ASTRO ONYX 408 - User Manual

1 YEAR LIMITED WARRANTY
408
FLEX HEAD
REVERSIBLE HD
CUT OFF TOOL
• Astro Pneumatic Tool Co. warrants our products to the original user against defective material or workmanship for a
period of 1 year from the date of 1st use. Astro reserves the right to determine whether the product failed because of
defective material, workmanship or other causes and to charge back for missing parts. Astro Pneumatic Tool Co., at its
discretion, will repair products covered under this warranty free of charge. The original user is to return the product
(with the exceptions listed below) with the distributor’s name, address, adequate proof of date of purchase or a copy of
warranty card, and a short note explaining the problem. Failures caused by accident, alteration, or misuse are not
covered by this warranty.
• Astro Pneumatic Tool Co. or its authorized service representatives must perform all warranty repairs. Any repair to the
product by unauthorized service representatives voids this warranty. The rights under this warranty are limited to the
original user and may not be transferred to subsequent owners.
• This warranty is in lieu of all other warranties, expressed or implied, including warranties of merchantability and fitness
for a particular purpose. Some states do not allow the exclusion of limitations of incidental or consequential damages
so the above limitations may not apply to you.
WARNING
Study, understand and follow all instructions provided with this product.
Read these instructions carefully before installing, operating, servicing or
repairing this tool. Keep these instructions in a safe accessible place.
PLEASE DO NOT RETURN ANY PRODUCT WITHOUT CALLING 1-800-221-9705 FOR INSTRUCTIONS
911

Summary

1 Year Limited Warranty

Intended Use and Product Information

Product Information

Details features like flex-head design, forward/reverse dial, and motor power.

Specifications

Lists technical details including wheel size, speed, length, weight, and air requirements.

Safety Precautions for Personal Injury

Provides critical warnings regarding chemical exposure, safety equipment, and proper operation.

General Warnings and Maintenance

General Safety Warnings

Highlights risks like explosive atmospheres, pressure, vibration, and rotating parts.

Maintenance Instructions

Covers lubrication, checking part tightness, disposal, storage, and ordering service parts.

Suggested Air Line Connection

Operating Instructions

General Operating Procedures

Emphasizes turning off air supply before adjustments and avoiding unattended operation.

Changing the Wheel

Step-by-step guide for removing and installing cut-off wheels, including flange alignment.

Adjusting Tool Features

Instructions for positioning the flex head, rotating the guard, and reversing motor rotation.

Parts Breakdown and List

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Astro Pneumatic Tool Co. 408 Flex Head Reversible HD Cut Off Tool is a robust and versatile air-powered tool designed for cutting sheet metals and other thin metal materials. It is engineered for heavy-duty applications, offering a combination of power, flexibility, and user-friendly features.

Function Description

The primary function of the 408 cut-off tool is to efficiently cut sheet metals and thin metal materials using standard 3" cut-off wheels. Its design incorporates a flex head, allowing the user to adjust the tool's angle for optimal clearance and access in various working conditions. The reversible motor rotation feature provides control over the direction of sparks, enhancing safety and convenience. The tool is intended for professional use in environments requiring precise and powerful metal cutting.

Important Technical Specifications

• Wheel Size: 3" (75mm)
• Free Speed: 16,000 RPM
• Overall Length: 9.6" (243.84 mm)
• Net Weight: 2.9 lbs. (1.315 kgs)
• Air Consumption: 5.3 CFM
• Power: 0.8 HP
• Air Inlet Thread NPT: 1/4"
• Air Pressure: 90 PSI (6.2 Bar)
• Recommended Cut-Off Wheels: Standard 3" wheels rated for 16,000rpm or above.

Usage Features

The 408 cut-off tool is designed with several features to enhance its usability and adaptability:

• Flex-Head Design: The tool's head can be set 25° forward or backward. This adjustable angle is crucial for achieving optimal clearance in tight spaces or when working on intricate geometries, allowing the user to maintain an ergonomic and effective cutting position. The flex head can be positioned in three ways: 25° upward, 25° downward, and standard-straight operation. To adjust, the user firmly grasps the tool below the knurled lock sleeve, pushes the lock sleeve outward with the thumb and forefinger, and then positions the wheel end as desired.
• Reversible Motor Rotation: A forward and reverse dial allows the user to choose the direction of motor rotation. This feature is particularly useful for controlling where sparks are thrown during cutting, which can be a significant safety and convenience factor in different work environments. The black knob on the side opposite the throttle controls this function, allowing selection between F=Forward and R=Reverse by turning it downward.
• Powerful Motor: Equipped with a 0.8 horsepower motor, the tool is built for full-throttle, heavy-duty applications, ensuring consistent performance even under demanding conditions.
• 360° Swiveling Exhaust Port: This feature allows the user to direct the exhaust air away from their face and/or debris around the work area, contributing to a cleaner and safer workspace.
• Adjustable Guard: The guard can be rotated to a desired position to direct debris away from the user and others. To adjust, the user gently pulls the guard in an outward direction and then rotates it.
• Wheel Changing Mechanism: The tool uses a straightforward process for changing cut-off wheels. It involves disconnecting the air source, using two supplied wrenches to secure the drive shaft and hex bolt, and then turning the hex bolt counter-clockwise to remove it. Reinstallation follows the reverse steps, ensuring the bottom drive flange slot aligns with the flat sides of the drive shaft to prevent loosening during operation.

Maintenance Features

Proper maintenance is essential for the longevity and optimal performance of the 408 cut-off tool:

• Lubrication: Before connecting the air hose and after every 3 to 4 hours of operation, 4 to 5 drops of good quality air tool oil should be applied at the air inlet. This ensures smooth operation and prevents internal wear. Before storing the tool, it should also be oiled at the air inlet and run for a short period to distribute the oil.
• Tightness of Parts: Users should regularly check that all connection parts are securely fastened. This procedure should be performed daily before beginning work to ensure safety and prevent component loosening.
• Storage: The tool should be stored in a location free from high humidity to prevent rust caused by residual moisture inside the tool. Oiling before storage is also recommended.
• Air Line Connection and Drainage: The manual provides a detailed guide for suggested air line connection, emphasizing the importance of an oil and water extractor. The extractor should be mounted at least 25 ft from the compressor to ensure maximum effectiveness in removing moisture from the compressed air. Air lines must be properly drained daily, especially at low points, to prevent water accumulation. Pitching air lines back towards the compressor helps condensed moisture flow into the air receiver for drainage.
• Ordering Service Parts: For replacement parts or components, users are advised to contact the sales agent or the service division of Astro Pneumatic Tool Co. at 1-800-221-9705, providing the part number, name, and quantities.

The 408 Flex Head Reversible HD Cut Off Tool is backed by a 1-year limited warranty against defective material or workmanship from the date of first use. The warranty covers repairs by authorized service representatives and requires proof of purchase for claims. Failures due to accident, alteration, or misuse are not covered.

ASTRO ONYX 408 Specifications