Cornwell Tools CAT650HD User manual

1CAT650HD 01/04/13
Operating Instructions • Warning Information • Parts Breakdown
Some dust created by power sanding, sawing, grinding, drilling, and other con-
struction 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.
Performance Rating: ................................ Heavy Duty
Max. Free Speed...................................... 1000 RPM
Orbital Stroke .................................................. 5 MM
Pad Size............................................................... 6"
Air Inlet ................................................... 1/4" NPTF
Min. Air Hose Size......................................... 3/8" ID
Recommended Air Pressure ........................... 90 PSI
Height ............................................................. 4.25"
Length ........................................................... 10.5"
Weight ....................................................... 3.5 LBS.
Air Consumption ............................................. 3 CFM
Sound Level ..................................................82 dBA
SPECIFICATIONS
CAT650HD
6" Gear Driven
Sander
Copyright © Professional Tool Products, 2013
All rights reserved.
RATED RPM OF THE ACCESSORY USED
MUST EXCEED THE MAXIMUM TOOL
RPM SHOWN
ALWAYS READ
INSTRUCTIONS BEFORE
USING POWER TOOLS
ALWAYS WEAR
DUST MASK
OR RESPIRATOR
WEAR HEARING
PROTECTION
AVOID PROLONGED
EXPOSURE TO VIBRATION
AVOID PROLONGED
EXPOSURE TO VIBRATION
WARNING
WARNING

2CAT650HD 01/04/13
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.
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efcientoperating
 condition.
•Operators and maintenance personnel must
bephysicallyabletohandlethebulk,weight
andpowerofthistool.
•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 ttings, and
replaceimmediately.Donotusequickdetach
couplingsat tool. Seeinstructions for correct
set-up.
•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.
•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se-
riousinjuryordeath.Beawareofexcesshose
leftonthewalkingorworksurface.
•Keepbodyworkingstancebalancedandrm.
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
briey 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ac-
cessories.
•Never mount a grinding wheel on a sander. A
grindingwheelthatburstscancauseveryseri-
ousinjuryordeathwhennotproperyguard-
ed. Inspect backing pad before each use. Do
notuseifcrackedordamaged.
•Avoiddirectcontactwithmovingsandingpad
topreventpinchingorcuttingofhandsoroth-
erbodyparts.
•Donotlubricatetoolswithammableorvola-
tileliquidssuchaskerosene,dieselorjetfuel.
• Donotforcetoolbeyonditsratedcapacity.
• Do not remove any labels. Replace any dam-
agedlabels.
•DO NOT USE SANDING DISC OR ACCESSORIES
ABOVE THEIR MAXIMUM RATED RPM.
WARNING

3CAT650HD 01/04/13
Operating Instructions • Warning Information • Parts Breakdown
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anduncleanair
willshortentoollifebecauseoffasterwearandmaycreatea
hazardouscondition.
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hook-upprocedurecanbeviewed
inFigure1.
The air inlet,  used for connecting air supply, has standard
1/4"NPTAmericanThread.
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.
LUBRICATION AND
MAINTENANCE
Lubricatethetooldailywithagoodgradeofairtooloil.Ifno
airlineoilerisused,run1/2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.Arust
inhibitiveoilisacceptableforairtools.
OPERATION
Selectasuitableabrasivediscandmakesurethatitisfixed
securelytothepad.Connectasuitableairsupplyas
recommended.Theairinletusedforconnectingairsupply
hasstandard1/4"NPTthread.
Apply the sander lightly to the work for proper sanding.
Take great care when sanding around sharp edges and
surfaces to avoid the disc snagging, i.e. the disc may be
broughttoanabruptstoporconsiderablyslowedwhichwill
causethetoolto kick in the operator's hands. It isalways
recommendedtouse safely glasses and a breathingmask.
The sanding of certain materials may create a hazardous
dustwhichmayrequirespecialbreathingequipment.Check
beforeusingthetool.Evenifthemachinehasalownoise
level, the actual sanding process may cause a noise level
suchthatearprotectorswillberequired.
Iftherearesharpareasonthematerialbeingsanded,safety
glovesarerecommended.Donotcontinuetouseabrasive
discsthatarewornorclogged.Thiswillmakethesanding
process inefficient and the need to apply unnecessarily
highforcetothetool.Donotuseundersizedoroversized
sandingdiscs.Thediscshouldbenomorethat1/4"largerin
diameterthanthepadandnotsmallerthanthepad.Anair
regulator(14)is locatedonthesideofthe motorhousing
(1).Itcanbeusedtovarythevolumeofcompressedairfed
tothemotorwhichwillvarythespeedofthesander.
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.
WARRANTY COVERAGE
CornwellQualityToolsCompany(“Cornwell”)warrantsthisproductagainstdefectsinmaterialandworkmanshipforaperiodofTWO(2)YEARS
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.
CornwellQualityToolsCompany•667SevilleRoad•Wadsworth,OH44281-1094

