Cornwell Tools CAT2500BP User manual

CAT2500BP Rev. 02/22/18
Operating Instructions • Warning Information
• Parts Breakdown
Copyright © Professional Tool Products, 2018.
All rights reserved
CAT2500BP
1/4"Sealed
Head Ratchet
WARNING
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.
Maximum Torque.............................35 ft.-lbs.
Free Speed ..................................220 RPM
Overall Length .................................6-3/4"
Average Air Consumption .......................3.7 CFM
Air Inlet ....................................1/4" NPT
Recommended Hose Size .......................3/8" I.D.
Recommended Air Pressure ......................90 psig
Sound Pressure Level ...........................88 dbA
Weight .......................................1.6 lbs.
SPECIFICATIONS
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
ALWAYS WEAR
HEARING
PROTECTION
AVOID PROLONGED
EXPOSURE TO
VIBRATION
WARNING

CAT2500BP 2 Rev. 02/22/18
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.
• It is the responsibility of the owner to make sure all
personnel read this manual prior to using this air tool.
It is also the responsibility of the air tool owner to keep
this manual intact and in a convenient location for all
to see and read. If the manual or product labels are
lost or not legible, contact Cornwell for replacements.
If the operator is not fluent in English, the product and
safety instructions shall be read to and discussed
with the operator in the operator's native language by
the purchaser/owner or his designee, making sure
that the operator comprehends its contents.
• 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 protection when
operating or performing maintenance on this tool
(users and bystanders).
• Always wear hearing protection when using this tool
(users and bystanders). 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.
• Keep tool out of reach of children.
• 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 on page 4.
• Air powered tools can vibrate during 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.
Do not point or indulge in any horseplay with this tool.
• Note direction of rotation BEFORE operating 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.
• This tool is not insulated against electric shock.
• This tool must not be used in explosive atmospheres.
• Do not force tool beyond its rated capacity.
•Use only impact sockets and accessories on this
tool. Do not use hand sockets or accessories.
• Use accessories recommended by Cornwell Tools.
• Do not use (or modify) the tool for any other
purpose than that for which it was designed
without consulting the manufacturer's authorized
representative.
• Do not remove any labels. Replace any damaged labels.
• This product may contain one or more chemicals
known to the State of California to cause cancer
and birth defects or other reproductive harm.
Wash hands thoroughly after handling.
WARNING

CAT2500BP 3 Rev. 02/22/18
PARTS BREAKDOWN - CAT2500BP
REF. # ITEM # DESCRIPTION QTY.
101 RS10117 Housing 1
102 RS10118C Handle Grip 1
103 RS10125 Muffler 1
104 RS10126 Deflector 1
105 RS10164 Air Inlet 1
106 RS10165 Regulator 1
107 RS10166 O - Ring 1
108 RS10167 Latch Spring 1
109 RS10175 Regulator 1
110 RS1837103 O - Ring (4 x 2mm) 1
111 RS10176 Valve Stem 1
112 RS10190 Spring Pin 1
113 RS10191 Trigger 1
114 RS7500104 Spring Pin 1
201 RS10192 Ratchet Housing (incl. #202) 1
202 Grease Fitting (incl. w/ #201) 1
203 * Collar 1
204 * Steel Ball (3mm) 3
205 * Thrust Washer Spring 3
206 * Anvil 1
207 * Anvil-Washer 1
208 * In-Concentric Ring 1
209 RS10168 Pin 1
210 RS10169 E - Ring 1
211 RS10170 Counter Sunk Screw 1
REF. # ITEM # DESCRIPTION QTY.
212 RS10171 Lever 1
213 RS10172 Spring 1
214 RS10173 Reverse Valve 1
215 RS10174 C - Ring 1
216 ** Pawl 1
217 ** Pawl A 1
218 ** Spring 1
219 RS10178 Pawl Pins 2
220 RS10179 Yoke 1
221 RS1837213 Drive Bushing 1
222 RS10180 Moter Shaft Balancer 1
223 RS10181 Connecting Collar 1
224 RS10182 Planet Cage 1
225 RS1837218 Planet Gear 3
226 RS10183 Internal Gear 1
227 RS10184 Lock Ring Key 1
301 RS222307 Bearing 1
302 RS10185 Front Bearing Plate 1
303 RS10186 Rotor Blades (4 Pack) 1
304 RS10187 Rotor 1
305 RS10188 Cylinder 1
306 RS1734413 Spring Pin 1
307 RS10189 Rear End Plate 1
308 RS2638309 Bearing 1
RSCAT2500BPWL Warning Label (not shown) 1
* RS10195 - Anvil Assembly (includes #203 to #208). ** RS10198 - Spring and Pawl Assembly (includes #216 to #218).

