Power Fist 9004391 User manual

V1.0 9004391
Please read and understand all instructions before use. Retain this manual for
future reference.

This page is intentionally left blank.

SPECIFICATIONS
Wheel Diameter 3 in.
Air Inlet 1/4 in.
Pressure Range 90 PSI
Air Consumption @ 90 PSI 4 CFM
Average CFM @ 15 Second Run Time 4 CFM
CFM @ Full Load 4 CFM
Speed Rating 18,000 RPM
Arbor Size 3/8 in.
Min. Hose Size 3/8 in.
Overall Length 12-3/16 in.
Material Aluminum
INTRODUCTION
The cut-o tool is ideal for a wide range of cutting applications, like cutting
sheet metal, steel pipes or bolts and nuts. The trigger lever controls the airow
and cutting wheel speed.
SAFETY
WARNING! Read and understand all instructions before using this tool.
The operator must follow basic precautions to reduce the risk of
personal injury and/or damage to the equipment.
HAZARD DEFINITIONS
Please familiarize yourself with the hazard notices found in this manual. A
notice is an alert that there is a possibility of property damage, injury or death
if certain instructions are not followed.
DANGER! This notice indicates an immediate and specic hazard that will result in severe
personal injury or death if the proper precautions are not taken.
WARNING! This notice indicates a specic hazard or unsafe practice that could result in a
serious injury if the proper precautions are not taken.
CAUTION! This notice indicates a potentially hazardous situation that may result in minor
or moderate injury if proper practices are not taken.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 3 www.princessauto.com / 1-800-665-8685

NOTICE! This notice indicates that a specic hazard or unsafe practice will result in
equipment or property damage, but not personal injury.
WORK AREA
1. Operate in a safe work environment. Keep your work area clean, well-lit
and free of distractions. Place lights so you are not working in a shadow.
2. Keep anyone not wearing the appropriate safety equipment away from
the work area.
3. Store unused tools properly in a dry, safe and secure location to prevent
rust, damage or misuse.
4. Do not install or use in the presence of ammable gases, dust or liquids.
PERSONAL SAFETY
WARNING! Wear personal protective equipment approved by the
Canadian Standards Association (CSA) or American National Standards
Institute (ANSI).
PERSONAL PROTECTIVE EQUIPMENT
1. Always wear impact safety goggles that provide front and side protection
for the eyes. Eye protection equipment should comply with CSA Z94.3-07
or ANSI Z87.1 standards based on the type of work performed.
2. Wear the appropriate type of full-face shield in addition to safety googles,
as the work can create chips, abrasive or particulate matter.
3. Wear gloves that provide protection based on the work materials or to
reduce the eects of tool vibration.
a. Do not wear gloves when operating a tool that can snag the material
and pull the hand into the tool.
4. Wear protective clothing and gloves designed for the work environment,
materials and tools.
5. Non-skid footwear is recommended to maintain footing and balance in the
work environment
6. Wear steel toe footwear or steel toe caps to prevent a foot injury from
falling objects.
7. Wear the appropriate rated dust mask or respirator. Wear a NIOSH
approved respirator when working on materials that produce hazardous
fumes, dust or particulate matter.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 4

