Trelawny VL203Ex Guide de dépannage

735.3002X

ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

ATEX CERTIFIED VL203Ex CHALLENGER NEEDLE SCALER

Operation & Maintenance

735.3002X

2ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

CONTENTS

Introduction 2

Declaration of Conformity 3

Operation 5

Maintenance 7

Exploded View

Parts List 11

Technical Specications 13

INTRODUCTION

Your new Telawny SPT power tool will more than satisfy your expectations. It has been manufactured under

stringent Trelawny SPT Quality Standards to meet superior performance criteria. You will nd your new tool

easy and safe to operate, and, with proper care, it will give you many years of dependable service.

WARNING

Carefully read through these original instructions before using your new TRELAWNY power tool

Take special care to read the warnings. Your TRELAWNY power tool has many features that will

make your job faster and easier. Safety, performance, and dependability have been given top

priority in the development of this tool, making

it easy to maintain and operate.

DISPOSAL

Do not dispose of electrical products together with household waste!

Waste electrical products should not be disposed of with household waste. Please recycle where

facilities exist. Check with your local authority or retailer for recycling advice.

ENVIRONMENTAL PROTECTION

The machine, accessories and packaging should be sorted for environmental-friendly recycling.

The plastic components are labelled for categorised recycling.

Part Number 733.3003X issue (1)

Appendix 1 - Hazardous Area Certification

The VL203/223 & VL303 Needle Scalers are certified compliant to the ATEX Directive (2014/34/EU)

for safe use within a hazardous area and has been assessed so by TRaC (Notified Body 0891).

This product conforms to the Standards:

EN 13463-1:2009

EN 13463-5:2011

EN ISO 4414:2010

and is attributed with the product certification codes:

II 2 G c IIA T4

ATEX Certificate Number: TRAC15ATEX0029X

Special Conditions of Safe Use

1. Air compressors used in conjunction with these Needle Scalers shall incorporate means to

prevent the ingress of dust or other foreign material into the air supply i.e. a filter on the

compressor intake.

2. For air compressors used in conjunction with these Needle Scalers, only lubricants that are

resistant to carbonisation are to be used

3. Equipment is to be operated at a maximum of 6.9bar (100p.s.i). Equipment must not be

operated below 5.5bar (80p.s.i).

4. The external painted surfaces of the equipment are not to be exposed to charging

mechanisms stronger than manual rubbing.

5. Any lubricating oil used must have an ignition temperature of >100°C

6. Air supply and vacuum hoses used in conjunction with the equipment must be

manufactured from anti-static material with a surface resistance not greater than 109Ω.

7. For the purpose of vacuum extraction at source, equipment used in conjunction with the

Needle Scalers must be suitably rated ATEX certified.

8. Ensure the lanyard is attached to the fall arrester and attached to a safety harness or belt.

9. Equipment is to be lubricated before use as detailed in the Operation & Maintenance

Manual.

Equipment must only be installed & maintained by suitably qualified and competent personnel in

accordance with the instructions provided and the terms of the applicable product services.

735.3002X

ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

OPERATION

General Information

Local safety regulations must be followed at all times.

Failure to follow these instructions could result in

damage to the Scaler and/or personal injury.

Operators should be familiar with the data given in the

specication section. Please keep these instructions in

a safe and accessible place.

Trelawny SPT Limited disclaims all responsibility

for damage to persons or objects arising as a

consequence of incorrect handling of the tool, failure

to inspect the tool for damage or other faults that may

inuence the operation prior to starting work, or failure

to follow the safety regulations listed or applicable

to the job site. The tool is primarily designed for the

removal of paint, rust and scale, it can be used both

indoors and out.

This tool must not be used in a xture.

Safety

Always, read instructions rst before use.

Do -

■Be aware that this tool is not electrically

insulated.

■ Be aware that the tool can create dust and ying

debris.

■Keep hands and clothing away from moving

parts.

■Be aware of others working around you.

■Ensure that this tool is lubricated daily.

■Store this tool in a secure and dry environment.

■Wear Personal Protective Equipment including

safety goggles, footwear, ear defenders and

gloves. In some environments it will be necessary

to wear facemasks or breathing apparatus.

