Cornwell Tools CAT-400AS Product manual

CAT-400AS 1 Rev. 12/06/05
• Operating Instructions
• Warning Information
• Parts Breakdown
CAT-400AS
Air Body Saw
Strokes per Minute
. . . . . . . . . . . . . . . . .
9,000
Air Inlet
. . . . . . . . . . . . . . . . . . . . . . . .
1/4 NPT
Hose Size
. . . . . . . . . . . . . . . . . . . . . . . .
3/8 I.D.
Air Pressure
. . . . . . . . . . . . . . . . . . . . . . .
90 PSI
Air Consumption
. . . . . . . . . . . . . . . . . .
7 CFM
Sound Level
. . . . . . . . . . . . . . . . . . . . . .
95 dBA
Length
. . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1/4"
Shipping Weight
. . . . . . . . . . . . . . . .
1-1/2 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.
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
Copyright
©
Professional
T
ool
Tool T
Products,
2005.
All
rights
rese
rv
ed
.

CAT-400AS 2 Rev. 12/06/05
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.
• 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 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.
• 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.
Do not point or indulge in any horseplay with this
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.
• 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 any
damaged labels.
• Use accessories recommended by
Cornwell Tools.

CAT-400AS 3 Rev. 12/06/05
Nipple
AIR SUPPLY
Tools of this class operate on a wide range of air pres sures.
It is recommended that air pres sure of these tools mea-
sures 90 PSI at the tool while running free. Higher pres sure
(over 90 psig; 6.2 bar) raises per for mance beyond the rated
capacity of the tool which will short en the tool’s 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 used for con nect ing air supply, has stan dard
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 di men sions and be tightly secured.
LUBRICATION
Lubricate the air motor daily with quality air tool oil. If no
air line oiler is used, run a teaspoon of oil through the tool.
The oil can be squirted into the tool air inlet or into the
hose at the nearest con nec tion to the air supply, then run
the tool.
OPERATION
The speed of this saw can be regulated. It has a
slotted screw which rotates 360 degrees. However,
only a quarter turn segment (90 degrees) within
the full turn regulates the speed of the saw. When
the screw is rotated a full quarter turn in either
direction, the tool speed will go from maximum to
minimum or vice versa. Rotate the screw within the
quarter turn until the desired speed is obtained.
To Change Blades:
1. Remove screw (#29)
2. Pull down protective cover (#16)
3. Loosen set screws (#11)
4. Insert blade into saw holder (#10) and tighten.
5. Close protective cover and re-install screw.
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 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 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.
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.

CAT-400AS 4 Rev. 12/06/05
PARTS BREAKDOWN - CAT-400AS
Ref.# Item # DESCRIPTION QTY
1 RS85801A Piston Assembly 1
2 RS85802 Damping Ring 1
3 RS85803 Gasket Plate 1
6 RS85806 Rubber Washer 1
7 RS85807 Piston Valve 1
8 RS85808 Washer 1
9 RS85809 Screw 3
10 RS85810 Saw Holder 1
11 RS85811 Screw 2
12 RS85812 Spring 1
13 RS85813 Handle 1
14 RS85814 Screw 2
15 RS85815 Screw 2
16 RS85816 Protective Cover 1
17 RS85817 Spring Pin 2
18 RS85818 Bushing 1
19 RS85819 Cylinder 1
20 RS85820 Valve Box 1
21 RS85821 Bushing 1
22 RS85822 Valve Liner 1
23 RS85823 Guide Frame 1
24 RS85824 Spacer 1
25 RS85825 Bottom Board 1
26 RS85826 Guide Plate 1
27 RS85827 Guide Block 2
28 RS85828 Guide Plate 1
29 RS85829 Screw 1
30 RS85830 Gasket 1
Ref. #
Item # DESCRIPTION Qty.
31 RS85831 Air Valve Body 1
32 RS85832 Valve Plug 1
33 RS85833 O-Ring 1
34 RS85834 Adjusting Valve 1
35 RS85835 O-Ring 1
36 RS85836 Spring 1
37 RS85837 Valve Rod 1
38 RS85838 O-Ring 1
39 RS85839 Valve Rod Sleeve 1
40 RS85840 Screw 4
41 RS85841 Spring Washer 4
42 RS85842 Air Inlet 1
44 RS85844 Trigger Assembly 1
45 RS85845 Spring Pin 1
50 RS85850 Screw 1
Also available:
CAT-S18T 18 Tooth Saw Blade (5 Pack) 1
CAT-S24T 24 Tooth Saw Blade (5 Pack) 1
CAT-S32T 32 Tooth Saw Blade (5 Pack) 1
CAT-F-FILE Flat File (3 Pack) 1
CAT-R-FILE
Round
File (3 Pack)
1
CAT-
HR
-FILE
Half Round
File (3 Pack)
1
CAT-
T
-FILE
T-FILET
Triangle
File (3 Pack)
1
CAT-250AS 1/4" NPT Swivel 1
32 RS85832 Valve Plug 1
34 RS85834 Adjusting Valve 1
35 RS85835 O-Ring 1
36 RS85836 Spring 1
37 RS85837 Valve Rod 1
38 RS85838 O-Ring 1
39 RS85839 Valve Rod Sleeve 1
40 RS85840 Screw 4
41 RS85841 Spring Washer 4
42 RS85842 Air Inlet 1
44 RS85844 Trigger Assembly 1
45 RS85845 Spring Pin 1