Cornwell Tools CAT-2115M User manual

CAT2115M 1 Rev. 07/19/07
Operating Instructions • Warning Information
• Parts Breakdown
CAT-2115M
3/8" Dr.
Super Duty
Impact Wrench
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
Some dust created by power sanding, sawing, grinding, drilling, and other con-
struction 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.
Working Torque:. . . . . . . . . . . . . . . . . . . . .20-260 ft.lbs.
Maximum Torque: . . . . . . . . . . . . . . . . . . . . . 300 ft.lbs.
Blowsperminute .........................1,400
FreeSpeed: .........................12,500rpm
Recommended Air Pressure: . . . . . . . . . . . . . . . .90 psi
AirInlet:..............................1/4"NPT
Minimum Hose Size: . . . . . . . . . . . . . . . . . . . . .3/8" I.D.
OverallLength...............................6"
Weight ................................2.65lbs.
SPECIFICATIONS

CAT2115M 2 Rev. 07/19/07
THIS INSTRUCTION MANUAL CONTAINS
IMPORTANT SAFETY INFORMATION.
READ THIS INSTRUCTION MANUAL CAREFULLY AND
UNDERSTAND ALL INFORMATION
BEFOREOPERATING THIS TOOL.
• Always operate,inspect and maintain
this tool in accordance withAmerican
National Standards Institute Safety Code of
Portable AirTools (ANSI B186.1) and any other
applicable safety codes and regulations.
• For safety, top performance and maximum dura-
bility of parts,operate this tool at 90 psig: 6.2 bar
max air pressure with 3/8" diameter air supply
hose.
• Always wear impact-resistant eye and face pro-
tection whenoperatingorperforming maintenance
on this tool.Always wear hearing protection
when using this tool.
• High sound levels can cause permanent hearing
loss.Use hearing protection as recommended by
your employer or OSHA regulation.
• Keep the tool in efficient operating condi-
tion.
• Operators and maintenance personnel must be
physically able to handle the bulk,weight and
power of this tool.
• Air under pressure can cause severe injury.
Never direct air at yourself or others.
Always turn off the air supply, drain hose of air
pressure and detach tool from air supply before
installing,removing or adjusting any accessory 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.Always
check for damaged, frayed or loose hoses and
fittings,and replace immediately.Do not use quick
detach couplings at tool. See instructions for cor-
rect set-up.
• Air powered tools can vibrate during
use. Vibration, repetitive motions or
uncomfortable positions over extended peri-
ods of time may be harmful to your hands and
arms.Discontinue use of tool if discomfort, tin-
gling feeling or pain occurs.Seek medicaladvice
before resuming use.
• Place the tool on the work before starting the
tool.
• Slipping, tripping and/or falling while oper-
ating air tools can be a major cause of serious
injury or death.Be aware of excess hoselefton
thewalkingorworksurface.
• Keep body working stance balanced
and firm.Do notoverreachwhenoperating the tool.
• Anticipate and be alert for sudden
changes in motion during start up and oper-
ation of any power tool.
• Do not carry tool by the hose.Protect the hose
from sharp objects 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 orburns.
• 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.
• Impact wrenches are not torque control
devices. Fasteners with specific torque
requirements must be checked with suitable
torque measuring devices after installation with
an impact wrench.
• Use only impact sockets and accessories
on this tool. Do not use hand sockets and
accessories.
• Do not lubricate tools with flammable or volatile liq-
uids such as kerosene, diesel or jet fuel.
• Do not force tool beyond its rated capacity.
• Do not remove any labels. Replace any
damaged labels.
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.