(Vacuum shroud available)

ALWAYS OBSERVE SAFE-WORKING PRACTICES

AT ALL TIMES

WARNING! Before operating, performing

maintenance or repairing the ATEX Certied

VL203 Needle Scalers, this manual must be

read and understood. If in any doubt, ask your

supervisor before using this equipment.

Do not -

■Allow the tool to run unattended.

■Use the Scaler as a lever.

■Modify this tool in any way, this will invalidate the

warranty and could also lead to serious injury.

■ Use wire or any other xing to lock the throttle

lever in the on/open position.

■Operate tool with the front tube (34) removed.

■Use the tool in potentially explosive

environments.

■Drag the tool by the air hose.

■Use petrol (gasoline), thinners or any other high

ash point solvent to clean the tool.

■Use the tool if you become tired, this can lead

to physical strain or injuries; where practical;

use a spring balance, balance weights or similar

equipment to take the weight of the tool.

■Hold the exposed needles or chisel, whilst the

tool is in use, this could cause vibration damage

to the hands.

Please note: Unrestrained hoses can whip if they

become detached. Care must be taken to avoid

damaging or tripping over the trailing air hose.

Always use a suitable vacuum system connected to

the 38mm vacuum take-off port tted to the tool.

The Beryllium Copper spark resistant needles may

create airborne dust, which maybe harmful to health if

ingested.

A Trelawny ATEX rated, 30 litre air operated vacuum

system with a HEPA lter, is available as a separate

vacuum or as a Kit containing either a VL203, VL223

or the VL303 Needle Scaler and also comes with an

Anti-static tool air hose.

30 litre ATEX Vacuum

Part Number: 303.10KAV30/DH

30 litre ATEX Vacuum Kit with a VL203Ex

Part Number: 139.2503

30 litre ATEX Vacuum Kit with a VL223Ex

Part Number: 139.2523

30 litre ATEX Vacuum Kit with a VL303Ex

Part Number: 139.2533

735.3002X

6ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

Starting work

Prior to operating the tool check: -

■ That all ttings are secure, free from leaks and air

hoses are in good condition.

■That the air pressure is correct for this tool 6.2

bar (90 p.s.i.).

■Put a few drops of a recommended lubricant into

the air inlet of the tool.

■Safe use of this tool requires a solid stance and

secure foothold, the tool may be used in other

postures but care must be taken that the operator

adopts a rm and stable position.

■Maintain contact with the work surface with

sufcient pressure only to keep the tool from

bouncing.

Excessive pressure can prevent the tool from working to

its full capacity.

Handled correctly the VL203Ex Needle Scaler will work

quickly and efciently.

Excessive operator pressure will not improve the

tool efciency but could cause premature tool

failure and operator fatigue.

Never allow the tool to run continuously whilst not in

contact with the surface being prepared.

To operate the tool, pull the throttle lever towards the

handle and then apply the needles to the surface to be

worked.

Do not place needles on the surface, and then pull the

throttle lever as this will result in the tool bouncing off the

surface.

To switch off, simply release the throttle lever.

Air Supply

The compressed air must be free from water and

dirt. The installation of a lter/regulator/lubricator air

preparation set (with moisture trap) adjacent to the tool

is strongly recommended.

In particularly cold temperatures it is recommended

that a proprietary anti-freeze lubricating oil is used.

Always clear the air hose before connection to the tool.

Ensure that no moisture (condensation) is present in

the air hose.

Ensure that only 10mm (3/8”) bore Antistatic air hose

is used and that all couplings are secure, leak free and

in good condition. (See Parts list for recommended

hose.)

For maximum efciency, limit the length of air hose to

10M (33ft). Where extra length is necessary, for each

additional 15M (50ft) of air hose used, the pressure

drop is approximately 0.16bar (3psi).

The correct air pressure for this machine is to

6.2bar (90psi).

Do not let the operating pressure fall below 5.5bar

(80p.s.i.) or rise above 6.9bar (100 psi) absolute

maximum.

The compressor should be able to supply a minimum

of 3.77 L/s (8cfm) of free air not displaced as quoted

by some compressor manufactures, this will give 3cfm

of headroom, so that the compressor isn’t continually

running.

NOTE:

If this tool stops working, it is most likely that the

plastic (17) ball has worn excessively and may have

passed into the cylinder, check the cylinder exhaust

holes for the remnant also. This is designed to run for

approximately 160hrs before requiring replacement.

