Cornwell Tools CAT-255HD User manual

CAT-255HD 1 Rev. 09/01/05
Operating Instructions • Warning Information • Parts Breakdown
CAT-255HD
1/2" Heavy Duty
Reversible Air Drill
with “Hand TITE” H.D.
Keyless Chuck
Free Speed . . . . . . . . . . . . . . . . . . . . . . 400 rpm
Maximum Capacity . . . . . . . . . . . . . . . . . . 1/2"
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . 1/4" NPT
Hose Size . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8"
Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 90 psi
Air Consumption . . . . . . . . . . . . . . . . . . . 4 cfm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . .8 1/2"
Shipping Weight . . . . . . . . . . . . . . . . . . . 4 lbs.
SPECIFICATIONS
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.
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
Copyright © Professional Tool Products, 2005
All rights reserved.
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CAT-255HD 2 Rev. 09/01/05
WARNING - FOLLOW THESE RULES FOR SAFE OPERATION!
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 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 fittings, 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. 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.
• Drill bits can bind suddenly and cause
rotation of the work piece or tool, causing
injury to arms and/or shoulders. Enough
torque is generated to cause falls. Always
use sharp bits. Use less downward pressure
at breakthrough.
• 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.
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CAT-255HD 3 Rev. 09/01/05
Nipple
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 (Figure 2) 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.
LUBRICATION & MAINTENANCE
Lubricate the air motor daily with quality air tool oil.
If no air line oiler is used, run a teaspoon 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. The amount of oil to be used is 1 ounce. Overfilling
will cause a reduction in the power of the tool.
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. If outside conditions are in order,
and the tool still performs erratically, disconnect tool from
hose and take tool to your nearest Cornwell authorized
service center.
OPERATION
Locate center of new hole by using a center punch. Place
drill bit tip in punch mark. Hold drill square with work and
start motor. Apply steady, even pressure. Do not force.
Too much pressure can cause bit to break or overheat.
Too little pressure will keep bit from cutting and cause it
to overheat. Reduce pressure just before bit cuts through
the work. When bit has penetrated work and is spinning
freely, take it from the work while the motor is running,
then turn off drill. If the drill jams in the work, release
throttle immediately. Disconnect the drill before removing
bit and determining cause of trouble. Do not attempt to
free the bit by starting and stopping the motor.
WARRANTY
Cornwell warrants its air tools for a period of 1 year 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 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’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.
Figure 2
Figure 1
Air Inlet
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CAT-255HD 4 Rev. 09/01/05
PARTS BREAKDOWN - CAT-255HD
Ref. # Item # DESCRIPTION QTY.
1 RS255HD01 Motor Housing (Incl. #44) 1
2 RS43009 Pin 1
3 RS79503 Air Inlet 1
4 RS79404N Trigger 1
5 RS79405N Valve Stem Set 1
6 RS79406N Reverse Bushing 1
7 RS79438N Set Screw 1
8 RS79408N Valve Spring 1
9 RS79409N O-Ring 1
10 RS79410N Reverse Lever 1
11 RS79511 Motor Gasket 1
12 RS79412N Reverse Retainer 1
13 RS21114 Ball Bearing 2
14 RS79514 Rear End Plate 2
15 RS79415N Rotor 1
16 RS25516 Rotor Blades 5
17 RS78717 Pin 1
18 RS78718 Cylinder 1
19 RS79519 Front End Plate 1
20 RS78620 Spacer 1
21 RS78621 Washer 1
22 RS79522 Internal Gear 1
Ref. # Item # DESCRIPTION QTY.
23 RS79523 Planet Gear with bushing 3
24 Pin (incl. w/#26 & 27) 6
25 Bushing (incl. w/#23) 3
26 RS78626 Work Spindle with pins 1
27 RS78627 Reduction Spindle with pins 1
28 RS21118 Ball Bearing 2
30 RS78630 Chuck Screw 1
31 RS43007 Tapping Screw 2
32 RS76232 Exhaust Diffuser 1
33 RS79429N Chuck Spacer 1
34 RS29120 Ball Bearing 1
35 RS25535 1/2" Keyless Chuck 1
36 RS25536 Clamp Nut 1
37 RS79431N O-Ring 1
39 RS78639 Retainer 1
40 RS79440N Handle 1
41 RS78641 Planet Gear 3
42 RS78642 Internal Gear 1
43 RS25543 Set Screw 1
44 RS25539 Rubber Grip 1
45 RS82250 Damping Diffuser 1
36
40
39
30 33
35
42
43
2828
34
21 20 27
26 24 25 22
24 23
41
13
1114
1516
14
19 13
37
5
69
12
108
1
7
4
2
31
3
32
44
45
18
17
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