Cornwell Tools blue POWER CAT851XLR User manual

CAT851XLR rev 04/25/18
CAT851XLR
Blue Power® 1.0 HP
Extended Cut-Off Tool
Operating Instructions • Warning Information
• Parts Breakdown
Copyright © Professional Tool Products, 2018
All rights reserved
ALWAYS READ
INSTRUCTIONS BEFORE
USING POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
ALWAYS WEAR HEARING
PROTECTION
ALWAYS WEAR FACE
PROTECTION
ALWAYS WEAR HAND
PROTECTION
AVOID PROLONGED
EXPOSURE TO VIBRATION
RATED RPM OF THE
ACCESSORY MUST
EXCEED THE MAXIMUM
TOOL RPM SHOWN
• MAXIMUM RPM OF 14,000
• MAX. AIR PRESSURE:
90 PSIG, 6.2 BAR
WARNING
RPMRPMRPM
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:
• 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.
Free Speed .................................14,000 RPM
Horsepower ....................................... 1.0
Wheel Size .........................................4"
Air Inlet Size ................................. 1/4" NPT
Recommended Hose Size ........................3/8" I.D.
Maximum Air Pressure ................... 90 psig, 6.2 bar
Average Air Consumption ........................4.1 CFM
Overall Length ................................... 13.6"
Vibration Level.............................. 1.3 m/sec²
Sound Pressure Level ........................... 87 dBA
Weight ....................................... 3.2 Lbs.
SPECIFICATIONS

CAT851XLR rev 04/25/18
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.
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.
• 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
(users and bystanders).
• Always wear hearing protection when using this tool
(users and bystanders). High sound levels can cause
permanent hearing loss. Use hearing protection as
recommended by your employer or OSHA regulation.
• Operators and maintenance personnel must be physically
able to handle the bulk, weight and power of this tool.
• Operation can cause impacts, cuts,abrasions and heat.
Wear gloves to protect hands.
• Keep the tool in efficient operating condition.
• 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
on page 4.
• Air powered tools can vibrate during 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.
• 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.
• Note direction of rotation BEFORE operating this tool.
• RPM of the accessory must exceed tool RPM.
• Use accessories rated at 14,000 RPM or more.
• Use accessories recommended by Cornwell Tools.
• 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.
• Never operate this tool without required Disc
Cover/Guard in place.
• Correct cut-off wheel mounting is necessary to prevent
injury from broken wheels. Do not use chipped or cracked
cut-off wheels. Cut-off wheels should be a free fit on the
spindle to prevent stress at the hole. Use only wheel collars
that come with the tool for mounting the cut-off wheel. Flat
washers or other adapters may over stress the wheel.
Tighten the wheel on the spindle to prevent spin off when
the tool is turned off.
• When using the cut-off tool, be careful not to exert
excessive force. Too much force could be hazardous
if it causes the tool spindle to bend or break.The burning
of the work piece or excessive speed reduction indicates
too much force being applied. Start the tool off the work,
set it down on the work evenly and move in the direction
desired to make the cut.When finished cutting, lift off the
work before stopping the motor.
• 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.
• Do not lubricate tools with flammable or volatile
liquids such as kerosene, diesel 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 beyond its rated capacity.
• Keep tool out of reach of children.
• Do not remove any labels. Replace any damaged labels.
• Failure to heed these warnings may result in serious or
fatal personal injury and/or property damage.
RPMRPMRPM