(Spare balls are supplied with the tool)

OPERATION

Please note,

Always use a lanyard or strap attached to a belt or

harness, but preferably this should be attached to a

xed and secure mounting point.

Always use Trelawny Beryllium Copper Needles.

735.3002X

ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

MAINTENANCE

Gloves and personal protective equipment must be

worn when using this tool.

Maintenance

Disconnect the tool from the air supply before

carrying out any of the following operations.

■Clean all debris from the exterior of the tool.

■This tool has been designed so that you only

require a vice, screwdriver, 3mm pin punch

and light hammer, no other specialist tools are

required to completely strip and service the tool.

■ For safe efcient running and at intervals of no

more than 120 hours, dismantle and clean with

highly rened parafn.

■Check all components for wear, replace the ball

valve (Item 17) and all O’Rings. Immediately

after cleaning, thoroughly oil the tool with one of

the recommended lubricants.

Maintenance must only be carried out

by a competent person, in a suitably equipped

workshop.

Removing Needles

■Disconnect from air supply, hold the Cover in a

vice using the ats provided, keeping the tool

horizontal, unscrew by hand, the Front Tube

assembly complete with Return Spring (32),

Needles, and Needle Holder.

■Check the condition of the Front Tube Locking

O’Ring (25). Take care not to invert the Needle

Scaler while removing the Front Tube or the

Piston may fall out of the Intermediate Tube.

■Remove the Needles from the Needle Holder and

dispose of the used Needles in an appropriate

manner.

Re-tting the Needles

Insert the new needles into the Needle Holder location

holes; ensure that the Needles are inserted into the

chamfered side of the holes. Fit new Front Tube

Locking O’Ring to the Intermediate Tube. Fit the

Return Spring over the needles (31) and insert the

Needle assembly into the Front Tube. Screw the Front

Tube assembly onto the intermediate Tube until hand

tight.

Recommended Lubricants

Oil the tool daily during use. Put a few drops of one of

the following bio-degradable air tool lubricants through

the air inlet.

SHELL Naturelle HF

CASTROL Carelube HTG 22

Always use clean oil from a sealed container

Tool Dismantling

Service kits are available, see parts section.

VERY IMPORTANT:

Only Trelawny Beryllium Copper Needles must

be used in this tool.

DO NOT substitute with any other needle.

IMPORTANT:

The plastic tool box containing the ATEX tool is not

ATEX certied or anti-static, neither is the foam

inserts containing the equipment.

Do not take the tool box into an ATEX restricted

area.

Before carrying out any dismantling,

ensuring the air supply is turned off, remove the

air-line from the tool. Clean all deposits from

the outside of the tool.

735.3002X

MAINTENANCE

ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

Piston Valve Pin replacement

■Hold the piston in a vice by the stem,

■Using a pair of pliers break off the valve pin,

■Use a 6mm drill & bit and remove the remainder

from the piston. A small socket (4mm) which

just ts over the actual pin, will stop damage

occurring.

■Drive the valve pin in up to its shoulder using a

vice or a small hammer.

Valve Body - Valve Stem removal

■ Hold the Valve Body (6) in a vice using the ats

provided.

■Using a 3 mm diameter punch, drive the Throttle

Lever retaining Spring Pin (8) out of the Valve

Body (6) and withdraw the Throttle Lever (7).

■Remove the Valve Cap with O’Ring (2), Valve

Spring (3), Valve Stem (4) and the Valve Seat

O’Ring (5).

Valve Body removal

■Remove the Front Tube and remove Needle

Holder, Needles and Return Spring as per

instructions for Needle replacement above.

■Replace the Front Tube without the Needles etc,

onto the Intermediate Tube and screw up until

hand tight.

■ Hold the Valve Body ats securely in a vice, with

the Cover (10) uppermost.

■Turn the tool anti-clockwise around the Valve

Body by holding the Cover and Front Tube,

unscrew the Valve Body from the handle until

loose, remove from vice and nally unscrew by

hand.

Piston and Cylinder removal

■ Hold the Cover in a vice using the ats provided,

keeping the Front Tube (34) horizontal.

■Unscrewing anti-clockwise by hand, remove

the Front Tube complete with the Needles

(31), Needle Holder (30) and Spring (32) as an

assembly.