CAT2500BP 4 Rev. 02/22/18
Operating Instructions • Warning Information • Parts Breakdown
AIR SUPPLY
Tools operate on a wide range of air pressures. It is recommended
that air pressure of these tools measures 90 psig at the tool with
the trigger fully depressed and no load applied to the tool. Higher
pressure (over 90 psig; 6.2 bar) raises performance beyond the
rated capacity of the tool, which will shorten tool life 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 water from air lines
and compressor prior to running tool. Clean the air inlet filter screen
weekly. 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.
Ensure an accessible emergency shut off valve has been installed in
the air supply line and make others aware of its location.
LUBRICATION
Lubricate the air motor daily with high 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. A rust inhibitive oil is
acceptable for air tools.
WARNING: After an air tool has been lubricated, oil will discharge
through the exhaust port during the first few seconds of operation.
The exhaust port must be covered with a towel before applying air
pressure to prevent serious injury.
OPERATION
The CAT2500BP 1/4" ratchet is designed to fasten and unfasten
threaded fasteners while operating under recommended conditions.
Note the directional setting of the reversing lever before depressing
the throttle. Ensure body stance to be in excellent balance and have
full control of the tool before use. Be fully alert as sudden reaction
torques and directional changes may unexpectedly occur. Be aware
that air ratchets are not torque wrenches or pry bars. Joints and
fasteners requiring a specific torque must be checked with a torque
wrench as the final step. Using the air ratchet to tighten or break-
free fasteners, can irreversibly damage its internal mechanism and
will void any remaining warranty.
Always turn off the air supply, drain hose of air pressure
and detach tool from air supply before installing, removing
or adjusting any part or accessory on this tool, or before
performing any maintenance on this tool.
WARNING: Use only impact sockets and accessories on this
tool. Do not use hand sockets and accessories.
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, disconnect tool from
hose and take tool to your nearest authorized service center.
Drain Daily
RegulatorOilerQuick CouplerLeader
Hose
Nipple
Do Not Install
Quick Coupling
Here
Nipple
Filter
Air Supply
Whip Hose
WARRANTY
Cornwell Quality Tools Company (“Cornwell”) warrants this product against defects in material and workmanship for a period of TWO (2) YEARS from the date of original retail purchase.
Subject to the conditions and limitations set forth below, Cornwell will, at its option, either repair or replace any part of the product(s) that proves defective by reason of improper
workmanship or materials.
This warranty does not cover any damage to this product that results from accident, abuse, misuse, natural or personal disaster, or any unauthorized disassembly, repair, or
modification. Repairs, disassembly and modification are only authorized to be made by Cornwell or a Cornwell Authorized Warranty Center.
WARRANTY SERVICE
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.
EXCLUSIONS AND LIMITATIONS
THIS WARRANTY AND THE REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES AND CONDITIONS, WHETHER ORAL OR WRITTEN,
EXPRESS OR IMPLIED. CORNWELL SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING, TO THE EXTENT PERMITTED BY APPLICABLE LAW, ANY WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IF CORNWELL CANNOT LAWFULLY DISCLAIM IMPLIED WARRANTIES UNDER THIS LIMITED WARRANTY, ALL SUCH
IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY.
IN NO EVENT SHALL CORNWELL BE LIABLE TO THE PURCHASER OR TO THE USER OF A CORNWELL PRODUCT FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES BASED
UPON BREACH OF WARRANTY, BREACH OF CONTRACT, NEGLIGENCE, TORT, OR ANY OTHER LEGAL THEORY. SUCH DAMAGES INCLUDE, WITHOUT LIMITATION, EXPENSES, LOST
REVENUES, LOST SAVINGS, LOST PROFITS, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE PURCHASE, USE OR INABILITY TO USE THE CORNWELL
PRODUCT.
Some states do not allow the exclusion or limitation of incidental or consequential damages or exclusions or limitation on the duration of implied warranties or conditions, so the above
limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary by state.
Repair kits and replacement parts are available for many Cornwell products, regardless of whether or not the product is still covered by a warranty plan.