Cornwell Tools CAT820 User manual

CAT820 Rev. 12/01/16
CAT820
Heavy Duty
Cut-Off Tool
Operating Instructions • Warning Information
• Parts Breakdown
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 .................................20,000 RPM
Air Inlet Size ................................. 1/4" NPT
Recommended Hose Size ........................3/8" I.D.
Maximum Air Pressure ................... 90 psig, 6.2 bar
Average Air Consumption .......................3.45 CFM
Overall Length .................................... 7.4"
Sound Pressure Level ........................... 90 dBA
Weight ...................................... 1.68 Lbs.
Wheel Size .........................................3"
SPECIFICATIONS
Copyright © Professional Tool Products, 2016
All rights reserved
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 20,000
• MAX. AIR PRESSURE:
90 PSIG, 6.2 BAR
WARNING
RPMRPMRPM

CAT820 2 Rev. 12/01/16
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 AirTools (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 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.
• Always wear face and hand protection when operating
this tool.
• 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 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 tool.
• Use accessories rated at 20,000 RPM or higher.
• Never operate this tool without required disc
cover/guard in place.
• 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 wheel on the spindle to prevent spin off when the
tool is turned off.
• 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.
• Use accessories recommended by Cornwell Tools.
• Keep tool out of reach of children.
• Do not remove any labels. Replace any damaged
labels.
• 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
injury and/or property damage.

CAT820 3 Rev. 12/01/16
REF. # ITEM # DESCRIPTION QTY
1 * HOUSING 1
2 * VALVE BUSHING 1
3 * SAFETY THROTTLE LEVER 1
4 * STOP ROD 1
5 * SPRING 1
6 * PIN 1
7 * PIN 1
8 * O-RING 1
9 * O-RING 1
10 * VALVE STEM 1
11 * SPRING 1
12 * O-RING 1
13 * VALVE PLUG 1
14 * MUFFLER COVER 1
15 * SNAP RING 1
16 * O-RING 1
17 * AIR REGULATOR 1
18 * O-RING (INCL W/#19) 1
19 * RS820DG19 AIR INLET ASSEMBLY (INC #18-21) 1
20 * TIP SLEEVE (INCL W/#19) 1
21 * SPRING (INCL W/#19) 1
REF. # ITEM # DESCRIPTION QTY
22 ** BEARING 1
23 ** END PLATE 1
24 ** PIN 2
25 ** ROTOR 1
26 ** ROTOR BLADE 4
27 ** CYLINDER 1
28 ** BUSHING 1
29 ** FRONT PLATE 1
30 ** PIN 1
31 ** BEARING 1
32 ** SPINDLE 1
33 RS820DG33 RETAINER 1
34 RS820DG34 GUARD 1
35 RS820DG35 COLLET NUT 1
36 87602 CUTTING WHEELS (5 PK.) 1
37 RS820DG37 WASHER 1
38 RS820DG38 SCREW 1
39 * RS820DG39 GRIP 1
40 RS820DG40 HEX WRENCH 1
41 RS820DG41 SPANNER WRENCH 1
Product Label Kit available as RSCAT820PLK.
* RS820DG01A HOUSING ASSEMBLY
(INCLUDES #1-21, 39)
** RS820DG02A AIR MOTOR ASSEMBLY
(INCLUDES #22-32)
PARTS BREAKDOWN - CAT820
RS820DG01A
HOUSING ASSEMBLY
RS820DG19
AIR INLET
ASSEMBLY
RS820DG02A
AIR MOTOR ASSEMBLY

CAT820 4 Rev. 12/01/16
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.
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 wear impact-resistant eye and face
protection to guard against flying debris
(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. 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.
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:
Disconnect tool from air supply
1. Use #41 Spanner Wrench to hold #32 Spindle.
2. Use #40 Hex Wrench to remove #38 Screw.
3. Use #41 Spanner Wrench to remove #35 Collet Nut
and #37 Washer.
4. Place Cutting Wheel onto #32 Spindle end and reverse
steps 1-3.

CAT820 5 Rev. 12/01/16
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.