Alpha Professional Tools AIR-680 User manual

Part No: AIR-680
Version 3.2


Alpha®Pneumatic
Air Polisher
Instruction Manual
MANUAL


TABLE OF CONTENTS
Introduction................................................................................3
About the Symbols ....................................................................3
Safety Instructions for Power Tools ...........................................4
AIR-680 Overview .....................................................................6
Specications ............................................................................6
Equipment Included...................................................................7
Optional Accessories............................................................7
Recommended Alpha®Accessories .....................................7
Special Features........................................................................7
Tool Set-Up Information.............................................................7
Connection Fittings ...............................................................8
Air Pressure and Volume ......................................................9
Rust Protection .....................................................................9
How to Add the Rust Inhibitor Oil........................................ 10
Polishing and Using The Tool .................................................. 11
Spindle Size........................................................................ 11
Air Valve Lever.................................................................... 11
Filter/Regulator System ......................................................12
Water Control Valve ............................................................12
 Silencer/Mufer................................................................... 13
Reversible Side Handle ......................................................13
Air Supply Hose Assembly.................................................. 13
Water Supply Hose Assembly.............................................13
Attaching the Exhaust Hose & Clamp.................................14
AIR-680 Schematic..................................................................15
AIR-680 Parts List ...................................................................16
Accessories and Factory Service ............................................18
Product Registration................................................................19

3
INTRODUCTION
Thank you for purchasing an Alpha®Air Polisher. This polisher is
the workhorse of a complete polishing system. A wide range of
accessories help you perform many different tasks. This tool lets
you grind, shape, bevel, contour and polish all kinds of natural stone
and man-made materials. You can easily change from one type of
disc to another in just a matter of seconds. The tool is used with
watertohelpyougetthebestpossiblenish,toreducethehealth
risks of dust, and to give the most savings in time and money. For
your safety, please read this manual thoroughly before you start
operating this polisher.
ABOUT THE SYMBOLS
According to the hazard level, all safety notes in this manual are
classiedinto“DANGER”,“WARNING”,and“CAUTION”.
DANGER! Deathorseriouspersonalinjuryisimminentwhen
handling this polisher incorrectly.
WARNING! Thereisapossibilityofdeathorseriouspersonal
injury when handling this polisher incorrectly.
CAUTION! Thereisapossibilityofpersonalinjuryorproperty
damage when handling this polisher incorrectly.
Note:Insomesituations,failingtoobserveWARNINGnotescould
result in death or serious personal injury. Be sure to read
and observe the safety notes to ensure safety and correct
use of the polisher.
For repair information call:
Headquarters,Oakland,NJ—(800)648-7229ext.505
Due to specially designed components this machine must be serviced only
with genuine ALPHA®parts.

4
SAFETY INSTRUCTIONS FOR POWER TOOLS
1. KNOW YOUR POWER TOOL.  Read owner’s manual carefully.
Learn its applications and limitations as well as specic potential
hazards particular to this tool.
2. KEEP WORKAREA CLEAN. Cluttered areas and benches invite
accidents.
3. AVOIDDANGEROUSENVIRONMENTS.Keepworkareasasdry
aspossible.Donotusetoolinpresenceofammableliquidsor
gases. Keep the area well lit.
4. KEEPCHILDRENANDVISITORSAWAY.Allvisitorsshouldbekept
a safe distance from the work area. Keep out of reach of children.
5. DON’TFORCETOOL.Itwilldothejobbetterandsaferattherate
for which it was designed.
6. WEARPROPERAPPAREL.Donotwearlooseclothingorjewelry
as it can get caught in moving parts. Rubber gloves and insulated
non-skid footwear are recommended. Wear protective covering to
contain long hair.
7. WEAR PROPER EYE PROTECTION. All users and bystanders
must always wear proper personal eye protection which conform with
ANSI/ISEAZ87.1(CAN/CSAZ94.3).Alsouseafaceordustmaskif
operationisdusty.Alwayswearcertiedsafetyequipment.
8. WEAR PROPER EAR PROTECTION. All users and bystanders
mustwearproperpersonalearprotectionwhichconformswithANSI
S12.6(S3.19)hearingprotection.
9. WEAR PROPER RESPIRATORY PROTECTION.All users and
bystanders must wear proper personal respiratory protection. Always
useNIOSH/OSHAapprovedrespiratoryprotectionappropriateforthe
dust exposure.
Warning: Some dust created by power sanding, sawing, grinding, drilling,
polishing and other construction activities contains chemicals known to the
State of California to cause cancer, birth defects, or other reproductive harm.
Some examples of these chemicals are:
- Lead from lead-based paints
- Crystalline silica from bricks, 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, work in a well ventilated area, and

