Cornwell tools Blue power cat540r User manual

CAT540R / CAT540RG 06/11/18

CAT540R

CAT540RG

Blue Power® 0.75 HP

Right Angle Die Grinder

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:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry

products, and

• arsenic and chromium from chemically-treated lumber.

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 .................................20,000 RPM

Horsepower ...................................... 0.75

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

Collet Size .......................................1/4"

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

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

Average Air Consumption ........................4.1 CFM

Overall Length ......................................7"

Vibration Level.............................. 0.6 m/sec²

Sound Pressure Level ........................... 87 dBA

Weight ....................................... 1.8 Lbs.

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

• MAXIMUM RPM OF 20,000

• MAX. AIR PRESSURE:

90 PSIG, 6.2 BAR

WARNING

RPMRPMRPM

CAT540R / CAT540RG 2 06/11/18

FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.

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.

• Always operate,inspect and maintain this tool in

accordance with American National Standards

Institute Safety Code of Portable Air Tools (ANSI B186.1)

and any other applicable safety codes and regulations.

• For safety, top performance and maximum durability

of parts, operate this tool at 90 psig: 6.2 bar max air

pressure with 3/8" diameter air supply hose.

• Always wear impact-resistant eye protection when

operating or performing maintenance on this tool

(users and bystanders).

• Always wear hearing protection when using this tool

(users and bystanders). High sound levels can cause

permanent hearing loss. Use hearing protection as

recommended by your employer or OSHA regulation.

• Always wear face and hand protection when operating

this tool (users and bystanders).

• Keep the tool in efficient operating condition.

• Operators and maintenance personnel must be

physically able to handle the bulk, weight and power

of this tool.

• Air under pressure can cause severe injury. Never

direct air at yourself or others. Always turn off the air

supply, drain hose of air pressure and detach tool

from air supply before installing, removing or

adjusting any accessory on this tool, or before

performing any maintenance on this tool. Failure to

do so could result in injury.Whip hoses can cause

serious injury.Always check for damaged,frayed or

loose hoses and fittings, and replace immediately.

Do not use quick detach couplings at tool. See

instructions for correct set-up on page 4.

• Air powered tools can vibrate during use.Vibration,

repetitive motions or uncomfortable positions over

extended periods of time may be harmful to your

hands and arms. Discontinue use of tool if discomfort,

tingling feeling or pain occurs. Seek medical advice

before resuming use.

• Slipping, tripping and/or falling while operating air tools

can be a major cause of serious injury or death. Be aware

of excess hose left on the walking or work surface.

• Keep body working stance balanced and firm.

Do not overreach when operating the tool.

• Anticipate and be alert for sudden changes in motion

during start up and operation of any power tool.

• Do not carry tool by the hose. Protect the hose

from sharp objects 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 20,000 RPM or higher.

• Never mount a grinding wheel, cut-off wheel,

router cutter or drill bit on a Die Grinder.

• Never use an arbor, mandrel or any other adapter

to convert the Die Grinder for any other application.

• 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 bonded abrasive mounted point grinding

wheels, rotary files and carbide burrs are

necessary to prevent injury from broken accessories.

Do not use chipped or cracked bonded abrasive

mounted point grinding wheels, rotary files and

carbide burrs. Tighten the bonded abrasive mounted

point grinding wheels, rotary files and carbide burrs

on the collet to prevent spin off when the Die Grinder

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 lubricate tools with flammable or volatile

liquids such as kerosene, diesel 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 beyond its rated capacity.

• Use accessories recommended by Cornwell Tools.

• Keep tool out of reach of children.

• Do not remove any labels. Replace any damaged labels.

• Failure to heed these warnings may result in serious or

fatal personal injury and/or property damage.

RPMRPMRPM

WARNING: This product can expose you to

chemicals including nickel, which is known to the

State of California to cause cancer and birth defects

or other reproductive harm. For more information

go to www.P65Warnings.ca.gov.

CAT540R / CAT540RG 3 06/11/18

PARTS BREAKDOWN - CAT540R / CAT540RG

Only parts identified by part number above are available for purchase.

