POWAIR0804 - Power tool PowerPlus - Free user manual and instructions

Product type	Pneumatic cut-off tool
Brand	PowerPlus
Model	POWAIR0804
Cutting disc diameter	3" (75 mm)
No-load speed	20000 min⁻¹
Operating pressure	6.3 bar (91 psi)
Air inlet size	1/4"
Average air consumption	595 l/min
Sound pressure level (LpA)	92 dB(A)
Sound power level (LwA)	103 dB(A)
Vibration level (aw)	4.3 m/s²
Power source	Compressed air (pneumatic)
Main functions	Fast cutting of silencers and exhaust pipes
Maintenance and cleaning	Lubrication before and after each use; regular greasing of the motor
Safety	Mandatory wearing of goggles and hearing protection; do not exceed 6.3 bar
Spare parts and repairability	Cutting discs, flanges, O-rings; repairs by qualified personnel only
General information	Compliant with EN ISO 11148-7:2012; standard warranty

Frequently Asked Questions - POWAIR0804 PowerPlus

How to lubricate the tool before first use?

Disconnect the tool from the air supply, pour a teaspoon of pneumatic tool oil into the air inlet, then run the tool for 20 seconds while covering the exhaust with a towel.

What air pressure is recommended?

The operating pressure is 6.3 bar (91 psi). Never exceed this pressure, as the tool could explode.

How to change the cutting disc?

Disconnect the tool from compressed air. Use the spindle wrench and Allen key to remove the spindle screw, replace the disc, then retighten the screw. Check the rotation direction.

What safety equipment to wear?

Always wear safety goggles and hearing protection (sound level >85 dB). Avoid loose clothing and jewelry.

The tool loses power under load, what to do?

This may be due to worn motor parts or lack of lubrication. Check the greasing and add oil if necessary.

How to store the tool?

Lubricate the tool before storage. Run it for 10 seconds to distribute the oil, then store it in a clean, dry place.

The tool does not stop, what to do?

The O-rings of the throttle valve may be dislodged. Put them back in place or have them repaired by a professional.

What type of lubricant to use?

Use only special lubricants for pneumatic tools. Ordinary lubricants can damage the rubber seals.

Does the cutting disc have a rotation direction?

Yes, check that the direction arrow on the disc matches the rotation direction indicated on the tool.

Where to find replacement cutting discs?

3" (75 mm) cutting discs are available at automotive accessory stores or from the PowerPlus dealer.

USER MANUAL POWAIR0804 PowerPlus

Exterior view of a power tool with metallic blade and handle (no text or symbols visible on the tool itself)

POWAIR0804

Close-up of a black mechanical component with a metallic handle and a cylindrical shaft, no visible text or symbols.

Fig. 2

POWAIR0804 NL

1 TOEPASSING....2
2 BESCHRIJVING (FIG. A) 2
3 INHOUD VAN DE VERPAKKING....2
4 VEILIGHEIDSREGELS....2
5 LUCHTTOEVOER ....3
6 SMERING 3
7 BELANGRIJK!!! 4
8 AANSLUITING EN GEBRUIK 4
8.1 Monteren van slijpschijven (Fig. 2)....4
8.2 Vervangen van slijpschijven (Fig. 2) ......4
8.3 De slijpschijf IN- en UIT-schakelen....5
9 ONDERHOUD....5
10 OPBERGEN....5
11 TECHNISCHE GEGEVENS....5
12 GELUID....6
13 PROBLEEMOPLOSSING....6
14 MILIEU....7
15 CONFORMITEITSVERKLARING....7

PNEUMATISCHE SLIJPER

POWAIR0804

1 TOEPASSING

2 BESCHRIJVING (FIG. A)

13 PROBLEEMOPLOSSING

15 DÉCLARATION DE CONFORMITÉ

VARO N.V. - Joseph Van Instraat 9 - BE2500 Lier - BELGIQUE, déclare que :

1 APPLIANCE 2
2 DESCRIPTION (FIG. A)....2
3 PACKAGE CONTENT LIST 2
4 SAFETY RULES....2
5 AIR SUPPLY....3
6 LUBRICATION ....3
7 IMPORTANT!!! 3
8 LOADING AND OPERATION....4
8.1 Fitting abrasive cutting discs (Fig. 2)....4
8.2 Changing abrasive cutting discs (Fig. 2)....4
8.3 Switching the cut off tool ON/OFF....4
9 MAINTENANCE....5
10 STORAGE ....5
11 TECHNICAL DATA ....5
12 NOISE....5
13 TROUBLE SHOOTING....5
14 ENVIRONMENT....7
15 DECLARATION OF CONFORMITY 7

PNEUMATIC CUT OFF TOOL POWAIR0804

1 APPLIANCE

This air cut off tool is designed for cutting mufflers and tail pipes quickly and efficiently. A chrome plated steel guard protects you from sparks.

Warning Read this manual and general safety instructions carefully before using the appliance, for your own safety.