5
work with approved safety equipment, such as dust masks that are specially
designedtolteroutmicroscopicparticles.  
To familiarize with the risks associated with a material, consult with your
employer, manufacturer/supplier and government agencies regarding the
hazards of the materials and their recommendations to protect yourself.
10. DON’TABUSEWATERSUPPLYHOSE.Don’tcarrytoolbysupply
hoseorexposetotrafcareaswhereitcanbecrushed.
11. ALWAYS SECURE WORK PIECE. Use clamps or a vise to hold work.
It’ssaferthanusingyourhandanditfreesbothhandstooperatetool.
12. DON’TOVERREACH.Keepproperfootingandbalanceatalltimes.
13. DISCONNECTTOOLS WHEN NOT IN USE. Always disconnect
tool before servicing; when changing accessories such as grinding
wheels, backer pads, etc.
14. REMOVEADJUSTINGKEYSANDWRENCHES. Form a habit of
checking to see that keys and adjusting wrenches are removed from
tool before turning it on.
15. MAINTAINTOOLSWITHCARE.Keeptoolscleanatalltimesfor
best and safest performance. Follow instructions for lubricating and
changing accessories. Keep handles dry, clean and free of oil or
grease. Inspect moving parts for alignment and binding as well as
for breakage and improper mounting.
16. AVOIDACCIDENTALSTARTING.Donotcarrya“connected”tool,
or make adjustments, or change discs without making sure the tool
is disconnected from the air supply.
17. USE ONLY RECOMMENDEDACCESSORIES. The use of any
accessories other than what is listed or recommended for this
particular tool may be hazardous.
18. KEEPHANDSAWAYFROMALLMOVINGPARTS.
19. USESIDEHANDLES.Suppliedwithtoolforcontrolandsafety.
20. USERECOMMENDEDGRINDINGWHEELSONLY.Donotuse
conventional abrasive grinding wheels with this tool. Only use
diamond grinding wheels which are rated for wet usage.
21. STAY ALERT. Watch what you are doing and use common sense.
Donotoperatetoolwhenyouaretired,orundertheinuenceof
medication or alcohol.

6
AIR-680 OVERVIEW







Line 


SPECIFICATIONS
Air Pressure .................................................. 85PSI
Air Consumption..........................................15 CFM
 NoLoadRPM..................................................4,000
Weight ................................................. 2.64lbs/1.2kg
Air Inlet.................................................... 1/4”BSPP
Water Inlet................................................ 1/8”BSPP
Spindle ..........................................................5/8”-11
1/4”BSPP
1/8”BSPP

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EQUIPMENT INCLUDED
 Airhose(15ft/4.5m).........................................1pc
 Waterhose(15ft/4.5m) ...................................1pc
 SideHandle(reversible).....................................1pc
 DoubleEndWrench(19mm/22mm)...................1pc
 RustInhibitorOil(8oz/237ml)(AIR-008)..........1pc
 Screw(w/O-RingSealforOilPort) ...................1pc
Exhaust Hose With Clamp .................................1pc
OPTIONAL ACCESSORIES
 SplashGuard(AWP-01) ....................................1pc
 C-ShapedHandle(AWP-21A) ...........................1pc
RECOMMENDED ALPHA®ACCESSORIES
CeramicaEXexiblediamondpolishingdiscs,waterproofSandpaper
discs,HookandLoopBackedFeltWheels,CoreDrillBits,Turboshine
andProlers.
SPECIAL FEATURES
The Alpha®AIR-680 polisher was designed with user comfort in
mind, for a full day of use. The silencer system will reduce the noise
volume below 80 dBA and the rubber body cover will insulate the
user from the cold and fatigue. The blue exhaust hose is designed
to guide the cold exhaust air and rust inhibitor oil away from the user
and the work area.
TOOL SET-UP INFORMATION
Unpack the tool carefully and study the helpful hints and warnings
contained in this manual. Please take time to familiarize yourself
withthefeaturesofthetool.Besuretollouttheregistrationcard
enclosed, and mail it back to the distribution center today.
1/4”BSPP
1/8”BSPP