8. The tool may contain high pressure. Use safety glasses and gloves for
protection during operation. Keep hands clear of the exposed rubber
portions of the hose.
9. The air source used with this tool may cause hearing damage. Wear ear
protection gear to eliminate or reduce the noise.
PERSONAL PRECAUTIONS
Control the tool, personal movement and the work environment to avoid
personal injury or damage to tool.
1. Do not operate any tool when tired or under the inuence of drugs,
alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the
moving parts of a tool. Keep long hair covered or bound.
3. Do not overreach when operating a tool. Proper footing and balance
enables better control in unexpected situations.
4. Support the workpiece or clamp it to a stable platform. Holding the
workpiece by hand or against your body may lead to personal injury.
5. Securely hold this tool using both hands. Using a tool with only one hand
can result in loss of control.
6. Keep your ngers away from the trigger/switch while carrying the tool,
attaching an air hose or an accessory. Lock the trigger/switch safety if
available.
7. Avoid unintentional starts. Be sure that the regulator/throttle switch is in
the neutral or OFF position when not in use and before connecting it to
any air source.
8. Never point the air stream or tool at any point of your body, other people
or animals. Debris and dust ejected at high speed can cause an injury.
9. Serious injury or death may occur from inhaling compressed air. The air
stream may contain carbon monoxide, toxic vapors or solid particles.
Never inhale compressed air directly from the pump or air tool.
SPECIFIC SAFETY
WARNING! DO NOT let comfort or familiarity with product (gained from
repeated use) replace strict adherence to the tool safety rules. If you use
this tool unsafely or incorrectly, you can suer serious personal injury.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 5 www.princessauto.com / 1-800-665-8685

WARNING! Some surfaces contain materials which can be toxic. When
working on materials that may contain lead, asbestos, copper chromium
arsenate or other toxic materials, extra care should be taken to avoid
inhalation and minimize skin contact.
1. Use the correct tool for the job. This tool was designed for a specic
function. Do not modify or alter this tool or use it for an unintended
purpose.
2. Do not use the tool if any parts are damage broken or misplaced. Repair or
replace the parts.
3. Only use a cut-o wheel that are specically designed for use with the
cut-o tool. Ensure the cut-o wheel is tightly installed.
4. Do not use a cut-o wheel that is dull or damaged. A dull tool requires
more force to use the tool, possibly causing the cut-o wheel to break.
This may cause an injury and will damage the workpiece.
5. Only use a cut-o wheel that exceeds the Speed Rating (see
Specications).
6. Always wait until the motor has reached full speed before starting a cut.
7. Never install more than one cutting or grinding disc at a time unless the
tool and cutting accessories are designed for that purpose.
8. Use the correct mounting hardware. The mounting hardware is designed
to hold the cut-o wheel on the tool to allow optimum performance and
safety of operation. Mismatched mounting hardware may result in a tool
malfunction and cause an injury.
9. Check the cut-o wheel for damage before each use. It can break or
shatter and cause serious injury or damage the tool and workpiece.
10. Always handle the cut-o wheel with care when mounting or removing it.
11. Remove adjusting keys and wrenches before using the tool. The tool may
eject an attached wrench or a key and cause an injury to you or a
bystander.
AIR TOOL PRECAUTIONS
1. Use only clean and dry compressed air as a power source. Contaminated
or moist air will gradually damage the tool.
2. Install an in-line shuto valve or regulator to allow immediate control over
the air supply in an emergency, even if a hose is ruptured.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 6

3. Discontinue tool use if it does not work properly or air is leaking. Tag or
mark the tool as ‘defective’ or ‘out of service’ until repaired.
4. Check the manufacturer’s maximum pressure rating for air tools and
accessories. Compressor outlet pressure must be regulated to never
exceed the maximum pressure rating of the tool (see Specications).
Exceeding the maximum PSI rating can create a bursting hazard, causing
injury and property damage.
5. Attach all accessories properly to the tool before connecting the air
supply. A loose accessory may detach or break during operation.
6. Never use oxygen, combustible gas or any other bottled gas as a power
source. Any power source other than an air compressor could cause an
explosion and serious personal injury.
7. Turn OFF the valve and discharge any remaining air pressure after each
use or before adjusting the tool.
8. Do not leave the air tool unattended with its compressed air supply on.
Turn o the compressed air supply and bleed the air tool of any remaining
compressed air before leaving the air tool unattended.
9. Serious injury may occur from loose debris being propelled at high speeds
from the compressed air stream. Always wear OSHA approved safety
glasses to protect the eyes during operation of the air compressor.
10. Always turn o the air compressor and drain tank pressure completely
before attempting maintenance or attaching air tools. Release pressure
slowly from the system.
11. Do not cover the air vents.
POWER TOOL PRECAUTIONS
1. Do not use any power tool with a malfunctioning power switch or control.
A power tool that fails to respond to the controls is dangerous and can
cause an injury. A qualied technician must repair and verify the power
tool is operating correctly, before it can be used.
2. Shut the power o and disconnect the cut-o tool from the power supply
(if possible) before making any adjustments, changing accessories,
cleaning, servicing or when storing. Such preventive safety measures
reduce the risk of starting the tool accidentally.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 7 www.princessauto.com / 1-800-665-8685

