.D.

andfittingsshouldhavethesameinsidedimensionsandbetightly

secured.

Ensureanaccessibleemergencyshutoffvalvehasbeeninstalledin

theairsupplylineandmakeothersawareofitslocation.

LUBRICATION

Lubricatetheairmotordailywith high qualityairtooloil.Ifnoair

line oiler is used, run 1/2 oz. of oil through the tool.The oil can

be squirted into the tool air inlet or into the hose at the nearest

connectiontotheairsupply,thenrunthetool.Arustinhibitiveoilis

acceptableforairtools.

WARNING:After an air toolhasbeenlubricated,oil willdischarge

throughtheexhaustportduringthefirstfewsecondsofoperation.

Theexhaustportmustbecoveredwithatowelbeforeapplyingair

pressuretopreventseriousinjury.

TROUBLESHOOTING

Other factors outside the tool may cause loss of power or erratic

action. Reduced compressor output, excessive drain on the air

line, moisture or restrictions in air pipes or the use of hose

connections of improper size or poor conditions may reduce air

supply.Gritorgumdepositsinthetoolmaycutpowerandmaybe

correctedbycleaningtheairstrainerandflushingoutthetoolwith

gum solvent oil or an equal mixture of SAE #10 and kerosene. If

outsideconditionsareinorder,disconnecttoolfromhoseandtake

tooltoyournearestauthorizedservicecenter.

OPERATION

OPERATION NOTE: Always shut off air supply, drain hose of air

pressure and disconnect tool from air supply when not in use,

before changing accessories or when making repairs.

         

tool at full throttle under a barrier (such as under a heavy work

table) to stop any possible broken wheel parts.

     

protection to guard against flying rust and chips

(users and bystanders). Even small projectiles can

  injure eyes and cause blindness.A cut-off wheel that

  breakscancauseveryseriousinjury.Dailymeasurethe

  toolspeedwithatachometertomakesurethespeed

  is not greater than the RPM marked on the cut-off

  wheel.          

speed lower than the tool speed.

Whenusingthecut-offtool,becarefulnottoexertexcessiveforce.

Toomuchforcecouldbehazardousifitcausesthetoolspindleto

bendorbreak.Theburningoftheworkpieceorexcessivespeed

reductionindicatestoomuchforcebeingapplied.Startthetooloff

thework,setitdownontheworkevenlyandmoveinthedirection

desired to make the cut.When finished cutting, lift off the work

beforestoppingthemotor.Alwaysusetherequiredwheelguardto

preventinjuryfrombrokencuttingparts.If a guard has withstood

a wheel breakage, discontinue its use and replace it with a

new guard. It may be damaged. Position the guard between the

cut-offwheelandtheoperator.Usebarrierstoprotectothersfrom

wheelfragmentsandsparks.

       

prevent injury from broken wheels. Do not use chipped or



the spindle to prevent stress at the hole. Use only wheel collars

          

washers or other adapters may over stress the wheel. Tighten

the wheel on the spindle to prevent spin off when the tool is

turned off.

WARNING: NEVER OPERATE THIS TOOL WITHOUT

REQUIRED DISC COVER/GUARD IN PLACE.

Ensureanaccessibleemergencyshutoffvalvehasbeeninstalledin

theairsupplylineandmakeothersawareofitslocation.

To Assemble Cutting Wheel:

1. Use#41doubleendedspannertohold#30spindle.

2. Use#40hexwrenchtoremove#37screw.

3. Use#39spannerwrenchtoremove#36nutand#35washer.

4. Placecuttingwheelontospindleendandreversesteps1-3.

CAT820R 5 Rev. 12/18/15

WARRANTY

CornwellQualityToolsCompany(“Cornwell”)warrantsthisproductagainstdefectsinmaterialandworkmanshipforaperiodofONE(1)YEARfromthedateoforiginalretailpurchase.

Subjecttotheconditionsandlimitationssetforthbelow,Cornwellwill,atitsoption,eitherrepairorreplaceanypartoftheproduct(s)thatprovesdefectivebyreasonofimproper

workmanshipormaterials.

This warranty does not cover any damage to this product that results from accident, abuse, misuse, natural or personal disaster, or any unauthorized disassembly, repair, or

modification.Repairs,disassemblyandmodificationareonlyauthorizedtobemadebyCornwelloraCornwellAuthorizedWarrantyCenter.

WARRANTY SERVICE

Inordertohaveyourtoolrepaired,returnthetooltoanyCornwellAuthorizedWarrantyCenter,freightprepaid.Pleaseincludeacopyofyourproofofpurchaseandabriefdescription

oftheproblem.Thetoolwillbeinspectedandifanypartorpartsarefoundtobedefectiveinmaterialorworkmanship,theywillberepairedfreeofcharge,andtherepairedtoolwill

bereturnedtoyoufreightprepaid.

EXCLUSIONS AND LIMITATIONS

THISWARRANTYANDTHEREMEDIES SET FORTHABOVEARE EXCLUSIVEAND INLIEU OFALLOTHERWARRANTIES, REMEDIESAND CONDITIONS,WHETHER ORAL ORWRITTEN,

EXPRESSORIMPLIED.CORNWELLSPECIFICALLYDISCLAIMSANYANDALLIMPLIEDWARRANTIES,INCLUDING,TOTHEEXTENTPERMITTEDBYAPPLICABLELAW,ANYWARRANTIES

OFMERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE.IFCORNWELLCANNOTLAWFULLYDISCLAIMIMPLIEDWARRANTIESUNDERTHISLIMITEDWARRANTY,ALLSUCH

IMPLIEDWARRANTIESARELIMITEDINDURATIONTOTHEDURATIONOFTHISWARRANTY.

INNOEVENTSHALLCORNWELLBELIABLETOTHEPURCHASERORTOTHEUSEROFACORNWELLPRODUCTFORANYSPECIAL,INCIDENTALORCONSEQUENTIALDAMAGESBASED

UPON BREACH OFWARRANTY, BREACH OF CONTRACT, NEGLIGENCE,TORT, ORANY OTHER LEGAL THEORY. SUCH DAMAGES INCLUDE, WITHOUT LIMITATION, EXPENSES, LOST

REVENUES,LOSTSAVINGS,LOSTPROFITS,ORANYOTHERINCIDENTALORCONSEQUENTIALDAMAGESARISINGFROMTHEPURCHASE,USEORINABILITYTOUSETHECORNWELL

PRODUCT.

Somestatesdonotallowtheexclusionorlimitationofincidentalorconsequentialdamagesorexclusionsorlimitationonthedurationofimpliedwarrantiesorconditions,sotheabove

limitationsorexclusionsmaynotapplytoyou.Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrightsthatvarybystate.

RepairkitsandreplacementpartsareavailableformanyCornwellproducts,regardlessofwhetherornottheproductisstillcoveredbyawarrantyplan.

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