CONNECTION FITTINGS
TheairandwaterhosettingsonthebackofthistoolareBSPP
(Britishstandardparallelpipeor“G”thread).Thesettingshave
parallelthreadsandsealoffontheatsurfaceonthebottomof
thethread.Thistypeofttingisusuallysuppliedwithan“O”ringor
sealing ring which we replaced with the silencer.
Parallel Thread Tapered Thread NPT


TryingtoconverteitherttingtoanAmericanstandardpipethread
(NPT),whichistapered,willcracktheEndcaseandisnotcovered
under warranty.
AIR PRESSURE AND VOLUME
The recommended air pressure for this tool is 85 PSI. The most
important factor in running this tool is the volume of air being sup-
plied to the tool. The volume is the air consumption needed to run
this tool at a constant speed under light downward hand pressure.
ThevolumeismeasuredinCFM(cubicfootperminute(ft3/min).You
need a minimum of 15 CFM per tool.
When choosing a compressor to run an AIR-680 polisher, we recom-
mend a rotary screw type with a minimum of a 5hp motor/15-20 CFM
anda60gallontank,pertool.(I.E. if you want to run four tools, you
will need a compressor with a 20hp motor capability of 80+ CFM and
an 80 to 100 gallon storage tank.)
It is also very important to keep your air cool, dry, and clean, so look for a
compressorwitharefrigerateddryerandhigh-efciencylterbuiltinor
purchaseaseparateairdryerandlterunitratedforyourcompressors
CFM.
RUST PROTECTION (A rust inhibitor oil is used to protect the
tool from rusting when not in use)
PROPER CARE AND MAINTENANCE ARE IMPORTANT
FACTORS IN PREVENTING THIS TOOL FROM RUSTING ON THE
INSIDE WHEN NOT IN USE.
Attheendofeachworkday,place2-3dropsofrustinhibitoroil(in-
cludedwitheachpolisher)directlyintotheOILPORTofthepneumatic
tool. After applying the rust inhibitor oil, turn the air valve slightly so
that the oil atomizes into a mist and coats the internal components
of the polisher. If the process is executed correctly, you should see
a mist coming out of the end of the polisher. The Exhaust Hose
(PartNo.658-95)andHoseClamp(PartNo.1030-1104)needtobe
removed to see the mist effect. See the detailed steps on the next
page for adding the oil to the pneumatic polisher.


10
When you remove the screw (658-91) without disconnecting the
air supply, compressed air will start leaking out and push the screw
while removing. When installing the oil port screw, install until the
O-ring and screw head make contact with the Endcase.
Warning: Over tightening of the oil port screw can strip the
screw and/or internal thread of the Endcase.
HOW TO ADD THE RUST INHIBITOR OIL
1. Disconnectthetoolfromyourairsupply.
2. Removethescrew(PartNo.658-91)using
a #1 phillips head miniature screw driver.
(SeeFig.1)
3. Add 2 -3 drops of the rust inhibitor oil into
theoilport.(SeeFig.2)
4. Reinstallthescrew(PartNo.658-91).
5. Reconnect the tool to your air supply.
6. Turnthevalvelever(PartNo.658-50)
slightly so the air is leaking through the
tool.(Spindleoftoolshouldnotspin
duringthisprocess).(SeeFig.3)
7. Replacement Rust Inhibitor Oil can be
purchased from Alpha® Professional Tools
(PartNo.AIR-008).
Lubricating the tool before and during work is not needed. Excessive
oil will turn to a tar-like substance inside the tool, causing the vanes
to stick in the rotor and slow the tool down. This is the reason we do
not recommend automatic oilers be used with this tool. Old or worn
compressors,whichemitoilthroughtheairlines,cansignicantly
shorten the life of the tool.