3. Never force the cut-o tool. Excessive pressure could break the tool,
resulting in damage to your workpiece or serious personal injury.
Excessive pressure is the cause if your tool runs smoothly under no load,
but roughly under load.
4. Position the cut-o tool's safety guard over the cut-o wheel when not in
use.
5. Check if the cut-o tool's moving parts are misaligned or binding before
each use. Correct the issue before using the cut-o tool to avoid an injury
or damage to the tool.
6. Always be aware of the position of your hands relative to the cut-o tool.
Avoid awkward hand positions where a sudden slip could cause a hand to
move into the cut-o wheel. Never reach behind or beneath the cut-o
tool.
7. Only use accessories that are specically designed for use with the cut-o
tool. Ensure the cut-o wheel is tightly installed.
8. Only use the cut-o wheel that exceeds the Speed rating (see
Specications).
9. Before using the cut-o tool on a workpiece, test the cut-o tool by
running it at the highest speed rating for at least 30 seconds in a safe
position. Stop immediately if there is any abnormal vibration or wobbling.
Check the tool to determine the cause.
10. Never touch the cut-o wheel or workpiece during or immediately after
use. They may be hot and could inict a burn injury.
11. The material and the motor housing can get very hot during operation.
Stop work until the cut-o tool and the cut-o wheel both cool down to a
safe temperature.
12. Do not cover the air vents. Proper cooling of the motor is necessary to
ensure normal life of the tool.
13. Never use a tool with a cut-o wheel that is cracked or worn. Change the
cut-o wheel before using it.
14. Do not place the cut-o tool down until the cut-o wheel has stopped
moving. The cut-o tool may catch the surface of work material and
wrench itself free, causing injury to the user or others in the work area.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 8

15. Avoid unintentional starts. Be sure that the regulator/throttle switch is in
the neutral or OFF position when not in use and before connecting it to
any air source.
16. Make sure any adjustment mechanisms are secure before using the tool
17. Never point the cut-o tool towards yourself. It could inict an injury.
18. Hold the cut-o tool by the insulated gripping surfaces when performing
an operation where the cut-o tool may contact hidden electrical wiring.
The cut-o tool's exposed metal surfaces may convey a shock to the
operator from a ‘live’ wire.
KICKBACK PRECAUTIONS
Kickback is a sudden reaction to a pinched or snagged accessory. If kickback
occurs:
• the cut-o wheel may pass over a body part, causing a seriously injury
• the cut-o tool may wrench the user’s arm causing muscle or joint injuries
• the tool may strike bystanders.
Kickback can be avoided by taking proper precautions:
1. Maintain a rm grip on the tool and position your body and arms to allow
you to resist a kickback. Kickback will propel the tool in the direction
opposite to the cut-o wheel’s teeth or direction of rotation. The tool may
pull out of your grasp.
a. Use clamps or a vice to hold down smaller workpieces.
2. Use special care when working on corners, sharp edges or exible
material. These workpieces have a tendency to snag the cut-o wheel.
3. Only use the cut-o wheel designed for the tool.
4. Support large panels to minimize the risk of pinching the cut-o wheel.
Large panels may sag under their own weight. Place supports under the
panel on both sides of the work area. Place other supports under the rest
of the panels to prevent them from falling.
5. Always make sure the work surface is free from nails and other foreign
objects. Cutting into a nail can cause the cut-o wheel and tool to jump
and damage the cut-o wheel.
6. Maintain the cutting edge of the cut-o wheel. A dull edge is more likely
to slip from the workpiece.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 9 www.princessauto.com / 1-800-665-8685

