Cornwell Tools CAT555 Product manual

CAT555 1 Rev. 08/31/09
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23,000
• MAXAIRPRESSURE:90PSIG,
6.2BAR
• RATEDRPMOFTHE
ACCESSORYUSEDMUST
EXCEEDTHEMAXIMUMTOOL
RPMSHOWN
Operating Instructions • Warning Information • Parts Breakdown
CAT555
Gearless Die
Grinder
Free Speed ................... 23,000 rpm
Maximum Capacity ..................1/4"
Air Inlet ....................... 1/4" NPT
Hose Size ..........................3/8"
Air Pressure .......................90 psi
Air Consumption ...................3 cfm
Length ...........................6.75"
Weight ......................... 1.5 lbs.
Sound Level ......................80 dBA
SPECIFICATIONS
Copyright © Professional Tool Products, 2009
All rights reserved

CAT555 2 Rev. 08/31/09
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!

CAT555 3 Rev. 08/31/09
WARRANTY
CornwellwarrantstheCAT555foraperiodof1yeartotheconsumer.WewillreplacetheCAT555coveredunderthis
warrantyifitisdefectiveinmaterialorworkmanshipduringthewarrantyperiod.Inordertohaveyourtoolreplaced,
return the tool to your authorizedCornwelldealer. Please provide 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,theCAT555willbereplacedfreeofcharge.
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.
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tooldailywithqualityairtooloil.Ifnoair
line oiler is used, run a half ounce 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.Overfillingwillcauseareduc-
tion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authorizedCornwelldealer.
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 (A)

CAT555 4 Rev. 08/31/09
cAT555 PARTS bREAKDOWN
21
7
23
27
1
28
8
9
12
10
16
15
14
13
14
20
19
18
17
2
3
4
5
6
22
24 25
26
30
29
11
32
33
27
21
31
RS555DG02A
Air Inlet Assy.
RS555DG01A
Motor Housing Assy.
RS555DG03A
Air Motor Assy.
Item # Description
RS555DG01A Motor Housing Assy. (Incl. #1-6, 21-31)
RS555DG02A Air Inlet Assy. (Incl. #21-27)
RS555DG03A Air Motor Assy. (Incl #7-17, 27)
RS55518 Connect Nut (Ref. #18)
RS550DG41 Grip (Ref. #28)
RS26437 ¼" Collet (Ref. #19)
RS26438 Collet Nut (Ref. #20)
RS26439 Wrench (Ref. #32)
RS26440 Wrench (Ref. #33)
Only parts identified by part number above are available for purchase.