11
POLISHING AND USING THE TOOL
This tool and the Alpha®accessories approved for use with this tool
are designed to be used under light downward hand pressure. You
needtoallowthepolishingpads,corebits,andprolerstodotheir
job. Applying excessive downward pressure to the tool will cause the
vanes to wear out in the middle and fail prematurely.
SPINDLE SIZE
The Alpha®AIR-680airpolisherfeaturesa5/8”-11spindle.Thistool
has been designed for portable/shop production and uses all modern
accessories. It is very important that you do not run anything heavier
than the recommended accessories on this machine. A drop of oil
should be applied to the outside threads whenever attachments are
changedtofacilitateremovalandpreventrust.ADoubleEndWrench
(19mm/22mm)isprovidedtoassistinchangingaccessories.
Maintenance and Usage Tip:
• Donotleavethetoolsubmersedinwater.Thiscouldexpose
the inner moving parts to moisture, which will shorten the life
of the tool.
• Do not leave threaded accessories (backer pads, core drill
bits,prolers) on thespindle of toolfor extended periodsof
time; this may result in making it difcult to remove these
accessories.
• Excessive force or impact to the spindle may result in
premature failure of gears, keyways and bearings, which may
not be immediately evident.
AIR VALVE LEVER
Thevalvelevercontrolstheowofair
throughthetool.Ithastwopositions-ON
or OFF. Run the tool at the recommended
pressure of 85 PSI, with the lever
pointing to the ON position. This will
produce4,000RPM.Donottrytovary
the speed. The tool works best at full



throttleonly.Donotattempttoexceedtherecommendedspeedby
excesspressure.Thiswillsignicantlyshortenthelifeofthetool.
When storing the tool overnight, disconnect from the air supply and
open the valve.
HELPFUL HINT:
• Air valve lever should be opened and closed slowly to allow
the tool to accelerate and decelerate during all applications.
Rapid acceleration and deceleration can wear out the ball
bearings prematurely.
HELPFUL HINT:
• Using a Filter Regulator System is
Recommended
FILTER/REGULATOR SYSTEM
Having a Filter/Regulator helps prevent
pressure drops when using a large
volume of air, so you can set the
pressure to the tools at 85 PSI, while the main system can run at
125 PSI. The F/R unit will also remove any water from the air supply
whilealsolteringtheairofcontaminationdowntovemicrons.By
only using aluminum and brass after the F/R unit, you are eliminating
any rust and contamination from getting into the air tools.
The Alpha® F/R Manifold System comes in two sizes, 53 CFM & 106
CFMandthreeadapterblocks:3/8”,1/2”and3/4”,andisdesigned
for installation at the point of use. All F/R manifolds are custom-
conguredtoaclientsspecicneedsandareavailablethroughour
distributor network, and via our website.
WATER CONTROL VALVE
Thisvalveletsyouadjusttheowofwater
through the spindle. It may be used to shut
off the water entirely when changing discs.
When storing the tool overnight, open the
valve and drain all water from the supply
hose and tool.

13
SILENCER / MUFFLER
To comply with OSHA Occupational Noise Exposure Standard
Number1926.52,thispolisherisequippedwithaninternalSilencer
System. When the polisher is operated correctly at 85 PSI, the sound
level emitted should be less than 80 dBA. The internal Silencer
System is also used to maintain a constant back pressure inside the
tool, to prevent the rotor assembly from exceeding the max speed
of the bearings; this helps prevent the polisher from exceeding the
recommended 4,000 RPM. The exhaust hose for this tool also helps
to reduce the noise level by venting the exhaust air and residual
air-line, thus eliminating the risk of excess rust inhibitor oil dripping
on the work piece.
Tools sent in for repair, where the body gasket or silencer is removed
ormodied,arenotcoveredunderourLimitedWarranty.
REVERSIBLE SIDE HANDLE
Attach the handle into the threaded socket on either the left or right
side of the tool. A locknut is slipped onto the threads to keep the
handle safely in position.
Maintenance and Usage Tip:
Donotapplymoreforceorpressurethantheforcecreatedbythe
weight of the polisher itself. The polishing discs are designed to work
properly under light downward hand pressure. Applying excessive
force or pressure may damage the vanes and could shorten the life
of the tool.
AIR SUPPLY HOSE ASSEMBLY
Thisnewhosehas1/4”NPTthreadsandiscomposedofaspecial
materialtoavoidkinksandremainexibledownto-40°F.Replace-
mentsareavailableshouldthehosebecomedamaged(PartNo.
1030-0002).
WATER SUPPLY HOSE ASSEMBLY
This new hose may be connected to any garden hose. It is composed
ofaspecialmaterialtoavoidkinksandremainexibledownto-40°F.
Replacementsareavailableshouldthehosebecomedamaged(Part
No.1030-0003).

