Cornwell Tools CAT-510 User manual

CAT-510 1 Rev. 07/07/05
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.
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
• MAXIMUM RPM OF 25,000
• MAX AIR PRESSURE: 90 PSIG,
6.2 BAR
• RPM OF THE ACCESSORY
MUST EXCEED TOOL RPM
Operating Instructions • Warning Information • Parts Breakdown
CAT-510
Mid Size
Rear Exhaust
Die Grinder
Free Speed . . . . . . . . . . . . . . . . . . . 25,000 rpm
Maximum Capacity . . . . . . . . . . . . . . . . . . 1/4"
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . 1/4" NPT
Hose Size . . . . . . . . . . . . . . . . . . . . . 3/8" O.D.
Air Pressure . . . . . . . . . . . . . . . . . . . . . . 90 psi
Air Consumption . . . . . . . . . . . . . . . . . . 4 cfm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7"
Shipping Weight . . . . . . . . . . . . . . . . . 1.5 lbs.
SPECIFICATIONS
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CAT-510 2 Rev. 07/07/05
THIS INSTRUCTION MANUAL CONTAINS
IMPORTANT SAFETY INFORMATION.
READ THIS INSTRUCTION MANUAL CAREFULLY
AND UNDERSTAND ALL INFORMATION BEFORE
OPERATING THIS TOOL.
• 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 and face
protection when operating or performing
maintenance on this tool.
• Always wear hearing protection when
using this tool. High sound levels can
cause permanent hearing loss. Use hearing
protection as recommended by your
employer or OSHA regulation.
• 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 powered tools can vibrate in
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.
• 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.
• Place the tool on the work before starting
the tool.
• 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.
• Correct grinding wheel mounting is
necessary to prevent injury from broken
wheels. Do not use chipped or cracked
grinding wheels. Grinding wheels should be
a free fit on the spindle to prevent stress at
the hole. Use only wheel collars that come
with the grinder for mounting the grinding
wheel.Flat washers or other adapters may
over stress the wheel. Always use heavy
paper blotter discs between the wheel
collars and the grinding wheel. Tighten the
wheel on the spindle to prevent spin off
when the air grinder is turned off.
• Do not lubricate tools with flammable or
volatile liquids such as kerosene, diesel or
jet fuel.
• Do not force tool beyond its rated
capacity.
• Do not remove any labels. Replace damaged
labels.
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!
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CAT-510 3 Rev. 07/07/05
WARRANTY
Cornwell warrants its air tools for a period of 1 year to the consumer. We will repair any air tool covered under this
warranty which proves to be defective in material or workmanship during the warranty period. 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.
This warranty gives you specific rights. You may also have other rights which vary from state to state.
The foregoing obligation is Cornwell’s sole liability under this or any implied warranty and under no circumstances shall
Cornwell be liable for any incidental or consequential damages.
Note: Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
AIR SUPPLY
Tools of this class operate on a wide range of air
pressures. It is recommended that air pressure of these
tools measures 90 PSI at the tool while running free.
Higher pressure (over 90 psig; 6.2 bar) raises performance
beyond the rated capacity of the tool which will shorten
tool life because of faster wear 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 the air tank daily. Clean the air inlet filter screen
on at least a weekly schedule. The recommended
hookup procedure can be viewed in the above figure.
The air inlet (Figure 2) 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.
LUBRICATION & MAINTENANCE
Lubricate the tool daily with quality air tool oil. If no air
line oiler is used, run a teaspoon 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. The amount of oil to be used is 1 ounce.
Overfilling will cause a reduction in the power of the
tool. A rust inhibitive oil is acceptable for air tools.
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. If outside
conditions are in order, and the tool still performs
erratically, disconnect tool from hose and take tool to
your nearest Matco authorized service center.
OPERATION
When using the grinder be careful not to exert
excessive force. Too much force could be hazardous if
it causes the cutting tool spindle to bend or break.
The burning of the work piece or excessive speed
reduction indicates too much force being applied.
Changing to a free cutting tool may be better for the
desired rate of speed and stock removal.
Avoid hazardous conditions by making sure there is
sufficient force on the spindle of the cutting tool by
placing the spindle 7/16" or more inside the collet.
Figure 2
Figure 1
Air Inlet Regulator
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CAT-510 4 Rev. 07/07/05
PARTS BREAKDOWN - CAT-510
PARTS LIST
Part # Description
RS510DG01A Motor Housing Assembly (includes Ref. #1-20, 37)
RS510DG02A Air Motor Assembly (includes Ref. #21-31)
RS820DG19 Air Inlet (includes Ref. #12-15)
RS511ADG31 Retainer (Ref. #32)
RS26437 Collet (Ref. #33)
RS26438 Collet Nut (Ref. #34)
RS26439 Wrench (Ref. #35)
RS26440 Wrench (Ref. #36)
RS510DG37 Grip (Ref. #37)
Only parts identified by Part No. above are available for purchase.
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