CAT-5000HD 01/14/04
CAT-5000HD
3/8" SUPER DUTY
AIR RATCHET
• Operating Instructions
• Warning Information
• Parts Breakdown
Working Torque . . . . . . . . . . . . . . . . . . . . . . .10-60 ft. lbs.
Ultimate Torque by Hand . . . . . . . . . . . . . . . . . . .70 ft. lbs.
Capacity (Standard Bolt Size) . . . . . . . . . . . . . . . . . . .3/8"
Net Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42 lbs.
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.42"
Air Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . .4 cfm
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/4" NPT
Recommended Hose Size . . . . . . . . . . . . . . . . . . . . . .3/8"
SPECIFICATIONS
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
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.
CAT-5000HD_op_man_011404 1/21/04 9:45 AM Page 1
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 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, re-
moving 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 re-
place 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 uncom-
fortable 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 jew-
elry 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.
• Use accessories recommended by Cornwell Tools.
2
CAT-5000HD 01/14/04
CAT-5000HD_op_man_011404 1/21/04 9:45 AM Page 2
Index # Part # Description Qty.Index # Part # Description Qty.
CAT-5000HD 01/14/04
101 RS5000HD101 Motor Housing 1
102 RS5000HD102 Valve Pin 1
103 RS5000HD103 Throttle Lever 1
104 RS1734308 Throttle Lever Pin 1
105 RS5000HD105 Housing Pin 1
106 RS5000HD106 Seal 1
107 RS5000HD107 Tip Valve 1
108 RS5000HD108 Conical Spring 1
109 RS5000HD109 Housing Grip 1
110 RS5000HD110 O-Ring 2
111 RS5000HD111 Inlet Bushing 1
112 RS5000HD112 Outlet Controller 1
113 RS5000HD113 O-Ring 1
201 * Reverse Lever 1
202 * Reverse Spring 1
203 * Reverse Pin 1
204 * Anvil Washer 1
205 * Anvil 1
206 * Thrust Washer Spring 2
207 * Steel Ball 2
208 * Ratchet Pawl 1
209 * Dowel Pin 1
210 * Thrust Washer 1
211 RS5000HD211 Yoke 1
212 * Retaining Ring 1
213 RS5000HD213 Drive Bushing 1
214 RS5000HD214 Crank Shaft 1
215 RS5000HD215 Needle Bearing 1
216 RS5000HD216 Ratchet Housing 1
217 RS5000HD217 Bushing 1
218 RS5000HD218 Planet Cage Assembly 1
220 RS5000HD220 Planet Gear 3
221 RS5000HD221 Lock Ring 1
222 RS5000HD222 Internal Gear 1
301 RS5000HD301 Lock Washer 1
302 RS30524 Ball Bearing 1
303 RS5000HD303 Front Plate 1
304 RS5000HD304 Cylinder 1
305 RS5000HD305 Blade 5
306 RS5000HD306 Rotor 1
307 RS5000HD307 Roll Pin 1
308 RS5000HD308 Rear Plate 1
309 RS21114 Ball Bearing 1
* Available only in head kit, Part #RHK5000
CAT-5000HD
SUPER DUTY 3/8" AIR RATCHET
3
CAT-5000HD_op_man_011404 1/21/04 9:45 AM Page 3
CAT-5000HD 01/14/04
Operating Instructions • Warning Information • Parts Breakdown
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 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 3/8" 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 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 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 and
reduces power.
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 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.
Cornwell Tools™ 1 Year Limited Warranty for Air Tools
Cornwell Tools 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 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.
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.
4
CAT-5000HD_op_man_011404 1/21/04 9:45 AM Page 4
Do Not Install
Quick Coupling
Here
Nipple
Leader Hose
Whip Hose
Nipple
Quick Coupler
Oiler
Air Supply
Filter
Regulator
Drain Daily
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