Cornwell Tools CAT412HDG User manual

CAT412HDG 1 04/24/09
CAT412HDG
4-1/2" Heavy Duty
Grinder
Free Speed ...................11,000 RPM
Spindle Size .....................3/8" - 24
Disc Size ..........................4-1/2"
Air Inlet ....................... 1/4" NPT
Hose Size ..........................3/8"
Air Pressure .......................90 psi
Air Consumption ...................4 cfm
Length ..............................9"
Sound Level ......................89 dBA
Weight ..........................4.1 lbs.
SPECIFICATIONS
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.
Copyright © Professional Tool Products, 2009
All rights reserved.
Operating Instructions • Warning Information • Parts Breakdown
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
• MAXIMUMRPMOF11,000
• MAXAIRPRESSURE:
90PSIG,6.2BAR
• RATEDRPMOFTHE
ACCESSORY USED
MUST EXCEED THE
MAXIMUMTOOL
RPMSHOWN
• USERECOMMENDEDGUARD

CAT412HDG 2 04/24/09
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!
This Instruction Manual Contains Important
Safety Information.
Read THIS INSTRUCTION MANUAL Carefully
and understand ALL INFORMATION Before
Operating THIS Tool.
• Always operate, inspect and maintain
 this tool in accordance with American
National Standards Institute Safety Code
of Portable Air Tools (ANSI B186.1) and
any other applicable safety codes and
regulations.
• Forsafety,topperformanceandmaximum
durability of parts, operate this tool at
 90psig/6.2barmaxairpressurewith3/8"
diameter air supply hose.
• Always wear impact-resistant eye and
 face protection when operating or
performing maintenance on this tool.
 Always wear hearing protection when
using this tool.
• Highsoundlevels cancausepermanent
hearing loss. Use hearing protection as
recommended by your employer or
OSHA regulation.
• Keepthetoolinefficientoperating
condition.
• Operators and maintenance personnel
must be physically able to handle the
 bulk,weightandpowerofthistool.
• Air under pressure can cause severe
injury. Never direct air at yourself or
 others. Always turn off the air supply,
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.
 Always check for damaged, frayed or
loose hoses and fittings, and
replace immediately. Do not use quick
detach couplings at tool. See instructions
for correct set-up.
•Air powered tools can vibrate in
use. Vibration, repetitive motions
or uncomfortable positions over
 extended periods 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.
• Place the tool on the work before
starting the tool. Do not point or indulge
 inanyhorseplaywiththistool.
• Slipping, tripping and/or falling while
operating air tools can be a major cause
 of serious injury or death. Be aware of
 excesshoseleftonthewalkingorwork
surface.
• 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
changes in motion during 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 objects and heat.
• Toolshaftmaycontinuetorotatebriefly
after throttle is released. Avoid direct
 contactwithaccessoriesduringandafter
 use. Gloves will reduce the risk of cuts
or burns.
• Keep away from rotating end of tool.
 Do not wear jewelry or loose clothing.
Secure long hair. Scalping can occur if
 hair is not kept away from tool and
accessories. Choking can occur if
 neckwear 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 lubricate tools with flammable
or volatile liquids such as kerosene,
diesel or jet fuel.
• Do not force tool beyond its rated
capacity.
• Do not remove any labels. Replace any
damaged labels.