AIR HOSE PRECAUTIONS
1. Inspect the tool's air hose for cracks, fraying or other faults before each
use. Discontinue use if the air hose is damaged or hissing is heard from
the air hose or couplers. Replace the defective air hose.
2. Do not allow people, mobile equipment or vehicles to pass over the
unprotected air hose. Position the air hose away from high trac areas, in
a reinforced conduit or place planks on both sides of the air hose to create
a protective trench.
3. Prevent damage to the air hose by observing the following:
a. Never carry the tool by the air hose.
b. Keep the air hose behind the tool and out of the tool's work path.
c. Keep the air hose away from heat, oil, sharp edges or moving parts.
d. Do not wrap the air hose around the tool as sharp edges may pierce
or crack the air hose. Gently coil the hose and either hang on a hook
or fasten with a device to keep hose together when storing.
4. A damaged or disconnected air hose under pressure may whip around and
inict personal injury or damage the work area. Secure the compressor's
air hose to a xed or permanent structure with clamps or cable ties.
5. Install an in-line shuto valve or regulator to allow immediate control over
the air supply in an emergency, even if a hose is ruptured.
6. Check the manufacturer’s maximum pressure rating for air tools and
accessories. Compressor outlet pressure must be regulated to never
exceed the maximum pressure rating of the tool (see Specications).
Exceeding the maximum PSI rating can create a bursting hazard, causing
injury and property damage.
7. Serious injury may occur from loose debris being propelled at high speeds
from the compressed air stream. Always wear OSHA approved safety
glasses to protect the eyes during operation of the air compressor.
8. Always turn o the air compressor and drain tank pressure completely
before attempting maintenance or attaching air tools. Release pressure
slowly from the system.
9. Serious injury or death may occur from inhaling compressed air. The air
stream may contain carbon monoxide, toxic vapors or solid particles.
Never inhale compressed air directly from the pump or air tool.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 10

VIBRATION PRECAUTIONS
1. This tool vibrates during use. Repeated or long-term exposure to vibration
may cause temporary or permanent physical injury. Take frequent breaks
when using the tool.
2. If you feel any medical symptoms related to vibrations (such as tingling,
numbness, and white or blue ngers), seek medical attention as soon as
possible.
3. Wear suitable gloves to reduce the eects of vibration.
4. DO NOT use this tool before consulting a physician if one of the following
applies:
a. Pregnant
b. Impaired blood circulation to the
hands
c. Past hand injuries
d. Nervous system disorders
e. Diabetes
f. Raynaud's Disease
UNPACKING
WARNING! Do not operate the tool if any part is missing. Replace the
missing part before operating. Failure to do so could result in a
malfunction and personal injury.
Remove the parts and accessories from the packaging and inspect for damage.
Contents:
•Cut-O Tool • Wrench • Hex Wrench
ASSEMBLY & INSTALLATION
INSTALL AIR COUPLER PLUG
Prepare a standard 1/4 in. NPT coupler plug (sold separately) for use with your
tool.
1. Wrap the external threads of the coupler plug with sealant tape.
a. Wrap tape in a clockwise direction so it will not unravel.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 11 www.princessauto.com / 1-800-665-8685