CAT2115M 3 Rev. 07/19/07
Item # Ref. # DESCRIPTION QTY
1 RS211501 AIR INLET 1
2 RS211502 DOWEL PIN 1
3 RS211503 O-RING 1
4 RS211504 O-RING 1
5 RS211505 DEFLECTOR 1
6 RS211506 SPRING 1
7 RS211507 VALVE STEM 1
8 RS211508 VALVE SEAT 1
9 RS211509 WASHER 1
10 RS211510 RETAINER RING 1
11 RS211511 SPRING PIN 1
12 RS211512 SPRING PIN 1
13 RS211513 O-RING 1
14 RS211514 TRIGGER 1
15 RS211515B FORWARD & REVERSE VALVE 1
16 RS211516 SPRING 1
17 RS211517 STEEL BALL 1
18 RS211518 BOLT 4
19 RS211519 END COVER 1
20 *RS211520 GASKET 1
21 RS211521 O-RING 1
22 RS211522 O-RING 1
23 RS211523 VALVE BODY 1
Item # Ref. # DESCRIPTION QTY
24 RS211524 LOCK WASHER 1
25 RS211525 SCREW 1
26 RS211526 O-RING 2
27 RS211527 CONNECTING PIPE 1
28 RS211528B COMPOSITE MOTOR HOUSING 1
29 RS351HD17 BALL BEARING 1
30 RS211530 END PLATE 1
31 RS211531 GUIDE PIN 1
32 RS351HD20 BLADE 6
33 RS351HD19 ROTOR 1
34 RS211534 CYLINDER 1
35 RS211535 FRONT PLATE 1
36 RS227B25 BALL BEARING 1
37 RS211537 GASKET 1
38 RS351HD25 HAMMER 2
39 RS351HD26 HAMMER CAGE 1
40 RS351HD27 HAMMER PIN 2
41 RS351HD28 ANVIL 1
42 RS351HD29 O-RING 2
43 RS351HD30 SOCKET RETAINER 1
44 RS211544 BUSHING 1
45 RS211545 HAMMER CASE - MAGNESIUM 1
46 RS211546 SPRING PIN 1
47 RS211547 SOFT GRIP 1
PARTS BREAKDOWN - CAT-2115M
30
13
14
10
11
46 12 6
8
7
92
28
45
39
40
29
40
38
38
37
44
42
43
41
18
1
21
22
25 27
26
23
24
4
26 3
5
20
36
35
34
19
42
17
16
33 15
47
32
31
*Replace item # RS211520 gasket each time the tool is taken apart.

CAT2115M 4 Rev. 07/19/07
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 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.
LUBRICATION
Lubricate the air motor daily with quality air tool oil. If
no air line oiler is used, run a 1/2 ounce of oil through the tool.
The oil can be squirted into the tool air inlet or into the hose at the
nearest connection to the air supply, then run the tool. Overfilling
will cause a reduction in the power of the tool.
OPERATION
The forward and reverse valve can be used as an air throttle, if
there are no other means of regulating air. Turn the valve knob all
the way to position 4 for maximum power.
The valve can be used to adjust torque to the approximate tight-
ness of a known fastener.To set the tool to desired torque, select
a nut or screw of known tightness of the same size, thread pitch
and thread condition as those on the job. Turn valve to low posi-
tion, apply wrench to nut and gradually increase power (turn
valve to admit more air) until nut moves slightly in the direction
it was originally set. The tool is now set to duplicate that tight-
ness - note valve setting for future use. When tightening nuts not
requiring critical torque values, run nut up flush and then tighten
an additional one-quarter to one-half turn (slight additional turning
is necessary if gaskets are being clamped). For additional power
needed on disassembly work, turn valve to its fully open position.
This impact wrench is rated at 3/8" USS bolt size. Rating must be
down graded for spring U bolts, tie bolts, long cap screws, double
depth nuts, badly rusted conditions and spring fasteners as they
absorb much of the impact power. When possible, clamp or wedge
the bolt to prevent springback.
Soak rusted nuts in penetrating oil and break rust seal before
removing with impact wrench. If nut does not start to move in
three to five seconds, use a larger size impact wrench. Do not
use impact wrench beyond rated capacity as this will drastically
reduce tool life.
The forward and reverse valve is used to change the rotation of
the tool. When the valve is out, the tool is in a forward or right
hand rotation. When the valve is pushed in, the rotation is reverse
or left hand.
NOTE: Actual torque on a fastener is directly related to joint hard-
ness, tool speed, condition of socket and the time the tool is
allowed to impact. Use the simplest possible tool-to-socket hook
up. Every connection absorbs energy and reduces power.
Operating Instructions • Warning Information • Parts Breakdown
Nipple
WARRANTY
Cornwell warrants its air tools for a period of 2 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 Authorized Warranty Center, freight prepaid. 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 defective in material or workmanship, they will be repaired free of charge and the repaired tool will be
returned 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 damages, so the above
limitation or exclusion may not apply to you.