Cornwell Tools CAT900HD Product manual

CAT900HD 7/30/14
CAT900HD
3" Reversing
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:
 
 
products, and
 
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
Horse Power......................................0.7
Cut Off Wheel.....................................3"
Air Inlet ....................................1/4" NPT
Minimum Hose Size........................... 3/8" I.D.
Maximum Air Pressure .................. 90 psig, 6.2 bar
Average Air Consumption ........................4 CFM
Length ..........................................9"
Shipping Weight ..............................1.9 Lbs
Sound Level ..................................90 dBA
Vibration Level............................... 1.6 m/s²
SPECIFICATIONS
Copyright © Professional Tool Products, 2014
All rights reserved
ALWAYS READ
INSTRUCTIONS BEFORE
USING POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID PROLONGED
EXPOSURE TO VIBRATION
RATED RPM OF THE
ACCESSORY MUST
EXCEED THE MAXIMUM
TOOL RPM SHOWN


90 PSIG, 6.2 BAR

WARNING
RPMRPMRPM

CAT900HD 2 7/30/14
FAILURE TO OBSERVE THESE WARNINGS COULD RE SULT IN IN JU RY.
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.
• Alwaysoperate,inspectandmaintainthistoolin
 accordancewithAmericanNationalStandards
 InstituteSafetyCodeofPortableAirTools(ANSIB186.1)
 andanyotherapplicablesafetycodesandregulations.
• Forsafety,topperformanceandmaximumdurability
 ofparts,operatethistoolat90psig:6.2barmaxair
 pressurewith3/8"diameterairsupplyhose.
• Alwayswearimpact-resistanteyeandface
 protectionwhenoperatingorperforming
 maintenanceonthistool(usersandbystanders).
• Alwayswearhearingprotectionwhenusingthistool
 (usersandbystanders).Highsoundlevelscancause
 permanenthearingloss.Usehearingprotectionas
 recommendedbyyouremployerorOSHAregulation.
• Keepthetoolinefficientoperatingcondition.
• Operatorsandmaintenancepersonnelmustbe
 physicallyabletohandlethebulk,weightandpower
 ofthistool.
• Airunderpressurecancausesevereinjury.Never
 directairatyourselforothers.Alwaysturnofftheair
 supply,drainhoseofairpressureanddetachtool
 fromairsupplybeforeinstalling,removingor
 adjustinganyaccessoryonthistool,orbefore
 performinganymaintenanceonthistool.Failureto
 dosocouldresultininjury.Whiphosescancause
 seriousinjury.Alwayscheckfordamaged,frayedor
 loosehosesandfittings,andreplaceimmediately.
 Donotusequickdetachcouplingsattool.See
 instructionsforcorrectset-uponpage4.
• Airpoweredtoolscanvibrateduringuse.Vibration,
 repetitivemotionsoruncomfortablepositionsover
 extendedperiodsoftimemaybeharmfultoyour
 handsandarms.Discontinueuseoftoolifdiscomfort,
 tinglingfeelingorpainoccurs.Seekmedicaladvice
 beforeresuminguse.
• Slipping,trippingand/orfallingwhileoperating
 airtoolscanbeamajorcauseofseriousinjury
 ordeath.Beawareofexcesshoseleftonthe
 walkingorworksurface.
• Keepbodyworkingstancebalancedandfirm.
 Donotoverreachwhenoperatingthetool.
• Anticipateandbealertforsuddenchangesin
 motionduringstartupandoperationofany
 powertool.
• Donotcarrytoolbythehose.Protectthehose
 fromsharpobjects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.
• 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lubricatetoolswithflammableorvolatile
 liquidssuchaskerosene,diesel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beyonditsratedcapacity.
• Use accessories rated at 20,000 RPM or more.
• Use accessories recommended by Cornwell Tools.
• Keeptooloutofreachofchildren.
• Donotremoveanylabels.Replaceanydamaged
 labels.
• 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.
• 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.
RPMRPMRPM

