Matco Tools RL500 User manual

1 RL500 05/28/03
• Operating Instructions
• Warning Information
• Parts Breakdown
SPECIFICATIONS
Speed . . . . . . . . . . . . . 20,000 RPM
Cutting Depth . . . . . . . . . . . . . . 1"
Weight . . . . . . . . . . . . . . . 1.78 Lbs.
Length . . . . . . . . . . . . . . . . . 7-1/2"
Wheel Size . . . . . 3" x 1/16" x 3/8"
Rec. Air Pressure . . 90 psig (6.2bar)
Avg. Air Consumption . . . . . 5 CFM
Air Inlet Size . . . . . . . . . . 1/4” NPT
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.
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
RL500
3" Cut-Off Tool

WARNING - READ AND UNDERSTAND ALL INSTRUCTIONS!
FAILURE TO FOLLOW ALL INSTRUCTIONS LISTED BELOW MAY RESULT
IN SERIOUS PERSONAL INJURY
SAVE THESE INSTRUCTIONS
2 RL500 05/28/03
This Instruction Manual Contains
Important Safety Information.
READ THIS INSTRUCTION MANUAL
CAREFULLY AND UNDERSTAND ALL
INFORMATION BEFORE OPERATING THIS
TOOL.
• 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.
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.
• 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 fit-
tings, and replace immediately. Do not
use quick detach couplings at tool. See
instructions for correct set-up.
• 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.
• 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 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.
• All cut-off wheels must be used with a wheel guard.
Cut-off tools must be disconnected from the air
supply when mounting or removing any wheel or
adjusting the wheel guard. After properly mounting
the wheel and guard, the cut-off tool should be
brought up to full speed and run for at least one
minute in a protected enclosure.
• Avoid direct contact with work surface druing
and after work.
• Cutting edges can become hot during use. Do not
touch.
• Never force the tool to cut faster or through heavier
gauge material than rated capacity.
• Do not lubricate tools with flammable or volatile
liquids such as kerosene, diesel or jet fuel.
!

3 RL500 05/28/03
RL500
3” Cut-Off Tool
19
20
21
22
23
24
25
21
26
11
10
9
8
7
6
4
5
18
17
16
1
2
35
27
31
28
30
33
32
29
13 14
12
3
15
34
Ref. No. Part No. Description Qty.
1 98101 Motor Housing 1
2 98102 Valve Bushing 1
3 98103 Lever Pin 1
4 98104 Valve Stem 1
5 98105 O-Ring 1
6 98106 O-Ring 1
7 98107 Spring 1
8 98107 Regulator 1
9 98109 O-Ring 1
10 98110 O-Ring 1
11 98111 Valve Screw 1
12 98112 Throttle Lever 1
13 98113 Stop Rod 1
14 98114 Spring 1
15 98115 Pin 1
16 98116 Silencer 1
17 98117 Deflector 1
18 98118 Air Inlet 1
Ref. No. Part No. Description Qty.
19 21114 Ball Bearing 1
20 98120 Rear End Plate 1
21 98121 Pin 1
22 98122 Cylinder 1
23 98123 Rotor Blade 1
24 98124A Rotor 1
25 98125 Rotor Spacer 1
26 98126 Front End Plate 1
27 10920 Ball Bearing 1
28 98128 Lock Nut 1
29 98201 Lock Nut 1
30 98202 Protector Guard 1
31 98203 Spindle 1
32 98204 Spacer 1
33 98205 Hex. Screw 1
34 98206 Hex Wrench 1
35 98207 Spanner Wrench 1

4 RL500 05/28/03
Nipple
AIR SUPPLY...
Tools of this class operate on a wide range of air
pressures. It is recommended that air pressure of
these tools measures 90 PSI at the tool while running
free. Higher pressure (over 90 psig; 6.2 bar) raises
performance beyond the rated capacity of the tool
which will shorten the tool’s life because of faster
wear 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 air tank daily. Clean the air
inlet filter screen on at least a weekly schedule.
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.
LUBRICATION...
Lubricate the air motor daily with quality motor oil.
If no air line oiler is used, run a teaspoon 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.
The oil plug is ONLY for adding standard SAE 10
or 20 grade oil after repair or maintenance of
the impact mechanism. The amount of oil to be
used is 1 ounce. Overfilling will cause a reduction
in the power of the tool.
OPERATION...
When using the cut-off tool be careful not to
exert excessive force. Too much force could be
hazardous if it causes the cutting tool spindle to
bend or break.
The burning of the work piece or excessive speed
reduction indicates too much force being applied.
Changing to a free cutting tool may be better for
the desired rate of speed and stock removal.
Avoid hazardous conditions by making sure there
is sufficient force on the spindle of the cutting
tool by placing the spindle 7/16" or more inside
the collet.
To Install Grinding Wheel:
1. Remove hex screw (#33) and washer (#32)
2. Place grinding wheel on the center of the
spindle.
3. Replace hex screw and washer. Tighten
securely with allen wrench (#34)
Air Inlet