Cornwell Tools CAT255HDA User manual

CAT255HDA 1 Rev. 04/13/09
CAT255HDA
1/2" Heavy Duty
Reversible
Air Drill
w/ Keyless Chuck
Free Speed ..................... 400 RPM
Chuck Size .........................1/2"
Spindle Size .....................1/2" - 20
Air Inlet ....................... 1/4" NPT
Hose Size ..........................3/8"
Air Pressure .......................90 psi
Air Consumption ...................4 cfm
Length ...........................8-1/2"
Sound Level ......................90 dBA
Weight ........................... 4 lbs.
SPECIFICATIONS
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:
• leadfromlead-basedpaints,
• crystallinesilicafrombricksandcement
and other masonry products, and
• arsenicandchromiumfrom
 chemically-treatedlumber.
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.
Copyright © Professional Tool Products, 2009
All rights reserved.
Operating Instructions • Warning Information • Parts Breakdown
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
• RATEDRPMOFTHE
ACCESSORY USED
MUST EXCEED THE
MAXIMUMTOOL
RPMSHOWN

CAT255HDA 2 04/13/09
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!
This Instruction Manual Contains Important
Safety Information.
Read THIS INSTRUCTION MANUAL Carefully
and understand ALL INFORMATION Before
Operating THIS Tool.
• Always operate, inspect and maintain
this tool in accordance with American
National Standards Institute Safety Code
of Portable Air Tools (ANSI B186.1) and
any other applicable safety codes and
regulations.
• 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"
diameter air supply hose.
• Always wear impact-resistant eye and
face protection when operating or
performing maintenance on this tool.
Always wear hearing protection when
using this tool.
• Highsoundlevels cancausepermanent
hearing loss. Use hearing protection as
recommended by your employer or
OSHA regulation.
• Keepthetoolinefficientoperating
condition.
• Operators and maintenance personnel
must be physically able to handle the
 bulk,weightandpowerofthistool.
• Air under pressure can cause severe
injury. Never direct air at yourself or
 others. Always turn off the air supply,
drain hose of air pressure and detach tool
from air supplybeforeinstalling,removing
 oradjustinganyaccessoryonthistool,or
before performing any maintenance on
this tool. Failure to do so could result in
injury. Whip hoses can cause serious injury.
 Always check for damaged, frayed or
 loose hoses and fittings, and
replace immediately. Do not use quick
detach couplings at tool. See instructions
for correct set-up.
•Air powered tools can vibrate in
 use. Vibration, repetitive motions
or uncomfortable positions over
 extended periods of time may be
harmful to your hands and arms.
 Discontinue use of tool if discomfort,
tingling feeling or pain occurs. Seek
medical advice before resuming use.
• Place the tool on the work before
starting the tool. Do not point or indulge
in any horseplay with this tool.
• Slipping, tripping and/or falling while
operating air tools can be a major cause
of serious injury or death. Be aware of
 excesshoseleftonthewalkingorwork
surface.
• Keepbodyworkingstancebalancedand
firm. Do not overreach when operating
the tool.
• Anticipate and be alert for sudden
changes in motion during start up and
operation of any power tool.
• Donotcarrytoolbythehose.Protectthe
hose from sharp objects and heat.
• Toolshaftmaycontinuetorotatebriefly
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 rotating 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.
• Drill bits can bind suddenly and cause
 rotation of the work piece or tool,
causing injury to arms and/or shoulders.
Enough torque is generated to cause
falls. Always use sharp bits. Use less
downward pressure at breakthrough.
• Do not lubricate tools with flammable
 or volatile liquids such as kerosene,
diesel or jet fuel.
• Do not force tool beyond its rated
capacity.
• Do not remove any labels. Replace any
damaged labels.

