Sealey Cp3004 User manual

1.1. GENERALSAFETY

 Follow all workshop safety rules, regulations and conditions when using the wrench.

 Remove the battery pack from the wrench before servicing or performing any maintenance.

 Maintain the wrench and battery pack in good condition.

Replace or repair damaged parts. Use an authorised service agent and recommended parts only. Unauthorised parts may be dangerous

and will invalidate the warranty.

 Ensure the wrench is in ‘neutral’ before installing the battery pack.



Keep the wrench, battery pack and charger clean for optimum performance.

Keep the work area clean and tidy and free from unrelated materials. Ensure that there is adequate lighting.

 Ensure that battery pack is correctly fitted to the wrench handle and latched in place before operating wrench.

WARNING! When working around vehicle brake systems we recommend that you wear suitable respiratory protection due to

the possible presence of asbestos dust from brake linings.

Use only impact sockets which are specifically designed for use with an impact wrench.

 Avoid unintentional starting.

 Wear approved safety eye/face shield, ear defenders and hand protection.

Remove ill-fitting clothing. Remove ties, watches, rings and other loose jewellery and contain long hair.

 Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.

Keep children and unauthorised persons away from the work area.

 DO NOT operate the wrench if any parts are missing as this may cause failure and/or personal injury.

 DO NOT use the wrench unless you have been instructed in its use by a qualified person.

 DO NOT operate the wrench where there are solvent fumes or flammable gases, liquids or solids.

 DO NOT leave the wrench operating unattended.

 DO NOT carry wrench with your finger on the trigger. Keep direction switch in ‘locked’ position when not in use.

 DO NOT use the wrench for a task it is not designed to perform.

 DO NOT operate the wrench when you are tired or under the influence of alcohol, drugs or intoxicating medication.

 DO NOT get the wrench or battery charger wet or use in damp or wet locations.

Keep wrench and charger in the case and store in a safe, dry, childproof area where the temperature will not exceed 104°F (40°C).

1.2. BATTERY SAFETY INSTRUCTIONS

 WARNING! The battery pack contains nickel-cadmium which is dangerous. It must therefore be handled with care.

Charge the battery pack prior to first use. The battery pack will have been shipped in a low charge state.

Use only the charger provided to charge the battery pack.

 DO NOT charge the battery pack when room temperature is below 50°F (10°C) or above 95°F (35°C).

 DO NOT attempt recharging the pack by means of an engine generator or a DC power source.

 DO NOT short-circuit the battery pack by touching both terminals at the same time with a metal object, or your fingers etc.

 DO NOT store battery pack (or wrench) in locations where the temperature may exceed 104°F (40°C ) e.g. in outside sheds, above

heaters etc.

 WARNING! Dispose of spent battery pack correctly as it contains nickel-cadmium.

DANGER! DO NOT attempt to disassemble the battery pack. For safety and environmental reasons DO NOT discard in domestic

waste or by burning. ONLY discard or recycle according to local authority regulations.

 WARNING! DO NOT allow a leaking battery to contact your person. If you come into contact with battery liquid take the following

immediate action:

 a) Skin contact: Wash immediately with soap and water, then wash in either lemon juice or vinegar.

 b) Eye contact: If acid enters eye, flush eye immediately with cool, clean running water for at least 15 minutes and seek immediate

medical attention.

1.3. MAINS POWER ELECTRICAL SAFETY (Relating to battery charger)

  WARNING! It is the user’s responsibility to check the following:

You must check all electrical equipment and appliances to ensure that they are safe before using. You must inspect power

supply leads, plugs and all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised

by the installation of appropriate safety devices. An RCCB (Residual Current Circuit Breaker) should be incorporated in the

main distribution board. We recommend that an RCD (Residual Current Device) is used with all electrical products. It is

particularly important to use an RCD with portable products that are plugged into a supply not protected by an RCCB. If in doubt

consult a qualified electrician. You may obtain an RCD by contacting your local Sealey dealer.

You must also read and understand the following instructions concerning electrical safety.

1.3.1. The Electricity At Work Act 1989 requires all portable electrical appliances, if used on business premises, to be tested by a qualified

person, using a Portable Appliance Tester (PAT), at least once a year.

1.3.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of the appliance and

the safety of the appliance operator. If in any doubt about electrical safety, contact a qualified electrician.

1.3.3. DO ensure that the insulation on all cables and the product itself is safe before connecting to the mains power supply. See 1.3.1.

above and use a Portable Appliance Tester (PAT).

1.3.4. DO ensure that cables are protected against short circuit and overload.

1.3.5. DO regularly inspect power supply leads, plugs and sockets for wear, damage or loose connections.

INSTRUCTIONS FOR:

MODEL No: CP3004

Thank you for purchasing a Sealey product. Manufactured to a high standard this article will, if used according to these instructions and properly maintained,

give you years of trouble free performance.