b. Do not tape all the threads. Leave several leading threads unwrapped
for easier alignment.
2. Screw the coupler plug into the tool's air inlet and tighten with a wrench
until snug.
3. Run the compressor at a low volume and check the connection for air
leaks. Do not use the tool until all air leaks are repaired or the faulty
component is replaced.
IMPORTANT! Vibration may cause failure if a quick coupler is connected
directly to the air tool. To overcome this, connect a leader hose to the
tool. A quick coupler may then be used to connect the leader hose to the
air line hose.
CUTTING WHEEL INSTALLATION
WARNING! Disconnect the tool from its air supply before changing
accessories, servicing or performing maintenance
WARNING! Do not use a toothed cut-o wheel with this tool. This will
cause kickback and may injury yourself or a bystander. See Kickback
Precautions.
1. Place the spanner wrench on the ats of the spindle to hold it in place.
2. Use the hex wrench to loosen and remove the bolt and washer.
3. Install the cutting wheel. Ensure the printed side is facing outward.
4. Replace the bolt and the washer.
• While holding the spindle with the spanner, tighten the bolt with the
hex wrench.
5. Allow the tool to run in idle for a few seconds with the cutting wheel
correctly assembled. A vibrating wheel should be immediately replaced.
OPERATIONS
WARNING! Never remove the metal guard as a shattered cutting wheel
can cause severe personal injury or death. The metal guard will contain
and redirect shards away from the user.
1. Install a cutting wheel appropriate for the material being cut.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 12

2. Connect the tool to an air source.
3. Push the safety lever forward, then press the trigger lever down.
4. Allow the cutting wheel to attain full speed before proceeding to the task.
5. Align the cutting wheel with the workpiece. Keep the metal guard
between yourself and the cutting wheel in case it breaks apart.
6. Apply gentle pressure to the tool and allow the cutting wheel to cut
through the workpiece. Too much force will slow the wheel and could
cause it to break.
7. Keep the tool steady during the cut. Do not attempt to move laterally or
twist the tool as it will break the cutting wheel.
8. Release the trigger once the cut is complete. Allow the wheel to stop
rotating before placing the tool down.
9. Stop the compressor once the task is complete and release residual
pressure from the tool and air hose. Disconnect the air hose from the tool.
PRESSURE DROP
Apply the air consumption and pressure rate numbers to the tool’s air inlet, not
the compressor’s outlet. Calculate the pressure drop for your air supply set-up
and increase the compressor outlet pressure to compensate. Make sure you do
not exceed the maximum pressure for any part of your air supply system.
Installing a pressure gauge at the tool inlet is the best way to measure the air
pressure and adjust the compressor’s output.
CARE & MAINTENANCE
1. Maintain the tool with care. A tool in good condition is ecient, easier to
control and will have fewer problems.
2. Inspect the tool components periodically. Repair or replace damaged or
worn components.. Only use identical replacement parts when servicing.
3. Only use accessories intended for use with this tool. Follow instructions
for changing accessories.
4. Keep the tool handles or gripping surfaces clean and dry.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 13 www.princessauto.com / 1-800-665-8685

5. Maintain the tool’s labels and name plates. These carry important
information. If unreadable or missing, contact Princess Auto Ltd. for
replacements.
WARNING! Only qualied service personnel should repair the tool. An
improperly repaired tool may present a hazard to the user and/or others.
AIR TOOL LUBRICATION
NOTICE! Only use air tool oil to lubricate the tool. Other lubricants are
not suitable and will damage the tool or cause a malfunction during use.
NOTICE! Never use a penetrating oil to lubricate an air tool. Penetrating
oil acts as a solvent that will dissolve the tool’s grease packing and may
damage the o-rings, causing the tool to seize or malfunction.
1. All air tools have an internal coating of grease to prevent corrosion during
shipping and storage. Remove this grease by adding a generous amount of
air tool oil in the air inlet and then run the tool under no load until the
exhaust is clear.
2. Manually add a drop or two of air tool oil into the tool’s coupler plug
before each use and after every hour of continuous use. The tool will not
work properly without lubrication and parts will wear prematurely.
3. Avoid adding too much air tool oil as this can cause premature power loss
and eventual tool failure. A qualied technician will need to take the tool
apart and clean out the excess oil.
4. Apply a generous amount of air tool oil to the tool before storing it for an
extended period of time (overnight, weekend, etc.). Run the tool for
approximately 30 seconds to ensure the oil is evenly distributed
throughout the tool. Store it in a clean and dry location.
DISPOSAL
Recycle a tool damaged beyond repair at the appropriate facility.
Contact your local municipality for a list of disposal facilities or by-laws for
electronic devices, batteries, oil or other toxic liquids.
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 14