CAT255HDA 3 04/13/09
AIR SUPPLY
Tools of this class operate on a wide range of air
pressures. It is recommended that air pressure of these
tools measures 90 PSI at the tool while running free.
Higher pressure (over 90 psig; 6.2 bar) raises performance
beyond the rated capacity of the tool which will shorten
tool life because of faster wear 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 the air tank daily. Clean the air inlet filter screen
on at least a weekly schedule. The recommended hook-
up procedure can be viewed in the above figure.
The air inlet (Figure 2) 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.
LUbRIcATION & mAINTENANcE
Lubricate the air motor daily with quality air tool oil.
Ifnoairlineoilerisused,run1/2ounceofairtool
oil through the tool by squirting oil into the tool air
inletorintothenearestconnectiontotheairinlet,
reconnectingairsupply,andthenrunningthetool.
Donotusemorethen1/2ounceofoil,asoverfilling
will reduce the performance of the tool.
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. If outside
conditionsareinorder,andthetoolstillperforms
erratically,disconnecttoolfromhoseandtaketoolto
your nearest Cornwell authorized service center.
OPERATION
Locate center of new hole by using a center punch.
Place drill bit tip in punch mark. Hold drill square with
workandstartmotor.Applysteady,evenpressure.Do
not force. Too much pressure can cause bit to break or
overheat. Too little pressure will keep bit from cutting
and cause it to overheat. Reduce pressure just before
bit cuts through the work. When bit has penetrated
workandisspinningfreely,takeitfromtheworkwhile
themotorisrunning,thenturnoffdrill.Ifthedrill
jamsinthework,releasethrottleimmediately.
Disconnect the drill before removing bit and determining
cause of trouble. Do not attempt to free the bit by
starting and stopping the motor.
WARRANTY
Cornwell warrants its air tools for a period of 1 year to the consumer. We will repair any air tool covered under this
warranty which proves to be defective in material or workmanship during the warranty period. 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 purchase and a brief description of the problem. 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 prepaid.
This warranty gives you specific rights. You may also have other rights which vary from state to state.
The foregoing obligation is Cornwell’s sole liability under this or any implied warranty and under no circumstances shall
Cornwell be liable for any incidental or consequential damages.
Note: Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitationorexclusionmaynotapplytoyou.
Figure 2
Figure 1
Air Inlet

CAT255HDA 4 04/13/09
PARTS bREAKDOWN - cAT-255HDA
Ref. # Item # DESCRIPTION QTY.
1 RS255HD01 Motor Housing (Incl. #44) 1
2 RS43009 Pin 1
3 RS79503 Air Inlet 1
4 RS79404N Trigger 1
5 RS79405N Valve Stem Set 1
6 RS79406N Reverse Bushing 1
7 RS79438N Set Screw 1
8 RS79408N Valve Spring 1
9 RS79409N O-Ring 1
10 RS79410N Reverse Lever 1
11 RS79411N Motor Gasket 1
12 RS79412N Reverse Retainer 1
13 RS21114 Ball Bearing 2
14 RS79414N Rear End Plate 2
15 RS79415N Rotor 1
16 RS78716 Rotor Blades 5
17 RS79417N Spring Pin 2
18 RS79418N Cylinder 1
19 RS79419N Front End Plate 1
20 RS78620 Spacer 1
21 RS78621 Washer 1
22 RS79422N Internal Gear 1
Ref. # Item # DESCRIPTION QTY.
23 RS78823 Planet Gear with bushing 3
24 Pin (incl. w/#26 & 27) 6
25 Bushing (incl. w/#23) 3
26 RS25526 Work Spindle with pins 1
27 RS78627 Reduction Spindle with pins 1
28 RS221RA32 Ball Bearing 2
30 RS79430N Screw 1
31 RS43007 Tapping Screw 2
32 RS76232 Exhaust Diffuser 1
33 RS182729A Chuck Spacer 1
34 RS29120 Ball Bearing 1
35 RS25535A 1/2" Keyless Chuck 1
36 RS25536A Clamp Nut 1
37 RS79431N O-Ring 1
39 RS78639 Retainer 1
40 RS25540A Handle 1
41 RS78641 Planet Gear 3
42 RS78642 Internal Gear 1
43 RS78643 Set Screw 1
44 RS25553 Rubber Grip 1
45 RS82250 Damping Diffuser 1