CAT412HDG 3 04/24/09
AIR SUPPLY
Toolsofthisclassoperateonawiderangeofair
pressures. It is recommended that air pressure of these
toolsmeasures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shorten
toollifebecause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recommended
hookupprocedure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airmotordailywithqualityairtooloil.
If no air line oiler is used, run 1/2 ounce of air tool
oil through the tool by squirting oil into the tool air
inlet or into the nearest connection to the air inlet,
reconnecting air supply, and then running the tool.
Do not use more then 1/2 ounce of oil, as overfilling
willreducetheperformanceofthetool.
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Cornwellauthorizedservicecenter.
OPERATION
Alwaysusetherecommendedwheel
guard to prevent injury from broken
grindingwheel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grindingwheelandtheoperator.Use
barrierstoprotectothersfromwheelfragmentsand
grinding sparks.
Alwayswearimpact-resistanteyeandface
protectionwheninvolvedintheoperation
of this tool. Even small projectiles can
injure eyes and cause blindness. A grinding
wheelthatburstscancauseveryserious
injury. Daily measure the air grinder speed
withatachometertomakesureit'snotgreaterthan
theRPMmarkedonthegrindingwheel.Neverusea
grindingwheelmarkedwithaspeedlowerthanthe
air grinder speed.
Beforegrinding,testgrindingwheelbybrieflyrunning
the tool at full throttle. Be sure to use a barrier (such as
underaheavyworktable)tostopanypossiblebroken
wheelparts.
To Assemble Grinding Discs:
1. Use stop spanner (#53) to hold gear shaft (#33).
2. Screwonflange(#38)withshouldersidefacing
tool. Tighten.
3. Attachgrindingdiscwheel.
4. Screwonflangenut(#40),shouldersidefacingtool.
Secure tightly!
WARRANTY
Cornwellwarrantsitsairtoolsforaperiodof1yeartotheconsumer.Wewillrepairanyairtoolcoveredunderthis
warrantywhichprovestobedefectiveinmaterialorworkmanshipduringthewarrantyperiod.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 purchase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 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circumstancesshall
Cornwellbeliableforanyincidentalorconsequentialdamages.
Note: Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitationorexclusionmaynotapplytoyou.
Figure 2
Figure 1
Air Inlet

CAT412HDG 4 04/24/09
PARTS bREAKDOWN - cAT412HDG
Ref. # Item # DESCRIPTION QTY.
1 RS21101 Motor Housing 1
2 RS21158 Spring Pin 1
3 RS21157 Air Inlet 1
4 RS21160 Throttle Lever Assy. 1
5 RS41205 Valve Stem 1
6 RS41206 Bushing 1
7 RS41207 O-Ring 2
8 RS21154 Valve Spring 1
9 RS21156 Throttle Valve Housing 1
10 RS41210 Throttle Lever Plug 1
11 RS43006 O-Ring 1
12 RS21146 Plunger 1
13 RS30524 Ball Bearing 2
14 RS21126 Rear End Plate 1
15 RS21124 Rotor 1
16 RS21125 Rotor Blade 4
17 RS21122 Spring Pin 1
18 RS41218 Cylinder 1
19 RS21120 Front End Plate 1
20 RS21118 Ball Bearing 1
21 RS41221 Lock Nut 1
22 RS41222 Bevel Gear 1
23 RS21151 Coupling Nut 1
24 RS43007 Screw 2
25 RS41225 Deflector 1
26 RS41226 Spacer 1
27 RS21102 Screw 1
28 RS21114 Ball Bearing 1
29 RS21113 Retaining Ring 1
Ref. # Item # DESCRIPTION QTY.
30 RS21110 Bevel Gear 1
31 RS21143 Wave Washer 1
32 RS21109 Ball Bearing 1
33 RS21111 Spindle 1
34 RS21112 Key 1
35 RS21108 Gasket 1
36 RS21107 Retainer 1
37 RS41237 Disc Cover 1
38 RS41238 Flange 1
40 RS41240 Flange Nut 1
41 RS41241 Adjust Screw 1
42 RS41242 Adjust Nut 1
43 RS41243 Screw 4
44 RS187144 Spring Washer 4
45 RS21128 Spring 1
46 RS21144 Governor Assy. (Incl. #12,
41, 42, 45, 46, 47(6), 48(2) 1
47 RS21145 Pendulum 6
48 RS21147 Spring Pin 2
49 RS21139 O-Ring 1
50 Torsion Spring (Incl. w/ #4) 1
51 Throttle Lever Lock (Incl. w/ #4) 1
52 RS78741 Spring Pin 1
53 RS21141 Spanner 1
54 RS41254 Pin Wrench 1
55 RS41255 Handle 1
56 RS188036 O-Ring 1
57 RS41257 Grinding Wheel (4-1/2") 1