Cornwell Tools CAT4135 User manual

1CAT4135 Rev. 06/26/09
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: .......................... 1,100 Ft./Lbs.
Maximum Torque: ............................... 800 Ft./Lbs.
Working Torque Range:............... 50 - 550 Ft./Lbs.
Free Speed: ........................................... 7,500 RPM
Avg. Air Consumption:.............................. 4.9 cfm
Overall Length:............................................ 6-7/8"
Weight: .......................................................... 4 lbs.
Sound Level: ............................................ 97.3 dBA
Air Inlet (NPT):................................................. 1/4"
Recommended Hose Size:............................... 3/8"
SPECIFICATIONS
CAT4135
Super Duty 1/2" 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

2CAT4135 Rev. 06/26/09
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.

3CAT4135 Rev. 06/26/09
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 CAT4135 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airregulator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airregulatortolowposition,
apply wrench to nut and gradually increase power (turn
regulator 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 regulator 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 regulator to its
fully open position. This impact wrench is rated at 1/2" 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 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
connection absorbs energy and reduces power.

4CAT4135 Rev. 06/26/09
PARTS BREAKDOWN - CAT-4135
ITEM PARTS NO PARTS NAME QTY ITEM PARTS NO PARTS NAME QTY
101 RS4135101 HAMMERCASE 1 310 RS2125310 PACKING-CYLINDER 1
102 RS1761103 HAMMER CASE BUSHING 1 401 RS2125401 TRIGGER-A 1
103 RS1761104 SOCKETRETAINER 1 402 RS2125423 TRIGGERB 1
104 RS4135104 O - RING 1 403 RS2125402 SPRING PIN 1
105 RS1761106 ANVIL 1 404 RS1077403 TRIGGER BUSHING 1
106 RS1761109 HAMMER FRAME 1 405 RS1077404 SPRING 1
107 RS1761108 HAMMER 2 406 RS2125405 REGULATOR A 1
108 RS1761107 HAMMER FRAME PIN 2 407 RS4135407 LEVER 1
110 RS4135110 PACKING-HAMMERCASE 1 408 RS2125407 REVERSEVALVE 1
111 RS1837220 HAMMER CASE GREASE FITTING 1 409 RS1735313 BALL 2
112 RS4135112 SPRING PIN 1 410 RS1077410 SPRING 1
201 RS4135201 HOUSING 1 411 RS2125415 O - RING 1
202 RS2125202 HANDLE GRIP 1 412 RS1734414 O - RING 1
203 RS4135203 HALF ROUND HD.HEX.BOLT 4 413 RS2125411 REGULATOR 1
204 RS2125204 HEX.SOC.HD.BOLT 1 414 RS2125412 SPRING 1
301 RS221RA32 BEARING 1 415 RS4135415 SPRING PIN 1
302 RS4135302 FRONT BEARING PLATE 1 416 RS1734405 O - RING 1
303 RS4135303 BOLT ASSY 3 417 RS2125416 TRIGGER TIP 1
304 RS4135304 BLADE 7 418 RS1735410 O - RING 2
305 RS4135305 ROTOR 1 419 RS2125418 AIR INLET 1
306 RS4135306 CYLINDER UNIT 1 420 RS1735412 SPRING PIN 1
307 RS227B25 BEARING 1 422 RS1735408 EXHAUST DEFLECTOR 1
308 RS4135308 O - RING 1 423 RS1735411 TAP BOLT 1
309 RS4135309 GASKET-CYLINDER 1