Cornwell Tools CAT800FR User manual

CAT800FR Rev. 10/18/18
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.
Wheel Size .........................................3"
Horsepower ...................................... 0.75
Free Speed .................................16,000 RPM
Overall Length .....................................10"
Weight ....................................... 2.4 Lbs.
Maximum Air Pressure ................... 90 psig, 6.2 bar
Air Inlet Size ................................. 1/4" NPT
Recommended Hose Size ........................3/8" I.D.
Average Air Consumption ........................3.6 CFM
SPECIFICATIONS
RPM OF THE ACCESSORY
MUST EXCEED TOOL RPM
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
• MAXIMUM RPM OF 16,000
• MAX. AIR PRESSURE:
90 PSIG, 6.2 BAR
WARNING
RPMRPMRPM
Copyright © Professional Tool Products, 2018
All rights reserved
OPERATING MANUAL •WARNING INFORMATION •PARTS LIST
CAT800FR
3" Flex Head Cut-Off Tool

CAT800FR 2 Rev. 10/18/18
CAT800FR
3" Flex Head Cut-Off Tool
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 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.
• 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. High
sound levels can cause permanent hearing loss. Use hearing
protection as recommended by your employer or OSHA
regulation (users and bystanders).
• 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.
• 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.
• Use accessories recommended by Cornwell.
• Do not operate a damaged or worn tool. Do not use quick-
detach couplings at tool. See instructions for correct set-up.
• RPM OF THE ACCESSORY MUST EXCEED TOOL RPM. Use
accessories rated at 20,000 RPM or higher.
• 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.
• 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 cut-off wheel on the spindle to prevent spin off when the
tool is turned off.
• NEVER OPERATE THIS TOOL WITHOUT THE REQUIRED DISC
COVER/GUARD IN PLACE.
• 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 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.
• This tool is not insulated against electric shock.
• Keep tool out of reach of children.
• Do not point or indulge in any horseplay with this tool.
• Note direction of rotation BEFORE operating this tool.
• This tool must not be used in explosive atmospheres.
• 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.
• Servicing and repairs should only be made by an authorized
service center.
• Failure to heed these warnings may result in personal injury
and/or property damage.
WARNING: This product can expose you to chemicals
including nickel, which is known to the State of
California to cause cancer and birth defects or other
reproductive harm. For more information go to
www.P65Warnings.ca.gov.
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY
RPMRPMRPM

CAT800FR 3 Rev. 10/18/18
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 recommended
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 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.
Always turn off the air supply, drain hose of air pressure and detach
tool from air supply before installing, removing or adjusting any part
of accessory on this tool, or before performing any maintenance on
this tool.
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.
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.
OPERATION
OPERATION 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.
NOTE: Before using, test cut-off wheel by briefly running the
tool at full throttle under a barrier (such as under a heavy work
table) to stop any possible broken wheel parts.
Always use the required wheel guard to prevent injury from
broken cutting 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 sparks.
Always wear impact-resistant eye and face
protection to guard against flying rust and chips
(users and bystanders). 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.
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.
WARNING: 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.
WARNING: NEVER OPERATE THIS TOOL WITHOUT
REQUIRED DISC COVER/GUARD IN PLACE.
Ensure an accessible emergency shut off valve has been installed
in the air supply line and make others aware of its location.
To Assemble Cutting Wheel:
1. Use #46 spanner to hold spindle
2. Use #48 hex wrench to remove #41 screw (left hand threads)
3. Use #47 spanner to remove #40 nut (do not remove
#39 wheel washer)
4. Place cutting wheel onto spindle and re-assemble

CAT800FR 4 Rev. 10/18/18
WARRANTY COVERAGE
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.

CAT800FR 5 Rev. 10/18/18
CAT800FR
3" Flex Head Cut-Off Tool
Item Part No Parts Name Qty
1 RS850XLR77 SCREW (M4*8) 1
2 RS251001 REVERSE/FORWARD KNOB 1
3 RS850XLR78 SNAP RING (RTW-18) 1
4 RS850XLR79 REGULATOR SET 1
5 RS850XLR60 O-RING (S16) 1
6 RS850XLR07 AIR INLET 1
7 RS251002 EXHAUST SLEEVE SET 1
8 RS251003 MUFFLER 1
9 RS820R14 VALVE SET 1
10 RS251030 PROTECTING RUBBER 1
11 RS621011 PIN (3*24L) 1
12 RS251005 LEVER 1
13 RS251006 VALVE STEM SET 1
14 RS251007 VALVE HOLDER SET 1
15 RS820R161A PIN (2.8*25.8L) 1
16 RS621017 HOUSING 1
17 RS21114 BEARING (626ZZ) 1
18 RS820R19 WASHER (17*33.2*0.8T) 1
19 RS251008 REAR PLATE 1
20 RS850XLR22 ROTOR BLADE 1
21 RS251009 ROTOR 1
22 RS251010 CYLINDER SET 1
23 RS820R25 BEARING SPACER 1
24 RS251011 FRONT PLATE 1
25 RS10920 BEARING (6000ZZ) 1
Item Part No Parts Name Qty
26 RS251012 COUPLING NUT 1
27 RS251013 WASHER 1
28 RS251014 HOUSING NUT 1
29 RS251015 STEEL BALL (1/4") 1
30 RS251016 SCREW 1
31 RS251017 SOCKET JOINT 1
32 RS251018 CLAMP NUT 1
33 RS251019 POWER SHAFT 1
34 RS251020 DRIVE SHAFT SET 1
35 RS251021 FLEX SHAFT SET 1
36 RS251022 STEEL RING 1
37 RS251023 LOCK RING SET 1
38 RS251024 RETAINER RING 1
39 RS251025 WHEEL WASHER 1
40 RS251026 NUT 1
41 RS850XLR56 SCREW (M5 x 12L) 1
42 RS251027 GUARD 1
43 RS850XLR45 NUT 1
44 RS60139 SCREW (M4 x 20L) 1
45 RS251028 SCREW 1
46 RS251029 STOP SPANNER 1
47 RS103841 STOP SPANNER (17mm) 1
48 RS31539 HEX (4M/M) 1
not shown RSCAT800FRPWL Product Warning Label 1
PARTS LIST