Cornwell Tools CAT-400 User manual

1CAT-400 Rev. 12/22/04
Operating Instructions • Warning Information • Parts Breakdown
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.
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
Max Torque in 10 seconds: ...................500 ft./lbs.
Torque Range in 5 seconds: .........50 - 400 ft. / lbs.
RPM: ............................................................... 7,700
Overall Length: ............................................. 7-1/2"
Avg. Air Consumption: ............................... 4.6 cfm
dBA: .................................................................. 97.3
Net Weight: ...............................................4.11 lbs.
Air Inlet: ........................................................... 1/4"
Hose Size: ......................................................... 3/8"
SPECIFICATIONS
CAT-400
1/2" Dr. Super
Duty Composite
Impact Wrench
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2CAT-400 Rev. 12/22/04
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.
THIS INSTRUCTION MANUAL CONTAINS
IMPORTANT SAFETY INFORMATION.
READ THIS INSTRUCTION MANUAL CAREFULLY
AND UNDERSTAND ALL INFORMATION
BEFORE OPERATING THIS TOOL.
• Always operate, inspect and maintain
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 performance and maximum
durability 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
protection when operating or performing
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
condition.
• 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
correct set-up.
• Air powered tools can vibrate in
use. Vibration, repetitive motions or
uncomfortable positions over extended
periods of time may be harmful to your
hands and arms. Discontinue use of tool if
discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming use.
• Place the tool on the work before starting
the tool.
• Slipping, tripping and/or falling while op-
erating air tools can be a major cause of
serious injury or death. Be aware of excess
hose left on the walking or work surface.
• Keep body working stance balanced and
firm. Do not overreach when operating
the tool.
• Anticipate and be alert for sudden chang-
es in motion during start up and opera-
tion 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 af-
ter use. Gloves will reduce the risk of cuts
or burns.
• 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 re-
quirements must be checked with suitable
torque measuring devices after installa-
tion with an impact wrench.
• Use only impact wrench sockets and ac-
cessories on this tool. Do not use hand
sockets and accessories.
• Do not lubricate tools with flammable or
volatile liquids such as kerosene, diesel or
jet fuel.
• Do not force tool beyond its rated capacity.
• Do not remove any labels. Replace any
damaged labels.
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3CAT-400 Rev. 12/22/04
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PARTS BREAKDOWN - CAT-400
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4CAT-400 Rev. 12/22/04
Operating Instructions • Warning Information • Parts Breakdown
AIR SUPPLY
Tools of this class operate on a wide range of air pressures.
It is recommended that air pressure of these tools mea-
sures 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 wa-
ter 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 teaspoon 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. The amount of oil to be used is 1 ounce.
Overfilling will cause a reduction in the power of the tool.
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 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.
OPERATION
The air regulator can be used to adjust torque to the ap-
proximate tightness 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 air regulator to low position, apply wrench
to nut and gradually increase power (turn regulator to ad-
mit more air) until nut moves slightly in the direction it was
originally set. The tool is now set to duplicate that tight-
ness - note regulator setting for future use. When tighten-
ing 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 disas-
sembly work, turn regulator 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 reversing 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 hardness, tool speed, condition of socket and the time
the tool is allowed to impact.
Use the simplest possible tool-to-socket hook up. Every con-
nection absorbs energy and reduces power.
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