Ref. # Item # DESCRIPTION QTY

1 RS15401 Regulator 1

2 RS288302 O-Ring (P10) 1

3 RS288303 O-Ring (P9) 1

4 RS288304 Snap Ring (ISTW12) 1

5 RS246605 O-Ring (3.5x1.4) 1

6 RS488306 Valve Stem 1

7 RS15407 Air Inlet 1

8 RS15408 Muffler 1

9 RS288309 Silencer 1

9-1 RS15459 Stainless Mesh 1

9-2 RS2883091 Silencer 1

10 RS31511 O-Ring (26.7 x 1.78) 1

11 RS288314 Spring 1

12 RS288315 Valve 1

13 RS288316 Washer (6x13.8x1.6T) 1

14 RS29014CW Housing Grip - Blue 1

14 RS29014CWG Housing Grip - Green 1

15 RS29015 Housing 1

16 RSCAT540R16 Safety Throttle Lever 1

17 RS621011 Spring Pin (3x4L) 1

18 RS21114 Bearing (626ZZ) 1

19 RS15419B Rear Plate 1

20 RS820R22 Rotor Blade 4

Ref. # Item # DESCRIPTION QTY

21 RS820R23 Rotor 1

22 RS29022A Cylinder 1

23 RS520118 Pin (2x6L) 2

24 RS820R25 Bearing Spacer 1

25 RS29125A Front Plate 1

26 RS10920 Bearing (6000ZZ) 3

27 RS29127 Bevel Gear (15T) 1

28 RS29128 Nut 1

29 RS850XLR33 Clamp Nut 1

30 RS29130 Angle Housing 1

31 RS288331 Grease Fitting (3/16") 1

32 RS30524 Bearing (608ZZ) 1

33 RS288732 Snap Ring (ISTW9) 1

34 RS29134 Bevel Gear (18T) 1

36 RS488336 Shaft 1

37 RS288337 Key 1

38 RS288338 Clamp Nut 1

39 RS520129 1/4" Collet 1

40 RS20636 Collect Nut 1

41 RS315B42CW Stop Spanner Wrench (14mm) 1

42 RS1535819CW Stop Spanner Wrench (19mm) 1

RSCAT540RPLK Product Label Kit for CAT540R 1

RSCAT540RGPLK Product Label Kit for CAT540RG 1

23 22

9-1

9-2

CAT540R / CAT540RG 4 06/11/18

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.

OPERATION

When using the Die Grinder, be careful not to exert excessive force

which could be hazardous and cause mounted spindle to bend or

break.

Bonded abrasive mounted point grinding wheels, rotary files and

carbide burrs can be moounted providing their speed rating exceeds

the speed of the Die Grinder. The shank size of the mounted

accessory must match the collet size fitted in the Die Grinder. Insert

the shank of the mounted point as far as possible into the collet and

tighten the nut using the supplied wrenches. Minimum shank gripping

length must be 10mm.

After mounting a new point, start the Die Grinder under bench and run

for a few seconds. if the Die Grinder starts to vibrate when first fitting a

mounted point or during operation, immediately remove from service.

If Die Grinder is dropped, replace bonded abrasive mounted point

grinding wheel, rotary file or carbide burr.

NOTE: DURING OPERATION SAFETY GOGGLES SHOULD ALWAYS

BE WORN TO GUARD AGAINST FLYING DEBRIS (USERS AND

BYSTANDERS).

NOTE: Always turn off the air supply, drain hose of air pressure

and detach tool from air supply before installing, removing or

adjusting any part or accessory on this tool, or before performing

any maintenance on this tool.

WARNING: Correct bonded abrasive mounted point grinding

wheels, rotary files and carbide burrs are necessary to prevent

injury from broken accessories. Do not use chipped or cracked

bonded abrasive mounted point grinding wheels, rotary files

and carbide burrs. Tighten the bonded abrasive mounted point

grinding wheels, rotary files and carbide burrs on the collet to

prevent spin off when the Die Grinder is turned off.

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.

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 Authorized Warranty Center, freight prepaid. Please include a copy of your proof of purchase and a brief description

of the problem. The tool will be inspected and if any part or parts are found to be defective in material or workmanship, they will be repaired free of charge, and the repaired tool will

be returned to you freight prepaid.

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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