Cornwell Tools AT-4000SD User manual

CAT-4000SD 1 Rev. 07/20/07
CAT-4000SD
1/4" DR.
SUPER DUTY
AIR RATCHET
• Operating Instructions
• Warning Information
• Parts Breakdown
at 90 p.s.i.
FreeSpeed...............................250RPM
Max.Torque.............................35Ft./Lb.
OverallLength ............................8-1/16"
Avg. Air Consumption. . . . . . . . . . . . . . . . . . . . . . . 1.96 cfm
NetWeight...............................1.45lbs.
dBA........................................ 90
SPECIFICATIONS
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 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.

CAT-4000SD 2 Rev. 07/20/07
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 pow-
er 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 instruc-
tions 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 discom-
fort, tingling feeling or pain occurs. Seek medical
advice before resuming use.
• Place the tool on the work before 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 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 changes in motion
during start up and operation 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 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.
• 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.
• Use accessories recommended by Cornwell Tools.

CAT-4000SD 3 Rev. 07/20/07
Ref. Part # Description Qty.
01 RS1401 Air Inlet 1
02 RS1402 Air Inlet O-Ring 1
03 RS1403 Muffler Deflector 1
04 RS1404 Muffler Deflector O-Ring 1
05 RS1405 Motor Housing 1
06 RS1406 Air Regulator 1
07 RS1407 Dowel Pin 2
08 RS1408 Air Regulator O-Ring 1
09 RS1409 Throttle Valve Spring 1
10 RS1410 Throttle Valve Spring Stem 1
11 RS1411 Throttle Valve Spring O-Ring 1
12 RS1412 Throttle Valve Spring O-Ring 1
13 RS1413 Regulating Valve 1
14 RS1414 Regulating Valve O-Ring 3
15 RS30516 Bearing 1
16 RS1416 Rear Plate 1
17 RS1417 Cylinder 1
CAT-4000SD
1/4" DR. SUPER DUTY AIR RATCHET
18 RS1418 Rotor 1
19 RS1419 Rotor Blade 4
20 RS1420 Front Plate 1
21 RS30524 Bearing 1
22 RS1422 Internal Gear 1
23 RS1423
Idler Gear Plate Assembly (INC. #24) 1
24 Idler Gear Pin (INC. w/ #23) 3
25 RS1425 Idler Gear 3
26 RS1426 Clamp Nut 1
27 RS1427 Needle Bearing 1
28 RS1428 Spacer 1
29 RS1429 Internal Gear Spacer 2
30A RS1430A
Ratchet Housing Assembly (INC. 52) 1
31 RS1431 Crank Shaft 1
32 RS1432 Drive Bushing 1
33 RS1433 Ratchet Yoke 1
34 RS1434 Dust Cover 1
35A * Reverse Button Assembly 1
36 * Anvil Upper Washer 1
37 * Spring Pin 1
38 * 1/4" Ratchet Anvil Assembly 1
39 * Spring 1
40 * Steel ball 1
41 * Ratchet Spring 1
42 * Lock Pin 1
43 * Ratchet Pawl 1
44 * Ratchet Pawl Pin 1
45 * Thrust Washer 1
46 * Clamp Washer 1
47 * Retaining Ring 1
48 RS1448 Throttle Lever 1
49 RS1449 Throttle Lever Pin 1
50 RS1450 Housing Cover 1
51 RS1451 Muffler Deflector Ring 1
52 RS1452 Grease Fitting 2
Ref. Part # Description Qty. Ref. Part # Description Qty.
*Available only in head kit, CAT-4000SDK.
50
41
43
42
06
51
H
01
02
CCM
29
04
07
09
08 03
22
49
25
24
16 15
05
48
23
26
11
12
27
14
28
10
13
29
52
52
30A
36
46
38
37
17
19
20 18
& 2
07
35A
44
40
32B 31B
33
34
21
39
47
45

CAT-4000SD 4 Rev. 07/20/07
Nipple
Leader Hose
Whip Hose
Nipple Filter
Air Supply
Regulator
Quick Coupler
Oiler
Drain Daily
Do Not Install
Quick Coupling
Here
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 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.
Operation
This ratchet wrench is rated at 1/4" 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
ratchet wrench. If nut does not start to
move in three to five seconds use an
impact wrench. Do not use impact
wrench beyond rated capacity as this
will drastically reduce tool life.
The forward/reversing button is used to
change the rotation of the tool. When the
button is set to the right, the tool will turn
in a right hand rotation. When the button
is set to the left, the tool will turn in a left
hand rotation.
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.
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. Grit or gum deposits
in the tool may cut power and may be
corrected by cleaning the air strainer
and flushing out the tool with gum solvent
oil or an equal mixture of SAE #10 and
kerosene. If outside conditions are in
order and the tool continues to perform
erratically, disconnect tool from hose
and take tool to your nearest authorized
service center.
Lubrication
Lubricate the air motor daily with quality
air tool oil. If no air line oiler is used, run
1/2 oz. 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. Grease ratchet
housing as needed (2 grease fittings).
Cornwell Tools™ Limited Warranty
Cornwell Tools warrants the CAT-4000SD for a period of 2 years
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 Tools 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 Tools' sole liability under
this or any implied warranty and under no circumstances shall
Cornwell Tools 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.
4