TROUBLESHOOTING
Visit a Princess Auto Ltd. location for a solution if the tool does not function
properly or parts are missing. If unable to do so, have a qualied technician
service the tool.
Problem(s) Possible Cause(s) Suggested Solution(s)
Tool runs at normal
speed, but loses
power under load.
1. Motor parts worn. 1. Have a qualied technician service
the tool.
2. Replace tool or parts.
Tool runs slowly.
Air ows slightly
from exhaust.
And/Or
Air ows slightly
from nozzle.
1. Motor parts jammed
with dirt particles.
OR
Airow blocked by
dirt.
2. Air regulator in closed
position.
3. Damage or excessive
wearing of internal
parts.
1. Check air inlet lter for blockage.
a. Pour air tool lubricating oil into
air inlet as per lubrication
instructions for clearing
shipping grease.
b. Operate tool in short bursts to
clear debris.
c. If tool still jammed, clean tool
and lubricate per lubrication
instructions.
2. Open the air regulator to desired
airow.
3. Have a qualied technician service
the tool.
a. Replace tool or parts.
Tools will not run.
Air ows freely
from exhaust.
1. Damage or excessive
wearing of internal
parts.
1. Have a qualied technician service
the tool.
2. Replace tool or parts.
Tool will not shut
o.
1. Throttle valve o-ring
dislodged from inlet
valve seat.
2. Trigger mechanism
jammed or dirty.
1. Replace throttle valve o-rings.
2. Clean trigger mechanism and
lubricate.
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 15 www.princessauto.com / 1-800-665-8685

Problem(s) Possible Cause(s) Suggested Solution(s)
Loss of power or
erratic
performance.
1. Excessive drain on the
air hose. Incorrect size
or type of hose
connectors.
2. Moisture or restriction
in the air hose/tank
3. Air compressor has
insucient ow.
1. Check the air hose and conrm the
hose tting is correct for the inlet
bushing.
2. Depressurize system and drain tank
and air hose of water.
3. Ensure tool is connected to a
compressor with a rate ow that
matches the tool.
PARTS BREAKDOWN
9004391 EXTENDED REACH AIR CUT-OFF TOOL V1.0
www.princessauto.com / 1-800-665-8685 Page 16

PARTS LIST
# DESCRIPTION QTY
1 Main Housing 1
2 Trigger 1
3 Trigger Lever 1
4 Spring 1
5 Pin 1
6 Pin 1
7 O-ring 1
8 O-ring 1
9 Valve Stem 1
10 Spring 1
11 O-ring 1
12 Cap Screw 1
13 Muer 1
14 Air Inlet 1
15 Bearing 1
16 Rear Plate 1
17 Pin 2
18 Rotor 1
19 Rotor Blade 4
20 Cylinder 1
21 Bushing 1
22 Front Plate 1
23 Steel Ball 1
24 Bearing 4
# DESCRIPTION QTY
25 Screw Nut 1
26 Sleeve 1
27 Ring Retainer 1
28 Nut 1
29 Nut 1
30 Bearing 1
31 Shaft Extension 1
32 Spindle Tubing 1
33 Gear 1
34 L-Head 1
35 Oil Valve 1
36 Bearing 1
37 Gear 1
38 Fix Ring 1
39 Woodru Key 1
40 Work Spindle 1
41 Safety Guard 1
42 Screw 3
43 Cutting Wheel 1
44 Spacer 1
45 Set Screw 1
46 Soft Grip 1
47 Wrench 1
48 Hex Wrench 1
V1.0 EXTENDED REACH AIR CUT-OFF TOOL 9004391
Page 17 www.princessauto.com / 1-800-665-8685

This page is intentionally left blank.

This page is intentionally left blank.

This page is intentionally left blank.