Cornwell Tools AT-4000SD Operating Instructions

• Operating Instructions
• Warning Information
• Parts Breakdown
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:
Always read
instructions
before using
power tools
•Lead from lead-based paints,
Always wear
safety goggles
•Crystalline silica from bricks and cement
and other masonry products, and
Wear hearing
protection
• 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.
Avoid
prolonged
exposure to
vibration
S P E C I F I C AT I O N S
at 90 p.s.i.
Free Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 RPM
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ft./Lb.
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1/16"
Avg. Air Consumption . . . . . . . . . . . . . . . . . . . . . . 1.96 cfm
Net Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 lbs.
dBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
CAT-4000SD
CAT-4000SD
1/4" DR.
SUPER Duty
AIR RATCHET
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.
CAT-4000SD
• 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.
Rev. 07/20/07
CAT-4000SD
1/4" DR. SUPER DUTY AIR RATCHET
50
07
06
08
05
19
21
20
03
04
09
16 15
17
18
H
CCM
48
11
10
12
07
13
49
14
52
2
&
22
35A
30A
33
32B
28
29
25
26
29
34
51
01
02
23
27
24
31B
44
36
37
52
43
42
38
41
40
39
46
45
47
Ref.
Part #
Description
01RS1401
Air Inlet
02RS1402
Air Inlet O-Ring
03RS1403
Muffler Deflector
04RS1404
Muffler Deflector O-Ring
05RS1405
Motor Housing
06RS1406
Air Regulator
07RS1407Dowel Pin
08RS1408
Air Regulator O-Ring
09
RS1409Throttle Valve Spring
10RS1410Throttle Valve Spring Stem
11RS1411Throttle Valve Spring O-Ring
12RS1412Throttle Valve Spring O-Ring
13
RS1413Regulating Valve
14RS1414Regulating Valve O-Ring
15RS30516Bearing
16RS1416Rear Plate
17RS1417Cylinder
Qty.
1
1
1
1
1
1
2
1
1
1
1
1
1
3
1
1
1
Ref.
Part #
Description
Qty.
18RS1418Rotor
19RS1419Rotor Blade
20RS1420Front Plate
21RS30524Bearing
22RS1422Internal Gear
23RS1423
Idler Gear Plate Assembly (INC. #24)
24
Idler Gear Pin (INC. w/ #23)
25RS1425Idler Gear
26RS1426Clamp Nut
27RS1427Needle Bearing
28RS1428
Spacer
29
RS1429Internal Gear Spacer
30ARS1430A Ratchet Housing Assembly (INC. 52)
31RS1431Crank Shaft
32RS1432Drive Bushing
33
RS1433Ratchet Yoke
34RS1434Dust Cover
1
4
1
1
1
1
3
3
1
1
1
2
1
1
1
1
1
Ref.
Part #
Description
35A
*Reverse Button Assembly
36
*
Anvil Upper Washer
37
*Spring Pin
38
*
1/4" Ratchet Anvil Assembly
39
*Spring
40
*Steel ball
41
*Ratchet Spring
42
*Lock Pin
43
*Ratchet Pawl
44
*Ratchet Pawl Pin
45
*Thrust Washer
46
*Clamp Washer
47
*Retaining Ring
48RS1448Throttle Lever
49RS1449Throttle Lever Pin
50RS1450Housing Cover
51RS1451
Muffler Deflector Ring
52RS1452Grease Fitting
*Available only in head kit, CAT-4000SDK.
CAT-4000SD
Rev. 07/20/07
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Operating Instructions •
Warning Information • Parts Break­down
Air Supply
Filter
Whip Hose
Do Not Install
Quick Coupling Nipple
Here
Nipple
Quick Coupler
Leader Hose
Air Supply
Oiler
Regulator
Drain Daily
and reduces power.
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
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.
CAT-4000SD
4
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.
Rev. 07/20/07