POWER FIST 9004391 Extended Reach Air Cut Off Tool Instruction Manual

POWER FIST 9004391 Extended Reach Air Cut Off Tool

Extended Reach Air Cut-Off Tool

Model Number: 9004391

Specifications

• Wheel Diameter: 3 in.
• Air Inlet Pressure Range: 90 PSI
• Air Consumption @ 90 PSI: 4 CFM
• Average CFM @ 15 Second Run Time: 4 CFM
• CFM @ Full Load Speed Rating: 4 CFM
• Arbor Size: 3/8 in.
• Min. Hose Size: 3/8 in.
• Overall Length: 12-3/16 in.
• Material: Aluminum

Introduction

The Extended Reach Air Cut-Off Tool is designed for cutting applications such as sheet metal, steel pipes, bolts, and nuts. The trigger lever controls the airflow and cutting wheel speed.

Safety Precautions

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. 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.

Hazard Definitions

DANGER: This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.

WARNING: This notice indicates a specific 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.

NOTICE: This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury.

Work Area Precautions

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 flammable gases, dust,or liquids.

Personal Safety Precautions

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 goggles, 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 effects of tool vibration.
   • 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.

Usage Instructions

1. Before use, inspect the tool for any visible damage or defects. Do not use if any damage is found.

2. Securely connect the air hose to the tool’s air inlet. Use only hoses with a minimum diameter of 3/8 in.

3. Ensure that the air pressure does not exceed 90 PSI. Excessive pressure can damage the tool and create a hazardous situation.

4. Wear the appropriate personal protective equipment as described in the manual.

5. Hold the tool firmly with both hands and turn on the airflow by pressing the trigger lever.

6. Make sure that the cutting wheel has reached full speed before making contact with the material to be cut.

7. Move the cutting wheel gently along the material to be cut.
   Apply moderate pressure to achieve a clean cut.

8. Be aware of the cutting wheel’s location at all times to avoid accidental contact with fingers or other body parts.

9. After use, turn off the airflow and disconnect the air hose from the tool.

10. Store the tool in a dry, safe, and secure location to prevent rust, damage, or misuse.

For more information and troubleshooting tips, please refer to the user manual or contact the manufacturer.

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

Product SPECIFICATIONS

INTRODUCTION

The cut-off 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 airflow 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 specific hazard that will result in severe personal injury or death if the proper precautions are not taken.
---|---
 WARNING!| This notice indicates a specific 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.

NOTICE!
This notice indicates that a specific 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 flammable 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 effects of tool vibration.
   • 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.
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 influence 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 fingers 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 suffer serious personal injury.

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 specific 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-off wheel that are specifically designed for use with the cut-off tool. Ensure the cut-off wheel is tightly installed.
4. Do not use a cut-off wheel that is dull or damaged. A dull tool requires more force to use the tool, possibly causing the cut-off wheel to break. This may cause an injury and will damage the workpiece.
5. Only use a cut-off wheel that exceeds the Speed Rating (see Specifications).
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-off 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-off 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-off 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 shutoff valve or regulator to allow immediate control over the air supply in an emergency, even if a hose is ruptured.
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 Specifications). 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 off 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 off 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 qualified technician must repair and verify the power tool is operating correctly, before it can be used.
2. Shut the power off and disconnect the cut-off 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.
3. Never force the cut-off 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-off tool’s safety guard over the cut-off wheel when not in use.
5. Check if the cut-off tool’s moving parts are misaligned or binding before each use. Correct the issue before using the cut-off tool to avoid an injury or damage to the tool.
6. Always be aware of the position of your hands relative to the cut-off tool. Avoid awkward hand positions where a sudden slip could cause a hand to move into the cut-off wheel. Never reach behind or beneath the cut-off tool.
7. Only use accessories that are specifically designed for use with the cut-off tool. Ensure the cut-off wheel is tightly installed.
8. Only use the cut-off wheel that exceeds the Speed rating (see Specifications).
9. Before using the cut-off tool on a workpiece, test the cut-off 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-off wheel or workpiece during or immediately after use. They may be hot and could inflict a burn injury.
11. The material and the motor housing can get very hot during operation. Stop work until the cut-off tool and the cut-off 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-off wheel that is cracked or worn. Change the cut-off wheel before using it.
14. Do not place the cut-off tool down until the cut-off wheel has stopped moving. The cut-off tool may catch the surface of work material and wrench itself free, causing injury to the user or others in the work area.
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-off tool towards yourself. It could inflict an injury.
18. Hold the cut-off tool by the insulated gripping surfaces when performing an operation where the cut-off tool may contact hidden electrical wiring. The cut-off 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-off wheel may pass over a body part, causing a seriously injury
• the cut-off 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 firm 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-off 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 flexible material. These workpieces have a tendency to snag the cut-off wheel.

3. Only use the cut-off wheel designed for the tool.

4. Support large panels to minimize the risk of pinching the cut-off 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-off wheel and tool to jump and damage the cut-off wheel.

6. Maintain the cutting edge of the cut-off wheel. A dull edge is more likely to slip from the workpiece.

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-traffic 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:
   • Never carry the tool by the air hose.
   • Keep the air hose behind the tool and out of the tool’s work path.
   • Keep the air hose away from heat, oil, sharp edges or moving parts.
   • 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 inflict personal injury or damage the work area. Secure the compressor’s air hose to a fixed or permanent structure with clamps or cable ties.
5. Install an in-line shutoff 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 Specifications). 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 off 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.

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 fingers), seek medical attention as soon as possible.
3. Wear suitable gloves to reduce the effects of vibration.
4. DO NOT use this tool before consulting a physician if one of the following applies:
   • Pregnant
   • Impaired blood circulation to the hands
   • Past hand injuries
   • Nervous system disorders
   • Diabetes
   • 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-Off 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.
   • Wrap tape in a clockwise direction so it will not unravel.
   • 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-off 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 flats 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.
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 efficient, 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.
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 qualified 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 qualified 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.

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 qualified technician service the tool.

1. Have a qualified technician service the tool.

2. Replace tool or parts.

Tool runs slowly. Air flows slightly from exhaust.

And/Or

Air flows slightly from nozzle.

| 1. Motor parts jammed with dirt particles.

OR

Airflow blocked by dirt.

2. Air regulator in closed position.

3. Damage or excessive wearing of internal parts.

| 1. Check air inlet filter 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 airflow.

3. Have a qualified technician service the tool.

a. Replace tool or parts.

Tools will not run. Air flows freely from exhaust.| 1. Damage or excessive wearing of internal parts.| 1. Have a qualified technician service the tool.

2. Replace tool or parts.

Tool will not shut off.| 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.

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 insufficient flow.

| 1. Check the air hose and confirm the hose fitting 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 flow that matches the tool.

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PARTS BREAKDOWN

PARTS LIST

www.princessauto.com / 1-800-665-8685

References

• princessauto.com

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