Cornwell Tools CAT650AS User manual

CAT650AS 1 rev 10/10/17
CAT650AS
bluePOWER®
Geared Air Saw
Operating Instructions • Warning Information
• Parts Breakdown
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.
Strokes per Minute ............................7,000 SPM
Ave. Air Consumption ............................4.0 CFM
Max. Rec. Air Pressure ........................... 90 psig
Air Inlet...................................... 1/4" NPT
Net Weight .....................................2.2 Lbs
Length ......................................... 10.5"
Sound Pressure Level ........................... 88.5 dBA
Cutting Capacity ................ 6 gauge (5.0mm) steel sheet
Stroke Length....................................10mm
Includes: .............18TPI, 24TPI and 32TPI Bi-Metal Blades
Vibration Level .................................18.3m/s²
Recommended Hose Size ............................ 3/8"
SPECIFICATIONS
WARNING
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
ALWAYS WEAR
HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
ALWAYS WEAR
BREATHING
APPARATUS
(USERS &
BYSTANDERS)
• MAXIMUM SPM OF 7000
• MAX AIR PRESSURE:
90 PSIG, 6.2 BAR
WARNING

CAT650AS 2 rev 10/10/17
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 the device. It
is also the responsibility of the device 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 Tools for replacements. If the operator is
not fluent in English, the product and safety instructions shall
be read 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.
• Cutting with these tools will create sharp edges. Wear
gloves to protect hands.
• Cutting edges and shear blades can become hot during
use. Do not touch.
• Never force the cutting tool to cut faster or through
heavier gauge material than rated capacity.
• Add for any tools with safety lever: 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.
• Always operate, inspect and maintain this tool in
accordance with American National Standards Institute
Safety Code for 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 5/16" diameter air supply hose.
• Always wear impact resistant eye & face protection (Users
& Bystanders) when operating or performing maintenance
on this tool .
• Always wear hearing protection when using this tool (Users
& Bystanders). 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 bulk, weight and power of this tool.
• Keep tool out of reach of children.
• Air powered tools can vibrate during use. Extended
exposure to vibration, repetitive motions or uncomfortable
positions during use 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.
• Compressed air 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 part or 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
and replace immediately any damaged, frayed or loose
hoses and fittings.
• Do not operate a damaged or worn tool. Do no use quick-
detach couplings at tool. See instructions for correct set-up.
• 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 walking or work surface.
• Keep body working stance balanced and firm. Do not
overreach when operating this tool.
• Anticipate and be alert for sudden changes in motion
during use of any power tool.
• Do not carry tool by hose. Protect the hose from sharp
objects and heat.
• Tool shaft may continue to reciprocate 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 reciprocating 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.
• This tool is not insulated against electric shock.
• This tool must not be used in explosive atmospheres.
• 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 replacement parts and accessories recommended by
Cornwell Tools.
• Servicing and repairs should only be made by an
authorized service center.
• 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.
• 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.
• This product may contain one or more chemicals known
to the State of California to cause cancer and birth defects
or other reproductive harm. Wash hands thoroughly after
handling.
• Failure to heed these warnings may result in serious or
fatal personal injury and/or property damage.
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY
WARNING

CAT650AS 3 rev 10/10/17
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 not exceed 90 psig
with trigger fully depressed and no load applied to the tool. Higher
pressure and unclean air will shorten tool life and may create a
hazardous condition.
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 hook-up procedure can be viewed
in Figure 1.
The air inlet (Figure 2), 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.
Ensure an accessible emergency shut off valve has been installed
in the air supply line and make others aware of its location.
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 service center.
LUBRICATION & MAINTENANCE
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.
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.
FIG. 1 FIG. 2
AIR INLET
WARNING
OPERATION
To properly maintain tool, grease can be applied as needed. To grease tool remove
tap screw (#48) with hex wrench supplied. Force grease into location using
CATMGG2 or similar grease kit. Recommended grease is high quality synthetic
(NLGI grade 2 with ISO VG 220 base) which has a lithium complex thickener.
Always turn off the air supply, drain hose of air pressure and detach tool from air
supply before installing, removing or adjusting any part or accessory on this tool,
or before performing any maintenance on this tool.
NOTE: During operation, safety goggles should always be worn to guard against
flying rust and chips (users & bystanders).
TO CHANGE BLADES
1. Detach tool from air supply.
2. Use (#46) hex wrench provided to loosen (#43) set screws.
3. Insert blade into blade guide (#44) and retighten (#43) set screws.
TO ADJUST BLADE GUARD
1. Detach tool from air supply.
2. Use (#47) 2mm hex wrench provided to loosen (#37) set screw.
3. Adjust (#40) saw blade guard to desired position and retighten (#38)
set screw.
WARRANTY
Cornwell warrants its air tools for a period of 2 year to the consumer. We will repair any air tool covered under this warranty which proves to be
defective in material or workmanship during the warranty period. 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.
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 circumstances shall Cornwell be liable for any
incidental or consequential damages.
Note: Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not
apply to you.

