Cornwell Tools CAT900HD Owner's 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

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 MAN U AL CON TAINS

IM POR TANT SAFE TY INFORMATION.

READ THIS IN STRUC TION MANUAL CARE FUL LY

AND UN DER STAND ALL IN FOR MA TION BE FORE

OP ER AT ING 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

Regulator Oiler Quick Coupler Leader

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.

Cornwell Tools CAT900HD Owner's manual

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