1. SAFETY INSTRUCTIONS

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND

CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY

CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

CORDLESS IMPACT WRENCH 19.2V 1/2”sq DRIVE SUPER TORQUE CONTROL 400lb.ft

Original Language Version CP3004 Issue: 3 - 05/01/12

2. INTRODUCTION & SPECIFICATION

3. OPERATING INSTRUCTIONS

The most powerful cordless impact wrench in the Sealey range.

Six torque settings with a maximum of 5500kg.cm (400lb.ft) -

enough to remove the most stubborn wheel nut. Forward and

reverse control integrated into housing for ease of use.

Suitable for workshop, body shop and tyre shop applications.

Features replaceable motor brushes and includes 19.2Volt 2Ah

Ni-Cad battery pack and charger.

IMPORTANT WARRANTY INFORMATION:

The battery pack fitted to this cordless tool is considered to be a consumable item and its ability to accept charge will reduce over

time. We will warranty it against mechanical and electrical defect for a period of one year - this does not cover fair wear and tear. If the

battery is not properly charged before first use, or regularly conditioned, its capacity will

diminish. Under these circumstances we will not replace the battery pack even if it is less

than one year old.

Remove battery pack from case and charge as below:

3.1. Removing/Installing Battery Pack.

 WARNING! Do not touch metal terminals.

3.1.1. To remove the battery from the wrench, press the release button on the top of battery

pack (Fig.2), withdraw pack from wrench (Fig.2).

3.1.2. The battery pack may be fitted to the wrench either way around to assist working in tight

spaces.

 WARNING! Do not use force when inserting the battery pack. If it does not slide in easily then it is not being inserted correctly.

 WARNING! Ensure you read, understand and apply safety instructions before use.

3.2. Charging Battery Pack.

NOTE! If you try to charge a battery pack that has just been used the charging light may not come on. If this occurs, let the pack

cool for a while, then re-insert and try to charge again. If you try to charge a battery that is new or been inactive for a long

period, it may not accept a full charge. This is normal and after a couple of charges the battery will accept a full charge.

If you wish to charge two battery packs, allow fifteen minutes between charging to allow the charger to cool, after three

consecutive charges allow one hour to cool before further use.

Battery:..................................... 19.2V

Drive Size: ..................................1/2”Sq

No-Load Speed:............................1800rpm

Torque Settings:..................................6

Torque Range: ...............850-5500kg.cm/60-400lb.ft

Impact Rate: ............................. 2200bpm

Weight:......................................3.2kg

Charge Time: .................................. 1hr

Battery Pack: .........19.2V 2Ah (Model No. CP3004BP)

Sound Power: ............................. 80.12dB

Sound Pressure: ...........................69.12dB

Fig.2

Release Button

Original Language Version CP3004 Issue: 3 - 05/01/12

1.3.6. DO check that the voltage marked on the product is the same as the power supply to be used and check the plug is fitted with the

correct capacity fuse (see right).

1.3.7. DO NOT pull or carry the appliance by the cables.

1.3.8. DO NOT pull the plug from the socket by the cable.

1.3.9. DO NOT use worn or damage leads, plugs or connections. Immediately replace, or have repaired, by qualified electrician.

A U.K. 3 pin plug with ASTA/BS approval is fitted. In case of damage, cut off and fit a new plug according to the following instructions

(UK only - see diagram right).

Ensure that the double insulated

charger is correctly connected via a three-pin plug, as follows:

a) Connect the Brown live wire to live terminal ‘L’.

b) Connect the Blue neutral wire to the neutral terminal ‘N’.

c) After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable

outer insulation extends past the cable clamp and that the clamp is tight. Note that the earth pin ‘E’

remains unconnected.

Double insulated products, which are always marked with this symbol , are fitted with live (brown) and

neutral (blue) wires only. To rewire, connect the wires as indicated above - DO NOT connect either wire to the earth terminal.

1.4. BATTERY CHARGER SAFETY INSTRUCTIONS

 WARNING! DO NOT attempt to charge any battery other than that supplied for the wrench. Other types of batteries may

explode!

All mains electrical supply safety features must be followed as described in 1.3. above.

Disconnect the charger from the mains supply when not in use.

 DO NOT charge battery if room temperature is below 41°F (5°C) or above 104°F (40°C)

 DO NOT expose the charger to damp or wet conditions.

 DO NOT pull or carry the charger by the power lead.

 DO NOT operate the charger if it has been dropped, or has received a sharp knock, or is damaged. Take the charger to an authorised

agent for repair or obtain a replacement.

 DO NOT dismantle the charger as this may cause damage and/or personal injury and will invalidate the warranty.