Note: When removing tool from vice, do not point the

front of the tool downward; the piston may fall out of

the Intermediate Tube causing damage.

■Hold a clean lint free cloth over the open end of

the Intermediate Tube, remove from vice and tilt

the Tube downwards to remove the Piston (26).

■Secure the Cover (10) in a vice with the

Intermediate Tube in the vertical position, using

the ats provided.

■Use a suitable 6mm bar through the holes

provided, unscrew the Intermediate Tube (22)

anticlockwise.

■Carefully remove the Intermediate Tube from the

cover and remove the Cylinder from its location

hole in the Cylinder Guide Plate, which is tted in

the cover.

■The Cylinder Guide Plate (12) can be pulled out

of the cover to gain access to the Guide Plate

Seal (13).

Cylinder Ball Valve replacement

This is a consumable item and will require replacing

after approximately 120 -160 hours use; this is

dependant on the cleanliness of the air supply and

frequency of lubrication.

Do not replace this plastic ball with a steel version, it

will damage the cylinder valve seat and piston valve

pin. The ATEX certication will also become invalid.

Remove the ball retaining O’Ring (18) from its groove

just inside the bore of the stem using a suitable

pointed implement. Remove the ball from the bore,

replace and ret new O’Ring into groove.

735.3002X

MAINTENANCE

ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

Vacuum Take-off

The vacuum take-off tted is also available as a spare

part. (See parts list for take-off and cuff) which ts over

the front tube.

Position the front of the cuff with the needle tips

20mm inside, adjust as the needles wear. Tighten the

caphead screw to secure.

Use a Trelawny recommended ATEX certied vacuum,

tted with a HEPA lter for 99.9% dust containment.

Assembly

Ensure all parts are clean and internal parts have a

lm of recommended lubricant.

Replace any parts that show signs of wear.

If the tool is being fully serviced, it is strongly

recommended to change all O’Rings (2), (5), (14), (18),

(25), (27), cushion ring (19), seals (13,) (29), ball valve

(17) and Needle Holder during assembly.

Valve assembly

Replacement of the Valve Body onto the Cover

assembly is the reverse of removal.

■Use a few turns of P.T.F.E. tape on the threads

of the handle and screw on the Valve Body

initially by hand,

■Then insert the Valve Body in a vice, holding

securely on the ats provided, and with the

Cover (10) uppermost.

■Finally tighten up clockwise by hand, holding

the Front Tube and Cover, and align the Throttle

Lever with the front of the tool when resistance

is felt.

■Replace the O’Ring (2) on the Valve Cap (1).

■Fit a new Valve seat O’Ring (5) in the Valve Body

(6).

■Insert the Valve Stem (4), in the Valve Body (6).

■Place the Valve Spring (3) on top of the Valve

Stem (4),screw down the Valve Cap (1) by hand,

and then fasten until fully tight with a at blade

screwdriver.

■Locate Throttle Lever (7) in the Valve Body (6)

using a 3 mm punch to align holes.

■Secure by inserting Spring Pin (8).

Tool assembly

Ensure that all components are clean and lubricated with

a thin lm of the recommended lubricating oil. Assembly

is the reverse of dismantling.

■Secure the Cover (10) vertically in a vice using

the ats provided, insert the Cylinder Guide Plate

ensuring that the at face is uppermost, ensure

that it is located onto the shoulder at the bottom

of the threaded section inside the Cover.

■Fit the Cylinder stem into the bore of the Cylinder

Guide Plate. With the removal holes uppermost

carefully slide the Intermediate Tube over the

Cylinder, screwing down by hand.

■Finally tighten by using a 6mm bar x 200mm through

the holes provided. (Do not over tighten). Gently

insert the Piston, small diameter rst into

the Intermediate Tube, if resistance is felt, turn

the piston slightly until it is located in the cylinder.

Note: When removing tool from vice, do not point the front

of the tool downward; the piston will fall out of the tube

and become damaged. Remove the tool from the vice

and follow as per Re-tting the Needles, hold the

tool horizontal when completing this operation.

Disposal

Dismantle into component form, segregate according

to material composition and dispose of using waste

recycling processes specied by local regulations.

735.3002X

10 ATEX Certied VL203Ex Needle Scaler Operation and Maintenance

EXPLODED DIAGRAM

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