CAT650AS 4 rev 10/10/17
PARTS
BREAKDOWN
CAT650AS
1
2
3
4
22
13
14
7
10
21
20
17
18
19
15
16
16
6
29
30
29
31
32
33
34
36
37
28
11
9
5
8
23
12
35
24
25
26
27
38
39
40
41
43
42
44
45
43
48
38
46
47
Ref. # Item # DESCRIPTION QTY
1 RS048101P Housing 1
2 RS93126 Throttle Valve Bushing 1
3 RS93127 Throttle Seat 1
4 RS93128 Throttle Valve 1
5 RS93129 Throttle Spring 1
6 RS048106 Throttle Pin 1
7 RS305A04 O-Ring (3.5 x 1.5mm) 1
8 RS048113 O-Ring 2
9 RS65009 Comfort Grip 1
10 RS305A10 O-Ring(12 x 2mm) 1
11 RS048112 Air lnlet 1
12 RS65012 Safety Throttle Lever 1
13 RS706132 Pin 1
14 RS21114 Ball Bearing (626ZZ) 1
15 RS705918 Rear End Plate (Incl. Steel Ball #16) 1
16 RS26216 Steel Ball (3/32") 2
17 RS32322 Cylinder 1
18 RS32319 Rotor 1
19 RS32320 Rotor Blade 4
20 RS388421 Spacer 1
21 RS04720 Front End Plate (Incl. Steel Ball #16) 1
22 RS10920 Ball Bearing (6000ZZ) 1
23 RS65023 Exhaust Ring 1
24 RS04827 Bevel Gear Shaft 1
25 RS04828 Clamp Nut 1
Ref. # Item # DESCRIPTION QTY
26 RS04829 Bushing 1
27 RS04830 Gear Housing 1
28 RS04831 Retainer Ring 1
29 RS108A12 Ball Bearing (607ZZ) 2
30 RS04833 Spacer Collar 1
31 RS04834 Bevel Gear 1
32 RS04835 Drive Ring 1
33 RS04836 Drive Wheel 1
34 RS04837 Hex. Screw 2
35 RS04855 Teflon Insert 1
36 RS04838 O-Ring 1
37 RS04839 Cover 1
38 RS24522 Set Screw (M4*3L) 2
39 RS04841 Set Screw (M4*8L) 1
40 RS04842A Saw Blade Guard 1
41 RS04843A Drive Shaft 1
42 RS04856 Chuck Sleeve 1
43 RS11042 Set Screw (M8*8L) 2
44 RS04848 Blade Guide 1
45 * Saw Blade (32T)
{see replacement blades below} 1
46 RS11047 Hexagon Wrench (4mm) 1
47 RS26126 Hexagon Wrench (2mm) 1
48 RS04850 Grease Cap Screw 1
not shown RSCAT650ASPLK Product Label Kit 1
Also Available:
· RS04830HK Head Assembly (Includes 27-44, 48)
* Replacement Blades:
· CATS18T – 18T Saw Blade (5 pack)
· CATS24T – 24T Saw Blade (5 pack)
· CATS32T – 32T Saw Blade (5 pack)
· CAT450FF – Flat File (3 pack)
· CAT450HRF – Half Round File (3 pack)
· CAT450RF – Round File (3 pack)
· CAT450TF – Triangle File (3 pack)
· CATS624T – 24 TPI Saw Blade – 6"(3 pack)
· CATS632T – 32 TPI Saw Blade – 6"(3 pack)