Cornwell Tools CAT2138 Owner's manual

Brand: Cornwell Tools

Model: CAT2138

Type: Owner's manual

CAT2138 4/21/15

Operating Instructions • Warning Information

• Parts Breakdown

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:

 

 

products, and

 

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.

Free Speed ............................................................. 6,500 RPM

Breakaway Torque ................................................. 

Working Torque Range .................................... 

Overall Length ................................................................. 4.4"

Weight ...........................................................................  lbs.

Average Air Consumption .............................................  cfm

Air Inlet......................................................................1/4" NPT

Recommended Hose Size .......................................... 

Sound Level ................................................................ 95 dBA

Vibration Level ..................................................... ²

SPECIFICATIONS

WARNING



3/8" Dr. Mini

Impact Wrench

ALWAYS READ

INSTRUCTIONS BEFORE

USING POWER TOOLS

ALWAYS WEAR

SAFETY GOGGLES

ALWAYS WEAR

HEARING PROTECTION

AVOID PROLONGED

EXPOSURE TO

VIBRATION

CAT2138 2 4/21/15

FAILURE TO OBSERVE THESE WARNINGS COULD RE SULT IN IN JU RY.

THIS INSTRUCTION MAN U AL CON TAINS

IM POR TANT SAFE TY INFORMATION.





OP ER AT ING 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.

• Impactwrenchesarenottorquecontroldevices.

 Fastenerswithspecifictorquerequirementsmust

 becheckedwithsuitabletorquemeasuring

 devicesafterinstallationwithanimpactwrench.

• 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

 

• 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

CAT2138 3 4/21/15

PARTS BREAKDOWN - CAT2138

    

 101 RS2138102 Anvil 1

 101A RS2138103 AnvilAssembly(Incl.#101,102&103) 1

 102 RS2138104 O-Ring 1

 103 RS1734201 SocketRetainerRing 1

 104 RS4112104 HammerPin 2

 105 RS4112105 HammerFrame 1

 106 RS4112106 Hammer 1

 201 RS2138105 Housing 1

 202 RS4112202 Packing 1

 203 RS4112203 RearCover 1

 204 RS4112204 HexSocketHeadBolt 4

 206 RS2138106 HammerCaseBushing 1

 301 RS4112301 Bearing(R6) 1

 302 RS4112302 FrontBearingPlate 1

 303 RS4112303 RotorBlade 6

 304 RS4112304 Rotor 1

 305 RS4112305 Cylinder 1

 306 RS4112306 RearEndPlate 1

 307 RS4112307 Bearing(R8) 1

 308 RS4135112 SpringPin 1

 309 RS0260309 SpringPin 1

    

 401 RS4112401 Trigger 1

 403 RS2138404 Spring 1

 404 RS2138405 RegulatorA 1

 405 RS4112405 Lever 1

 406 RS1734414 O-Ring 1

 407 RS4112407 RegulatorB 1

 408 RS4150417 TriggerTip 1

 409 RS4112409 ReverseValve 1

 410 RS1077409 O-Ring 1

 411 RS4112411 O-Ring 1

 412 RS1077402 SpingPin 1

 413 RS1735313 Ball(2.5) 2

 414 RS1077410 PositioningSpring 1

 415 RS1077413 SpringPin 1

 416 RS0260405 SealBushing 1

 417 RS0260406 Seal 1

 418 RS0260407 TipValve 1

 419 RS1077419 Spring 1

 420 RS222411 ExhaustDeflector 1

 421 RS4112421 AirInlet 1

RSCAT2138WL WarningLabel(notshown) 1

401

412

408

413 A

414

413

409 410

411 415 420

421

416

417

418

419

403

404 405

406 407

206

103

101A

102

101

104

308

307

309

306

305

304

204

303

203

302

202

301

105

106

201

CAT2138 4 4/21/15

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 con-

nection 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toolisanimpactingtoolandnotatorquemeter.Whenspecific

torque is required, it must be checked with a torque meter after

fitting the fastener with the impact. This impact wrench is rated

at 3/8” SAE bolt size. Rating must be downgraded for spring

Ubolts,tiebolts,longcapscrews,doubledepthnuts,badlyrusted

conditionsandspringfastener,astheyabsorbmuchoftheimpact

power.Whenpossible, clamporwedgethebolt to prevent spring

back.

Soak rusted nuts in penetrating oil and break rust seal before

removingwithimpactwrench.Ifnutdoesnotstarttomoveinthree

tofiveseconds,usealargersizeimpactwrench.Donotuseimpact

wrenchbeyondratedcapacityasthiswilldrasticallyreducetoollife.

The reversing valve is used to change the direction of the tool.

Whenthevalveisout,thetoolisinforwardorrighthanddirection.

When the valve is pushed in, the tool is in reverse or 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.



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.

WARRANTY

CornwellQualityToolsCompany(“Cornwell”)warrantsthisproductagainstdefectsinmaterialandworkmanshipforaperiodofONE(1)YEAR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.

Drain Daily

Regulator Oiler Quick Coupler Leader

Hose

Nipple

Do Not Install

Quick Coupling

Here

Nipple

Filter

Air Supply

Whip Hose