2 DESCRIPTION (FIG. A)

1. Trigger
2. Cutting disc
3. Trigger lock
4. Flange
5. Safety guard
6. Spindle screw
7. Spindle
8. Coupler

3 PACKAGE CONTENT LIST

■ Remove all packaging materials.
- Remove remaining packaging and packing inserts (if included).
- Check that the package contents are complete.
- Check the appliance, the power cord, the power plug and all accessories for transportation damage.
- Keep the packaging materials as far as possible until the end of the warranty period. Then take it to your local waste disposal system.

WARNING Packaging materials are not toys! Children must not play with plastic bags! There is a danger of suffocation!

1 x Pneumatic cut off tool

1 x male Orion coupler

3 x Cutting disc

1 x oil bottle (empty)

1 x Hex key

1 x PTFE sealing tape

1 x Spanner

1 x Manual

1 x male Euro coupler

If any parts are missing or damaged, please contact your dealer.

4 SAFETY RULES

• WARNING! Do not exceed maximum operating pressure of the air tool. The air cut off tool could explode and result in death or serious injury.
• Disconnect the air cut off tool from the air compressor before changing tools or accessories, servicing and during non-operation.
• Always wear safety glasses and use hearing protection during operation.
• Do not wear loose fitting clothing and jewelry which may become caught in moving parts and result in serious injury.

POWAIR0804 EN

• Do not depress trigger when connecting the air hose.
• Never trigger the tool when not applied to a work object. Accessories must be securely attached.
• Make sure all connections are secure and check air hoses for weak or worn condition before each use.
• WARNING! Disconnect air supply before installing or performing any maintenance.

5 AIR SUPPLY

- Air supply MUST be greater than air requirement of the tool. Recommended air compressor is 3/4HP with a tank for intermittent use; 1,5HP or larger for heavier duty use. The use of air filters and air line lubricators is recommended.

- For air hose, you best use 3M or 7.5M long with 5mm ID. However, hoses longer than 7.5M should use 10mm even 12 mm ID. This for proper performance and more convenience. Using fittings or air hoses which are too small can create a pressure drop and reduce the power of the air tool.

WARNING! Keep hoses away from heat, oil and sharp edges. Replace any hose that is damaged, weak or worn Never carry a tool by the hose or pull the hose to move the tool or a compressor.

6 LUBRICATION

An automatic in-line filter-regulator-lubricator is recommended (Fig 1) as it increases tool life and keeps the tool in sustained operation. The in-line lubricator should be regularly checked and filled with air tool oil.

Proper adjustment of the in-line lubricator is performed by placing a sheet of paper next to the exhaust ports and holding the throttle open approximately 30 seconds. The lubricator is properly set when a light stain of oil collects on the paper. Excessive amounts of oil should be avoided.

In the event that it becomes necessary to store the tool for an extended period of time (overnight, weekend, etc.), it should receive a generous amount of lubrication at that time. The tool should be run for approximately 30 seconds to ensure oil has been evenly distributed throughout the tool. The tool should be stored in a clean and dry environment.

• It is most important that the tool be properly lubricated by keeping the air line lubricator filled and correctly adjusted. Without proper lubrication the tool will not work properly and parts will wear prematurely.
• Use the proper lubricant in the air line lubricator. The lubricator should be of low air flow or changing air flow type, and should be kept filled to the correct level. Use only recommended lubricants, specially made for pneumatic applications. Substitutes may harm the rubber compounds in the tools, O-rings and other rubber parts.

7 IMPORTANT!!!

If no filter/ pressure regulator/ lubricator is installed in the compressed air system, then pneumatic tools must be lubricated with 2 to 6 drops of oil at least once a day or after every two hours of use. This must be done directly along the male coupler or the screw (OIL) provided for the purpose on the side of the tool's housing.

POWAIR0804 EN

Automatic lubrication is also possible using the supplied mini oiler that you have to install between the threaded connector of the tool and the male coupler. Make sure that the oiler is always filled with suitable oil.

Fig. 1

1. Tool

2. Quick connector

3. Quick coupler

4. Air hose

5. Quick connector

6. Quick coupler

7. Lubricator

8. Regulator (0-8.5 bar)

9. Filter

10. Cut-off valve

11. Air compressor

8 LOADING AND OPERATION

■ Before each use, drain water out of air compressor tank and condensation from air lines. After clearing air compressor moisture and lubricating the tool, connect it to an air hose of a recommended size.

- Depress the trigger to remove or install the parts.

8.1 Fitting abrasive cutting discs (Fig. 2)

CAUTION! Always disconnect the tool from the source of compressed air before fitting or removing an abrasive cutting disc.

Maintain a firm grip on the compressed air line in order to prevent whiplash when you disconnect the quick-release connector.

- Hold the spindle in place with the spindle wrench and remove the spindle screw with the Allen key as shown.

- Place a suitable abrasive cutting disc (available from auto accessory stores) on to the spindle, making sure that the directional arrow on the abrasive cutting disc (if applicable) agrees with the direction of rotation marked on the tool.

- Place the flange on to the abrasive cutting disc as illustrated.