CAT900HD 3 7/30/14
PARTS BREAKDOWN - CAT900HD
Ref. # Item # DESCRIPTION QTY
 1  RS2871R01 MotorHousing 1
 2  RS2871R02 SpringPin(3x22) 1
 3  RS2871R03 AirInlet 1
 4  RS2871R04A ThrottleLeverAssembly 1
    (Includes#4,7,60,61)
 5  RS2871R05 ThrottlePin 1
 6  RS2871R06 ReverseValve 1
 7   SpringPin(2x16)(Includedwith#4) 1
 8  RS2871R08 Spring 1
 9  RS2871R09 RubberSeat 1
 10  RS2871R10 TipValve 1
 11  RS233A12 RotorBushing 1
 12  RS10920 BallBearing(6000ZZ) 1
 13  RS30516 BallBearing(696ZZ) 1
 14  RS2871R14 RearEndPlate 1
 15  RS2871R15 Rotor 1
 16  RS2871R16 RotorBlade (5packw/#46Spring) 1
 17  RS31717 SpringPin(2.5x6) 1
 18  RS2871R18 Cylinder(Includes#62) 1
 19  RS2871R19 FrontEndPlate 1
 21  RS2871R21 CuttingWheelCover 1
 22  RS2871R22 Spindle 1
Ref. # Item # DESCRIPTION QTY
23  RS2871R23 Retainer 1
24  RS78825 Pin(4x13.8) 1
 25  RS2871R25 WaveWasher 1
 26  RS2871R26 Washer 1
 27  RS187127 Washer 1
 28  RS2871R28 Screw 1
 29  RS178830 Screw(M5x35) 1
 30  RS187130 3"CuttingWheel 1
 45  RS2871R45 SpringPin(2x4) 1
 46   Spring(Includedwith#16) 5
 47  RS2871R47 O-Ring(15.8x2.4) 2
 48  RS2871R48 ReverseValveKnob 1
 49  RS2871R49 O-Ring(31x1.5) 1
 51  RS2871R51 RearCover 1
 52  RS900HD52 HousingCover 1
 53  RS233A28 DoubleEndedSpanner(14-19) 2
 54  RS187132 HexKeyWrench(4mm) 1
 60   SafetyBar(Includedwith#4) 1
 61   Spring(Includedwith#4) 1
 62   SteelBall(3/32")(Includedwith#18) 1
 64  RS2871R64 SnapRing 1
 65  RS2871R65 SetScrew(M2x5) 1

CAT900HD 4 7/30/14
Drain Daily
RegulatorOilerQuick CouplerLeader
Hose
Nipple
Do Not Install
Quick Coupling
Here
Nipple
Filter
Air Supply
Whip Hose
AIR SUPPLY
Tools of this class 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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con-
nection 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
 Always use the recommended wheel guard to
 prevent injury from brocken grinding 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grindingwheelandtheoperator.Usebarrierstoprotect
othersfromwheelfragmentsandgrindingsparks.
     
protection to guard against flying rust and
chips (users and bystanders). Even small
 projectilescaninjureeyesandcause blindness.A
 grindingwheelthatburstscancauseveryserious
injury.Dailymeasurethetoolspeedwithatachmetertomakesure
it'snotgreaterthantheRPMmarkedonthegrindingwheel.Never
use a grinding wheel marked with a speed lower than the tool
speed.
NOTE: Before grinding, test grinding wheel by briefly running the
toolatfullthrottle.Besuretouseabarrier(suchasunderaheavy
worktable)tostopanypossiblebrokenwheelparts.
NOTE:Always 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.
TO ASSEMBLE CUTTING WHEEL:
1.Usedoubleendedspanner(#53)toholdspindle(#22).
2.Usehexkeywrench(#54)toremovescrew(#29).
3. Use double ended spanner (#53) to remove screw (#28)
andwasher(#27).
4.Placecuttingwheelontospindleendandreversesteps1-3.
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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.
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.