MAINTENANCE
Vacuum Take-off
The vacuum take-off fitted is also available as a spare
part. (See parts list for take-off and cuff) which fits 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 certified vacuum, fitted with a HEPA filter for 99.9%
dust containment.
Assembly
Ensure all parts are clean and internal parts have a film 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), Cushion Ring (19), Seals (13,) (29), 6mm
Ball (17) and Needle Holder (30) during assembly.
Valve assembly
Re-assembly of the VL223 is the reverse of stripping.
Secure the Cover (10a) in a vice, holding on the flats
provided, with the valve opening uppermost.
Replace the O’Ring (2) on the Valve Cap (1). Fit a new
Valve seat O’Ring (5) in the Cover with the chamfer
uppermost. 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 flat blade screwdriver. Locate
Throttle Lever (7) in the Valve Body (6) using a 3mm
punch to align holes.
Secure by inserting Spring Pin (8).
Tool assembly
Ensure that all components are clean and lubricated with
a thin film of the recommended lubricating oil. Assembly
is the reverse of dismantling.
Secure the Cover (10) vertically in a vice using the flats
provided, insert the Cylinder Guide Plate (12) ensuring
that the flat face is uppermost, ensure that it is located
onto the shoulder at the bottom of the threaded section
inside the Cover. Fit the Cylinder’s 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 (26), small
diameter first into the Intermediate Tube (22), 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-fitting the Needles, hold the tool
vertical when completing this operation.
Disposal
Dismantle into component form, segregate according to
material composition and dispose of using waste
recycling processes specified by local regulations.
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 and Cylinder 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) and Cylinder (15).
Secure the Cover (10a) in a vice with the Intermediate
Tube in the vertical position, using the flats 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 Guide Plate (12), which is fitted
in the Cover. The Cylinder Guide Plate 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 may 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, as
it will damage the cylinder valve seat and piston valve pin.
The ATEX certification 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 or if it has
worn excessively and may have passed into the cylinder,
check the cylinder exhaust holes for the remnant also.
Replace and refit new O’Ring into groove.
Piston Valve Pin replacement
Hold the piston in a vice by the stem, using a pair of
cutters remove the top of the Valve Pin (28), using a drill
& 6mm drill bit and remove the remainder from the piston.
A small socket (4mm) which just fits 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 flats 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 flats 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 finally unscrew by hand.