- Hold the spindle in place with the spindle wrench and replace/re-tighten the spindle screw with the Allen key to secure the abrasive cutting disc and the flange in place.

8.2 Changing abrasive cutting discs (Fig. 2)

- Disconnect the tool from the source of compressed air. Maintain a firm grip on the compressed air line in order to prevent whiplash when you disconnect the quick-release connector.

- Remove the abrasive cutting disc you no longer wish to use from the spindle.

- Subsequently fit the new abrasive cutting disc (available from auto accessory stores) to the spindle as described above.

8.3 Switching the cut off tool ON/OFF

- To switch ON: Push the trigger lock and depress the trigger

■ To switch OFF: Release the trigger

WARNING! Do not over tighten the parts.

9 MAINTENANCE

This air cut off tool requires lubrication BEFORE Initial use and BEFORE and AFTER each additional use throughout its life.

• WARNING Disconnect the air cut off tool from the air supply and hold it with air inlet up.
• Pull the trigger, put one teaspoon of air tool oil in the air inlet, and then switch the reverse button in both directions to help circulate oil in the motor.
• Reconnect the air cut off tool to the air supply and cover the exhaust port with a towel and run for 20 seconds Oil will discharge from the exhaust port when air pressure is applied.

WARNING! Any excess oil in the motor is immediately expelled from the exhaust port. Always direct exhaust port away from people or objects.

10 STORAGE

The air cut off tool must be lubricated before storing Follow the air motor lubrication instructions. Only run for 10 seconds Instead of 20 seconds because more oil needs to remain in the tool when storing.

11 TECHNICAL DATA

Model	POWAIR0804
Cutting disc	3" (75mm)
No load speed	20000min ^-1
Air pressure	6.2bar / 90psi
Air inlet size	14"
Avg. air consumption	113l/min

12 NOISE

Noise emission values measured according to relevant standard. (K=3)

Acoustic pressure level LpA	92 dB(A)
Acoustic power level LwA	103 dB(A)

ATTENTION! Wear hearing protection when sound pressure is over 85 dB(A).

aw (Vibration)

4,3 m/s²

K = 1.5 ~m / s^2

13 TROUBLE SHOOTING

The following form lists the common operating system with problem and solutions. Please read the form carefully and follow it.

POWAIR0804 EN

WARNING: If any of the following symptoms appears during your operating, stop using the tool immediately, or serious personal injury could result. Only a qualified persons or an authorized service center can perform repairs or replacement of tool.

Disconnect tool from air supply before attempting repair or adjustment. When replacing O-rings or Cylinder, lubricate with air tool oil before assembly.

PROBLEMS	POSSIBLE CAUSES	REMEDIES
Tool runs at normal speed but loses under load	Motor parts worn.	Lubricating clutch housing.Check for excess clutch oil. Clutch cases need only be half full. Overfilling can cause drag on high speed clutch parts, i.e. a typical oiled/lubricated wrench requires 1/2 ounce of oil.GREASE LUBRICATED:NOTE: Heat usually indicates insufficient grease in chamber. Severe operating conditions may require more frequent lubrication.
	Cam clutch worn or sticking due to lack of lubricant.
Tool runs slowly. Air flows slightly from exhaust	Motor parts jammed with dirt particles	Check air inlet filter for blockage.Pour air tool lubricating oil into air inlet as per instructions.Operate tool in short bursts quickly reversing rotation back and forth where applicable.Repeat above as needed.
	Power regulator in closed position
	Air flow blocked by dirt.
Tools will not run. Air flows freely from exhaust	One or more motor vanes stuck due to material build up.	Pour air tool lubricating tool into air inlet. Operate tool in short bursts of forward and/or reverse rotation where applicable.Tap motor housing gently with plastic mallet.Disconnect supply. Free motor by rotating drive shank manually where applicable
Tool will not shut off	‘O’ rings throttle valve dislodged from seat inlet valve.	Replace ‘O’ ring.

14 ENVIRONMENT

Should your appliance need replacement after extended use, do not discard it with the household rubbish but dispose of it in an environmentally safe way.

15 DECLARATION OF CONFORMITY

VARO N.V. - Joseph Van Instraat 9 - BE2500 Lier - BELGIUM, declares that, product: Pneumatic cut off tool trade mark: POWERplus model: POWAIR0804

is in conformity with the essential requirements and other relevant provisions of the applicable European Directives, based on the application of European harmonized standards. Any unauthorized modification of the apparatus voids this declaration.

European Directives (including, if applicable, their amendments up to the date of signature); 2006/42/EC

European harmonized standards (including, if applicable, their amendments up to the date of signature); EN ISO 11148-7 : 2012

Keeper of the Technical Documentation : Philippe Vankerkhove, VARO – Vic. Van Rompuy N.V.

The undersigned acts on behalf of the company CEO,

Hugo Cuypers Certification Manager Date: 29/01/2014

POWAIR0804 DE

3 FÖRPACKNINGSINNEHÅLL

4 SIGURNOSNA PRAVILA

Close-up of a white and black industrial power tool with a metallic blade and screw base (no visible text or symbols)

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