Cornwell Tools CAT4000SDR User manual

CAT4000SDR Rev. 11/10/15
CAT4000SDR
1/4" Mini
Air Ratchet
(High Torque)
Operating Instructions • Warning Information
• Parts Breakdown
Maximum Torque .......................42 ft.-lbs.
Free Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 RPM
Overall Length............................7.36"
Average Air Consumption ..................3.5 CFM
Air Inlet ........................... 1/4"-18 NPT
Recommended Hose Size ..................3/8" I.D.
Recommended Air Pressure ................ 90 psig
Sound Pressure Level......................95 dbA
Vibration Level .......................4.23m/sec²
Weight .............................. 1.34 lbs.
SPECIFICATIONS
Copyright © Professional Tool Products, 2015
All rights reserved
AVOID PROLONGED EXPOSURE TO VIBRATION
ALWAYS WEAR HEARING PROTECTION
ALWAYS WEAR SAFETY GOGGLES
ALWAYS READ INSTRUCTIONS BEFORE
USING POWER TOOLS
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.
WARNING

CAT4000SDR 2 Rev. 11/10/15
FAILURE TO OBSERVE THESE WARNINGS COULD RE SULT IN IN JU RY.
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.
• Alwaysoperate,inspectandmaintainthistoolin
 accordancewithAmericanNationalStandards
 InstituteSafetyCodeofPortableAirTools(ANSI
 B186.1)andanyotherapplicablesafetycodes
 andregulations.
• Forsafety,topperformanceandmaximumdurability
 ofparts,operatethistoolat90psig:6.2barmaxair
 pressurewith3/8"diameterairsupplyhose.
• Alwayswearimpact-resistanteyeprotectionwhen
 operatingorperformingmaintenanceonthistool
 (usersandbystanders).
• Alwayswearhearingprotectionwhenusingthistool
 (usersandbystanders).Highsoundlevelscancause
 permanenthearingloss.Usehearingprotectionas
 recommendedbyyouremployerorOSHAregulation.
• Keepthetoolinefficientoperatingcondition.
• Operatorsandmaintenancepersonnelmustbe
 physicallyabletohandlethebulk,weightand
 powerofthistool.
• Keeptooloutofreachofchildren.
• Airunderpressurecancausesevereinjury.Never
 directairatyourselforothers.Alwaysturnoffthe
 airsupply,drainhoseofairpressureanddetach
 toolfromairsupplybeforeinstalling,removingor
 adjustinganyaccessoryonthistool,orbefore
 performinganymaintenanceonthistool.Failure
 todosocouldresultininjury.Whiphosescancause
 seriousinjury.Alwayscheckfordamaged,frayedor
 loosehosesandfittings,andreplaceimmediately.
 Donotusequickdetachcouplingsattool.See
 instructionsforcorrectset-uponpage4.
• Airpoweredtoolscanvibrateduringuse.Vibration,
 repetitivemotionsoruncomfortablepositionsover
 extendedperiodsoftimemaybeharmfultoyour
 handsandarms.Discontinueuseoftoolifdiscomfort, 
 tinglingfeelingorpainoccurs.Seekmedicaladvice
 beforeresuming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.
• Slipping,trippingand/orfallingwhileoperatingairtools
 canbeamajorcauseofseriousinjuryordeath.Beaware
 ofexcesshoseleftonthewalkingorworksurface.
• Keepbodyworkingstancebalancedandfirm.Donot
 overreachwhenoperatingthetool.
• Anticipateandbealertforsuddenchangesinmotion
 duringstartupandoperationofanypowertool.
• Donotcarrytoolbythehose.Protectthehose
 fromsharpobjects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lubricatetoolswithflammableorvolatile
 liquidssuchaskerosene,dieselorjetfuel.
• Thistoolisnotinsulatedagainstelectricshock.
• Thistoolmustnotbeusedinexplosiveatmospheres.
• Donotforcetoolbeyonditsrated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.Replaceanydamagedlabels.
• 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

CAT4000SDR 3 Rev. 11/10/15
PARTS BREAKDOWN - CAT4000SDR
REF. # ITEM # DESCRIPTION QTY.
1 RS4000SDR01 Housing with bushing 1
2 RS4000SDR02 Throttle Lever 1
3 RS848002 Roll Pin (3x22) 1
4 RS305A04 O-Ring (3.5x1.5) 1
5 RS305A05 O-Ring (4.5x1.7) 1
6 RS305A06 Throttle Pin 1
7 RS305A07 Spring 1
8 RS305A08 Air Regulator 1
9 RS305A09 O-Ring (6x2) 2
10 RS305A10 O-Ring (12x2) 1
11 RS250ARR11 Valve Plug 1
12 RS250ARR12 Air Inlet 1
13 RS32237 Muffler 1
14 RS4000SDR14 Comfort Grip 1
15 RS30516 Ball Bearing (696ZZ) 1
16 RS26215 Rear End Plate (including #17) 1
17 RS26216 Steel Ball (3/32") 3
18 RS281418 Cylinder 1
19 RS305A19 Rotor Blade 4
20 RS281420 Rotor 1
21 RS26220 Front End Plate (including #17) 1
22 RS30524 Ball Bearing (608ZZ) 1
23 RS700572 Ball Bearing (6901ZZ) 2
REF. # ITEM # DESCRIPTION QTY.
24 RS281424A Planet Gear 3
25 RS281425 Pin 3
26 RS281426 Planetary Gear 1
27 RS281427 Internal Gear 1
28 RS281428 Needle Bearing 1
29 RS281429 Ratchet Housing 1
30 RS281430 Drive Bushing 1
31 RS250ARR31 Ratchet Yoke 1
32 * Washer 1
33 * Reverse Button 1
34 * Ratchet Anvil (1/4") 1
35 * Pin 1
36 * Spring 1
37 * Lock Pin 1
38 * Ratchet Pawl 1
39 * Washer 1
40 * Wave Washer 2
41 * Thrust Washer 1
42 * Retaining Ring 1
43 RS4000SDR43 Clamp Nut 1
RS4000SDRPLK Product Label Kit (not shown) 1
* Head Kit, CAT4000SDRRHK (includes #32 thru #42)
2
3
4
5
6
7
8
9
10
11
9
13
12
1
14
15
16
18
17 19
17
17
20
21
23
24 25
26
27
23
28
29
43
42
41
40
39
38
37
36
35
34
33
32
30
31
22

CAT4000SDR 4 Rev. 11/10/15
Operating Instructions • Warning Information • Parts Breakdown
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AuthorizedWarrantyCenter,freightprepaid.Pleaseincludeacopyofyourproofofpurchaseandabriefdescription
oftheproblem.Thetoolwillbeinspectedandifanypartorpartsarefoundtobedefectiveinmaterialorworkmanship,theywillberepairedfreeofcharge,andtherepairedtoolwill
bereturnedtoyoufreightprepaid.
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.
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
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 fasteners as they
absorbmuchoftheimpactpower.Whenpossible,clamporwedge
thebolttopreventspringback.
Theforward/reversingbuttonisusedtochangethedirectionofthe
tool.Whenthebuttonissettotheright,thetoolwillturninaright
handdirection.Whenthebuttonissettotheleft,thetoolwillturn
inalefthanddirection.
NOTE: 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.
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conditionabsorbsenergyandreducespower.
NOTE: During operation, safety goggles must always be worn
to guard against flying rust and chips (users and bystanders).
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