CAT851XLR rev 04/25/18
PARTS BREAKDOWN - CAT851XLR
Only parts identified by part number above are available for purchase.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
17
15
18
19
20
21
23 22
25
26
27
29
30
31
32
9-1
9-2
36
38
39
40
41
44
16
37
62
49
50
52
53 54
55
48 51
56
57
58
59
45
47
46
61
60
63
28
33
34
34
35
42
64
65
49
67
66
68
43A
REF. # ITEM # DESCRIPTION QTY
1 RS15401 Regulator 1
2 RS288302 O-Ring (P10) 1
3 RS288303 O-Ring (P9) 1
4 RS288304 Snap Ring (ISTW12) 1
5 RS246002 O-Ring (3.5x1.4) 1
6 RS488306 Valve Stem 1
7 RS15407 Air Inlet 1
8 RS15408 Muffler 1
9 RS288309 Silencer 1
9-1 RS15459 Stainless Mesh 1
9-2 RS2883091 Silencer 1
10 RS31511 O-Ring (26.7 x 1.78) 1
11 RS288314 Spring 1
12 RS288315 Valve 1
13 RS288316 Washer (6x13.8x1.6T) 1
14 RS29014CW Housing Grip 1
15 RS15416 Housing 1
16 RSCAT851XLR16 Safety Throttle Lever 1
17 RS621011 Spring Pin (3x24L) 1
18 RS21114 Bearing (626ZZ) 1
19 RS15419B Rear Plate 1
20 RS850XLR22 Rotor Blade 4
21 RS25523 Rotor 1
22 RS15424A Cylinder 1
23 RS520118 Pin (2x6L) 2
25 RS29527A Front Plate 1
26 RS10920 Bearing (6000ZZ) 1
27 RS2880L28 Coupling Nut 1
28 RS25429 Coupling 1
29 RS30RXL30 Bearing (699ZZ) 1
30 RS850XLR32 Nut 1
31 RS850XLR33 Clamp Nut 1
32 RS850XLR34 Spindle Housing 1
33 RS850XLR35 Spindle 1
34 RS288734 Bearing (609ZZ) 2
35 RS2943935 Pinion Gear (13T) 1
REF. # ITEM # DESCRIPTION QTY
36 RS2943936 Angle Housing 1
37 RS288331 Grease Fitting (3/16") 1
38 RS25480 Snap Ring 1
39 RS2943939 Nut 1
40 RS2943940 Spring 1
41 RS2943941 Pin 1
42 RS30516 Bearing (696ZZ) 1
43A RS85565 Nut 1
44 RS2943944 Pinion Gear (19T) 1
45 RS2943945 Face Plate 1
46 RS144W10 Bearing (6902ZZ) 1
47 RS850XLR49 Screw (M4x10) 4
48 RS294394 Guard Link 1
49 RS187551 Bushing 2
50 RS2943950 Latch 1
51 RS700MB67 Screw (M4x27L) 1
52 RS700MB65 Nut 3
53 RS187539 Steel Ball 1
54 RS187540 Spring 1
55 RS187541 Screw (M4x5L) 1
56 RS2943956 Disc Cover 1
57 RS700MB37 Screw (M4x6L) 3
58 RS2943958 Washer (for arbor hole 3/8") 1
RS29439581 Washer (for arbor hole 5/8") 1
59 RS2943959 Disc Nut 1
60 RS288337 Key 1
61 RS2943961A Shaft w/Nut 1
62 RS61040 Disc Spanner 1
63 RS25453 4"Cutting Wheel 1
64 RS15465 Handle Link 1
65 RS15466 Trigger 1
66 RS700MB72 Washer 1
67 RS15468 Screw (M4x22L) 1
68 RS60138 Side Handle w/Grip 1
RSCAT851XLRPLK Product Label Kit (not shown) 1

CAT851XLR rev 04/25/18
Drain Daily
RegulatorOilerQuick CouplerLeader
Hose
Nipple
Do Not Install
Quick Coupling
Here
Nipple
Filter
Air Supply
Whip Hose
AIR SUPPLY
Tools operate on a wide range of air pressures. It is required 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
connection 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
Let the tool do the work. Do not put extreme pressure on the tool.
This will only slow down the speed of the cutting wheel, reduce cut-
ting efficiency, and put an additional burden on the motor. Start the
tool off the work, set it down on the work evenly and move in the
direction desired to make the cut.
When finished cutting, lift off the work before stopping the motor.
Always use the required wheel guard to prevent injury from broken
cut-off wheel parts. If a guard has withstood a wheel breakage,
discontinue its use and replace it with a new guard. It may be
damaged. Position the guard between the cut-off wheel and the
operator. Use barriers to protect others from wheel fragments and
cutting sparks.
Always wear impact-safety eye and face protection to guard
against flying debris (users and bystanders). Use only wheels
rated at 14,000 RPM or higher. Even small projectiles can injure
eyes and cause blindness. A cut-off wheel that breaks can cause
very serious injury. Daily measure the tool speed with a tachometer
to make sure the speed is not greater than the RPM marked on the
cut-off wheel. Never use a cut-off wheel marked with a speed
lower than the tool speed.
NOTE: Before using, test cut-off wheel by briefly running the tool at
full throttle, under a barrier (such as a heavy work table) to stop any
possible broken wheel parts.
NOTE: Always 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.
Correct cut-off wheel mounting is necessary to prevent injury from
broken wheels. Do not use chipped or cracked cut-off wheels. Cut-off
wheels should be a free fit on the spindle to prevent stress at the hole.
Use only wheel collars that come with the tool for mounting the cut-
off wheel. Flat washers or other adapters may over stress the wheel.
Tighten the wheel on the spindle to prevent spin off when the tool is
turned off.
When using the cut-off tool, be careful not to exert excessive force.
Too much force could be hazardous if it causes the tool spindle to bend
or break. The burning of the work piece or excessive speed reduction
indicates too much force being applied. Start the tool off the work, set
it down on the work evenly and move in the direction desired to make
the cut. When finished cutting, lift off the work before stopping the
motor.
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 Authorized Warranty Center, freight prepaid. Please include a copy of your proof of purchase and a brief description
of the problem. The tool will be inspected and if any part or parts are found to be defective in material or workmanship, they will be repaired free of charge, and the repaired tool will
be returned to you freight prepaid.
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.