Cornwell tools Cat511 User manual

CAT511 Rev. 8/20/14

CAT511

1/4" Mini

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:

 

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

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 ............................... 25,000 RPM

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

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

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

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

Average Air Consumption ........................3 CFM

Length .......................................

Weight .....................................0.81 Lbs

Sound Level ..................................93 dBA

SPECIFICATIONS

ALWAYS READ

INSTRUCTIONS BEFORE

USING POWER TOOLS

ALWAYS WEAR

SAFETY GOGGLES

ALWAYS WEAR HEARING

PROTECTION

AVOID PROLONGED

EXPOSURE TO VIBRATION

RATED RPM OF THE

ACCESSORY MUST

EXCEED THE MAXIMUM

TOOL RPM SHOWN





90 PSIG, 6.2 BAR

WARNING

RPMRPMRPM

CAT511 2 Rev. 8/20/14

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andface

 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.

• 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.

• 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.

• 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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.

• RPM of the accessory must exceed tool RPM.

• Use accessories rated at 25,000 RPM or more.

• Use accessories recommended by Cornwell Tools.

• 

cutter or drill bit on a Die Grinder.

 

to convert the die grinder for any other application.

 

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

to the "off" position when released.

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

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

• 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.

• Handlingthebrasspartsofthisproductwillexposeyou

 tolead,achemicalknowntotheStateofCaliforniato

 causebirthdefectsandotherreproductiveharm.Wash

hands thoroughly after handling.

RPMRPMRPM

CAT511 3 Rev. 8/20/14

PARTS BREAKDOWN - CAT511

Ref. # Item # DESCRIPTION QTY

 1 RS3430131 HousingAssembly(incl.#1.1-11) 1

 1.1  Housing 1

 1.2  ValveBushing 1

 2  TriggerAssembly(incl.#2,28,29,30,31) 1

 3  ThrottlePin 1

 4  O-Ring 1

 5  O-Ring 1

 6  ValveStem 1

 7  Spring 1

 8  AirRegulator 1

 9  O-Ring 1

 10  O-Ring 1

 11  ValvePlug 1

 12 RS14320112 CylinderAssembly(incl.#12.1-12.10) 1

 12.1  Bearing(625ZZ) 1

 12.2  RearEndPlate 1

Ref. # Item # DESCRIPTION QTY

 12.3  SetPin 1

 12.4  Rotor 1

 12.5  RotorBlade 4

 12.6  Cylinder 1

 12.7  RotorSpacer 1

 12.8  FrontPlate 1

 12.9  Bearing(608ZZ) 1

 12.10  ColletHolder 1

 13 RS231B28 Retainer 1

 14 RS231B29 HousingCap 1

 15 RS26437 Collet 1

 16 RS26438 ColletNut 1

 17 RS26441 AirInlet 1

 18 RS26439 Wrench 1

 19 RS26440 Wrench 1

NotShown RSCAT511LK ProductLabelKit 1

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

CAT511 4 Rev. 8/20/14

Drain Daily

RegulatorOilerQuick CouplerLeader

Hose

Nipple

Do Not Install

Quick Coupling

Here

Nipple

Filter

Air Supply

Whip Hose

AIR SUPPLY

Tools of this class 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the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con-

nection 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mounted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grindingwheel,rotaryfileorcarbideburr.

NOTE: During operation, safety goggles must always be worn

to guard against flying rust and chips (users and bystanders).

NOTE:Always 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.

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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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