Cornwell Tools CAT2125 User manual

1CAT2125 Rev. 09/10/09
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.
Breakaway Torque ...............................500 Ft./Lbs.
Working Torque Range...................25-350 Ft./Lbs.
Maximum Applied Torque:................. 370 Ft./Lbs.
Free Speed: ......................................... 11,500 RPM
Avg. Air Consumption:.............................. 4.5 cfm
Overall Length:............................................ 5-3/4"
Weight: ........................................................ 2.4 lbs.
Air Inlet (NPT):................................................. 1/4"
Recommended Hose Size:............................... 3/8"
Sound Level: .............................................93.5 dBA
SPECIFICATIONS
CAT2125
Super Duty 3/8" Dr.
Composite Impact
Wrench
Copyright © Professional Tool Products, 2009
All rights reserved
RATED RPM OF THE ACCESSORY
USED MUST EXCEED THE MAXIMUM
TOOL RPM SHOWN
ALWAYS READ
INSTRUCTIONS BEFORE
USING POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID PROLONGED
EXPOSURE TO
VIBRATION

2CAT2125 Rev. 09/10/09
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efcient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 ttings, 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
rm. 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 brief-
ly 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. Se-
cure 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specic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ammable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.

3CAT2125 Rev. 09/10/09
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 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lterscreenonatleast
a weekly schedule. The recommended hookup
procedurecanbeviewedintheabovegure.
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ttingsshouldhavethe
same inside dimensions and be tightly secured.
LUBRICATION
Lubricate the tool daily with quality air tool oil. If no air
line oiler is used, run a half 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.Overllingwillcauseareductioninthepowerof
the tool. A rust inhibitive oil is acceptable for air tools.
WARRANTY
Cornwell warrants its air tools for a period of 1 year to the consumer. We will repair any CAT2125 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 in-
clude 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specic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 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
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valvetolowposition,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 tightness - note valve
setting for future use. When tightening nuts not requiring
criticaltorquevalues,runnutupush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" SAE 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ve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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 connection absorbs energy
and reduces power.

4CAT2125 Rev. 09/10/09
PARTS BREAKDOWN - CAT2125
ITEM PARTS NO PARTS NAME QTY
101 RS2125101 HAMMER CASE 1
102 RS1081103 HAMMER CASE BUSHING 1
103 RS1734201 SOCKETRETAINER 1
104 RS1734202 O - RING 1
105 RS1081106 ANVIL 1
106 RS1081109 HAMMER FRAME 1
107 RS1081108 HAMMER 2
108 RS1081107 HAMMER FRAME PIN 2
109 RS2125109 PACKING 1
110 RS1837220 HAMMER CASE GREASE FITTING 1
201 RS2125201 HOUSING 1
202 RS2125202 HANDLE GRIP 1
203 RS2125203 HALF ROUND HD.HEX.BOLT 4
204 RS2125204 HEX.SOC.HD.BOLT 1
301 RS227B25 BEARING 1
302 RS2125302 FRONT BEARING PLATE 1
303 RS2125303 SPRING PIN 1
304 RS2125304 ROTOR 1
305 RS1081305 BLADES 7
306 RS2125306 CYLINDER UNIT 1
307 RS30524 BEARING 1
308 RS2125308 O - RING 1
309 RS2125309 WASHER 1
ITEM PARTS NO PARTS NAME QTY
310 RS2125310 PACKING-CYLINDER 1
401 RS2125401 TRIGGER-A 1
402 RS2125402 SPRING PIN 1
403 RS1077403 TRIGGER BUSHING 1
404 RS1077404 SPRING 1
405 RS2125405 REGULATOR A 1
406 RS4135407 LEVER 1
407 RS2125407 REVERSE VALVE 1
408 RS1735313 BALL 2
409 RS1077410 SPRING 1
410 RS1734414 O - RING 1
411 RS2125411 REGULATOR 1
412 RS2125412 SPRING 1
413 RS1837309 SPRING PIN 1
414 RS1734405 O - RING 1
415 RS2125415 O - RING 1
416 RS2125416 TRIGGER TIP 1
417 RS1735410 O - RING 2
418 RS2125418 AIR INLET 1
419 RS1735412 SPRING PIN 1
421 RS1735408 EXHAUST DEFLECTOR 1
422 RS1735411 TAP BOLT 1
423 RS2125423 TRIGGER B 1