 DO NOT insert foreign objects or material into the hole reserved for the battery pack.

 DO NOT recharge a second battery pack immediately after charging the first. Consecutive charging will overheat the charger. Allow the unit

to cool for 15 minutes before charging the next pack.

Store the charger in the same manner as battery pack in paragraph 1.2.

Blue-

Neutral

Wire

Brown-

Live

Wire

Cable

Clamp

FUSE RATING

5AMP

Power Switch

Forward/Reverse Button

Battery Pack

Carbon Brush Cover

Fig.1

4. MAINTENANCE

4.1. CLEANING

Keep the outer case of the wrench clean. DO NOT wash with water or use solvents or abrasives. Use a damp cloth.

4.2. CARBON BRUSHES

If the wrench performance starts to degrade over a long period of time, check the brushes. When new the brush length is 11mm, if they

are less than 4mm the carbon brushes require replacement.

4.2.1. To replace brushes, unscrew the brush cap (Fig.4) extract the old brush (Fig.5). Replace with a new one (Fig.6).

4.2.2. Repeat the process on the other side.

NOTE! Always replace brushes as a pair. Part No. CP3004.16.

For any other service or maintenance, contact your authorised service agent.

Fig.4 Fig.5 Fig.6

3.4. TORQUE CONTROL (Fig.3)

3.4.1. These torque figures are a guide only, the actual output may differ slightly from given figures due to different materials, grease

condition etc.

NOTE! For critical fixings such as wheel nuts always use a calibrated torque wrench according to the vehicle manufacturer’s, or

product, guidelines.

Setting Torque

I.............80ft.lb/108Nm

II.............140ft.lb/190Nm

III ............180ft.lb/244Nm

IV ............280ft.lb/380Nm

V.............350ft.lb/475Nm

VI ............400ft.lb/542Nm

Fig.3

Original Language Version CP3004 Issue: 3 - 05/01/12

3.2.1. Plug the charger into the supply.

3.2.2. Slide battery pack so that the groove on the battery lines up with the ridge on the charger

(battery only fits the charger in one position) and switch on the supply.

3.2.3. The red charging light (Fig.2A) will come on and charging will begin. If the charging light

goes out too soon, remove the battery pack and allow to cool for two minutes before

charging again.

3.2.4. If the charging light goes out within a minute even after repeating this procedure a couple of

times, then the battery is dead and requires replacing.

3.2.5. When the battery light switches to green you may remove the fully charged battery pack.

3.2.6. After charging, unplug the charger from the power source.

3.3. USING THE WRENCH

3.3.1. Use only impact sockets which are specifically designed for use with an impact wrench. The

use of normal chrome vanadium sockets is dangerous since these are more brittle and are

liable to shatter.

3.3.2. Fit the socket to the wrench by snapping it onto the square drive.

3.3.3. Fit the battery pack to the wrench.

3.3.4. Select the required direction of rotation. To change direction, push Forward/Reverse button

(Fig.1) to the left or right. Familiarise yourself with this operation before use. DO NOT

attempt to change the direction of rotation whilst trigger is depressed.

When the wrench is not in use, use the Forward/Reverse button to lock off the trigger by placing the switch in the middle position.

3.3.5. When tightening, release the trigger as soon as the impact sound is heard. Take care not to over-torque small fixings.

NOTE! For critical fixings such as wheel nuts always use a calibrated torque wrench according to the vehicle manufacturer’s, or

product, guidelines.

Charging

LEDs

Fig.2A

Risk of Hand Arm Vibration Injury

CP3004 Impact Wrench: When operated in accordance with these instructions and tested in accordance with EN 28662-2: 1994 results

in the following vibration emission declared in accordance with BS EN12096: 1996.

Measured vibration emission value: .....0.5m/s²

Uncertainty:........................0.19m/s²

These values are suitable for comparison with emission levels of other tools that have been subject to the same test.

This tool may cause hand-arm vibration syndrome if its use is inadequately managed.

Recommended Measures to reduce risk of hand-arm vibration syndrome:

This item represents a low Hand Arm Vibration risk to users. The calculated maximum usage period exceeds 8 hours. We recommend

appropriate safety equipment is utilised and regular breaks for the operator are employed to reduce any residual risk of fatigue or

repetitive strain injury.

Environmental Protection

Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to a

recycle centre and disposed of in a manner which is compatible with the environment.

When the product is no longer required, it must be disposed of in an environmentally protective way.

Rechargeable battery contains nickel cadmium (NiCad). It is recyclable. Take to your local recycling centre to be disposed of

properly. Do not incinerate NiCad battery as it may explode when exposed to fire. Do not attempt to open battery pack.

Battery Removal

For battery removal refer to section 3.1•

Dispose of batteries according to local authority guidelines.

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.