14
PROCEDURE FOR CONNECTING EXHAUST HOSE AND HOSE
CLAMP
1. Slide the Exhaust Hose (Part No.
658-95) over the water & air hoses
which should be already connected
tothepolisher.(SeeFig.4)
2. Exhaust Hose should be pulled up and
wrapped around the bottom portion of the
EndcaseAssembly(PartNo.658-94/96).
(SeeFig.5)   
3. SlidetheHoseClamp(PartNo.1030-
1104)overtheExhaustHoseandEndcase
Assembly.(SeeFig.6)   
4. Using a screw driver, tighten to a snug
t.(SeeFig.7)

15
ALPHA®AIR-680 SCHEMATIC (VER.3.1)
43

16
ALPHA®AIR-680 PARTS LIST (VER. 3.2)
DRAWING NO PART NO. DESCRIPTION QUANTITY
1  
   1
3 Oil Seal 1
4  1
5  1
6  1
7  1
   
   1
10   1
11   1
  Oil Seal 1
13   1
14   1
15   1
16   1
17   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
30   1
31   1
   
33   1
34   1
35   4

17
ALPHA®AIR-680 PARTS LIST (VER. 3.2)
DRAWING NO PART NO. DESCRIPTION QUANTITY
36   1
37   1
   1
   1
40   1
41   1
   1
43   1
44   1
45   1
46   1
47   1
   1
   1
50  Needle Pin 1
51   1
   1
53   
54   1
55   1
56   1
57   1
   1
   1
60   1
61   1
   1
63   1
64   
65   


All the accessories can be purchased at a local distributor in your area. For
more information concerning Alpha®Air Polisher and factory service, please
contact the Alpha®distribution centers listed below.
COMPANY HEADQUARTERS Alpha Professional Tools®
& REPAIR CENTER:   103BauerDrive
     Oakland,NJ07436
HoursofOperation:   8:30a.m.–5:00p.m.EST
TelephoneNumber:   201-337-3343
Toll-FreeNumber:   800-648-7229
CANADIAN REPAIR CENTER: Edgewood Sales & Marketing
257 West Church Street
Waterford,ONN0E1Y0
TelephoneNumber:   519-896-4992
Limited Warranty of Alpha®Air Polisher (AIR-680) for USA and Canada ONLY!
Alpha Professional Tools®warrants this product against defects in material and
workmanship for a period of one year from the date of original retail purchase
(proofofpurchaserequired).IfAlphaProfessionalTools®receives notice of such
defects during the warranty period, our obligation assumed under this warranty is
limited to the repair or replacement of parts, without charge. This warranty does
not apply to Alpha®accessories. Returns within the warranty period should be
sent in freight prepaid to an Authorized Warranty Service Center.
The warranty does not apply in situations where:
•The tool has been misused, abused or improperly maintained
•Alterations or repairs were made by others
•Repairs due to normal wear and tear
Some States do not allow limitations on how long an implied warranty lasts or
the exclusion or limitation of incidental or consequential damages, so the above
limitationmaynotapply.Thiswarrantygivesyouspeciclegalrightsandyoumay
also have other rights which vary from state to state.
For Warranty Claims: Send complete tool with all your information and details
of the problem to an Authorized Warranty Repair Center, transportation prepaid.
Donotsendtoolaccessories.
NOTE: Any tools purchased through an unauthorized distributor are not
covered under warranty.





AIR-680   






Dealer’sName:_________________________________

[phone]
MailorFaxto:
Alpha Professional Tools®
103BauerDrive,Oakland,NJ07436
Fax:800-286-0114
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