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
Copyright © Professional Tool Products, 2014
All rights reserved
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.