4CAT650HD 01/04/13
PARTS BREAKDOWN - CAT650HD
46
4-1
31-1
13
5
6
78910
11
12-1
14
13
16
18
20
21
22
23
25
24
27
28 48
49
17
15
19
51
26
52
2
59
60
45
43
41
40
39
38
37
21
21
36
32
35
34
33
30
29
62
61
63
54
58
57

5CAT650HD 01/04/13
PARTS BREAKDOWN - CAT650HD
*Also Available: CAT650HPAD Velcro Pad 6" (caT650Hd) 1
Ref. No. Part No. Description Qty.
01 RS650HD01 Housing 1
02 RS786002 Cone Muffler 1
03 RS786003 Muffler Body 1
04-1 RS246502 Screw 1
05 RS246002 O-Ring (3.5 x 1.4) 1
06 RS246506 Valve Stem 1
07 RS246507 Bushing 1
08 RS246006 Washer 1
09 RS246509 Valve 1
10 RS246510 Spring 1
11 RS786011 Packing 1
12-1 RS246512 Housing Back Seat 1
13 RS246513 O-Ring 2
14 RS246514 Regulator 1
15 RS246515 Snap Ring 1
16 RS246516 Lever 1
17 RS31512 Pin (3mm x 24L) 1
18 RS246009 Air Inlet 1
19 RS246519 Screw w/ Washer 2
20 RS246520 Snap Ring 1
21 RS10920 Bearing 3
22 RS246522 Rear Plate 1
23 RS246523 Rotor Blade (Pk of 8) 1
24 RS246524 Rotor 1
25 RS786025 Cylinder 1
26 RS246531 O-Ring 1
27 RS246529 Front Plate 1
28 RS221RA32 Bearing 1
29 RS246533 Rotor Key 1
Ref. No. Part No. Description Qty.
30 RS246534 Motor Shaft Balancer 1
31-1 RS246535 Housing Cover 1
32 RS246536 Screw 4
33 RS246537 Faceplate 1
34 RS246538 Dustproof Washer 1
35 RS246540 Gear 1
36 RS246541 Screw 4
37 RS246543 Gear Link 1
38 RS246544 Washer 1
39 RS246545 Dustproof Washer 1
40 RS246547 Gear Seat 1
41 RS246546 Screw 4
43 RS246548 Balancer 6" 1
45 RS246549 Screw 1
46 RS246550 Shroud 1
48 * Velcro Pad 6" 1
49 RS103953 Screw 6
51 RS246526 Pin (3x12L) 1
52 RS288548 Hex Wrench 1
54 RS246554 Exhaust Sleeve 1
57 RS246503 Silencer 2
58 RS246504 Stainless Mesh 2
59 RS246040 Pin (3x8) 1
60 RS246542 Washer 1
61 RS246532 Washer 1
62 RS246539 Washer 1
63 RS246528 O-Ring 1