Alpha AIR-658 User manual

Part No: AIR-658
Version 3
103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: [phone]
www.alpha-tools.com
Alpha®Pneumatic
Air Polisher
Instruction Manual
MANUAL
For repair information call:
Headquarters, Oakland, NJ — [phone]
Due to specially designed components this machine must be serviced only
with genuine ALPHA®parts.
(Shown with optional Splash Guard / sold separately)

2
TABLE OF CONTENTS
Introduction...................................................................................................... 3
About the Symbols .......................................................................................... 3
Safety Instructions for Power Tools ................................................................. 3
Recommended Accessories............................................................................ 5
Special Feature ............................................................................................... 5
Specifications .................................................................................................. 5
Accessories ..................................................................................................... 5
Air-658 Overview............................................................................................. 6
Tool Set-up Information ................................................................................... 6
Air Fitting and Pressure................................................................................... 6
Lubrication....................................................................................................... 7
Spindle Size..................................................................................................... 7
Air Valve Lever ................................................................................................ 8
Water Control Valve......................................................................................... 8
Silencer/Muffler................................................................................................ 8
Reversible Side Handle................................................................................... 9
Water Supply Hose.......................................................................................... 9
Optional Accessories....................................................................................... 9
Splash/Safety Guard.................................................................................. 9
Customizing Splash Guard ........................................................................ 9
C-Shaped Handle .................................................................................... 10
Installing C-Shaped Handle ..................................................................... 10
Pneumatic Air Polisher Schematic................................................................. 11
Air Polisher Parts List .................................................................................... 12
Accessories and Factory Service .................................................................. 14
Product Registration...................................................................................... 15

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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 granite and marble. 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 finish, to reduce the health risks of dust, and to give the most savings
in time and money from modern accessories. 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 classified 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.
SAFETY INSTRUCTIONS FOR POWER TOOLS
KNOW YOUR POWER TOOL. Read owner’s manual carefully. Learn its
applications and limitations as well as specific potential hazards particular
to this tool.
KEEP WORK AREA CLEAN. Cluttered areas and benches invite
accidents.
AVOID DANGEROUS ENVIRONMENTS. Keep work areas as dry as
possible. Do not use tool in presence of flammable liquids or gases. Keep
the area well lit.
1.
2.
3.

4
KEEP CHILDREN AND VISITORS AWAY. All visitors should be kept a safe
distance from the work area. Keep out of reach of children.
DON’T FORCE TOOL. It will do the job better and safer at the rate for
which it was designed.
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.
WEAR PROPER EYE PROTECTION. Use safety glasses at all times. Also,
use a face mask if work area is dusty.
WEAR PROPER EAR PROTECTION. Wear ear protectors when using
for extended periods.
DON’T ABUSE WATER SUPPLY HOSE. Don’t carry tool by supply hose
or expose to traffic areas where it can be crushed.
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.
DON’T OVERREACH. Keep proper footing and balance at all times.
DISCONNECT TOOLS WHEN NOT IN USE. Always disconnect tool before
servicing; when changing accessories such as grinding wheels, backer
pads, etc.
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.
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.
AVOID ACCIDENTAL STARTING. Don’t carry a “connected” tool, or make
adjustments, or change discs without making sure the air valve is in the off
position to prevent the flow of air.
USE ONLY RECOMMENDED ACCESSORIES. The use of any accessories
other than what is listed or recommended for this particular tool may be
hazardous.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

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KEEP HANDS AWAY FROM ALL MOVING PARTS.
USE SIDE HANDLES. Supplied with tool for control and safety.
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.
STAY ALERT. Watch what you are doing and use common sense. Do
not operate tool when you are tired, or under the influence of medication
or alcohol.
RECOMMENDED ALPHA®ACCESSORIES
Ceramica EX flexible diamond polishing discs, waterproof Sandpaper discs, Hook
and Loop Backed Felt Wheels, Core Drill Bits, Twistouch Turbo and Profilers.
SPECIAL FEATURE
The Alpha®Air Polisher was designed with human engineering for operator comfort.
It comes equipped with a silencer which reduces the level of noise as well as
guiding the cold exhaust air away from an operator during the polishing process.
This feature also eliminates excess lubricant dripping on the work piece. Portions
of the body design are made with synthetic materials and covered with rubber to
prevent fatigue and coldness to hands.
SPECIFICATIONS
RPM Weight Air
Consumption
Air
Pressure
Air
Inlet
Water
Inlet Spindle
U.S. No Load 3,500
2.64 lb 15 CFM 87 PSI
1/4” BSPP 1/8” BSPP 5/8”-11
METRIC 1.2 kg 420 ℓ/ Min 0.6Mpa (6 bar)
ACCESSORIES
Water hose (10 ft / 3m).......................................................1pc
Air hose (10 ft / 3m)............................................................ 1pc
Wrench (22mm) .................................................................1pc
Side handle ........................................................................1pc
Lubrication Oil (1oz / 30 cc sample bottle)...............................1pc
17.
18.
19.
20.

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AIR-658 OVERVIEW
Rubber Splash Guard
(optional / sold separately)
Reversible Handle
10 ft Water Hose
10 ft Air Hose
Adjustable Air Valve
Adjustable Water Valve
Rubber Body cover
Internal Water Line
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 fill out the registration card enclosed, and mail it back to the distribution
center today.
AIR FITTINGS AND PRESSURE
Your new Alpha®polisher is designed for continuous duty polishing. When select-
ing your compressor, buy a system which can handle a constant flow of air. We
recommend that you purchase a heavy duty two stage cast iron type unit. The
system should include a regulator and
a moisture trap.
Each tool requires: 87 PSI
(
0.6Mpa / 6 bars) ; however the
range of 85-90 PSI is acceptable.
(6 kg / cm2) of air pressure and
15 CFM (420 l / min.) of air flow.
•

7
We suggest a minimum of 5 HP air compressor with a holding tank of 50
cubic feet (1,400 l) capacity for one tool.
Air hose fitting is 1/4” BSPP
The use of heavy duty 3/8” (10mm) hose is suggested for all lines.
LUBRICATION (Lube Oil is used to protect the tool from rusting when not in use)
PROPER CAREAND LUBRICATIONARE IMPORTANT FACTORS IN THE USEFUL
LIFE OF THIS TOOL.
At the end of each workday, 2-3 drops of lubricant oil, solvent free oil (included with
each polisher) should be placed in the air inlet at the base of the tool. Rotate the
spindle counter clockwise, by hand 3-4 revolutions. Reinstall the air hose and run
the tool for a minute or two. (Replacement containers of oil may be purchased from
Alpha Professional Tools®Part # AIR-008.)
Maintenance and Usage Tip
Automatic oilers are not recommended: the volume, grade, and composition of oil
used may cause premature failure. In-line air dryers are recommended to extend
the life of the tool. Old or worn compressors, which emit oil through the air lines,
can dramatically shorten the life of the tool.
SPINDLE SIZE
The Alpha® AIR-658 air polisher features a 5/8”-11 size 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 22mm Spindle Wrench 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, profilers) on
the spindle of tool for extended periods of time; this may result in making it
difficult to remove these accessories.
Excessive force or impact to the spindle may result in premature failure of
gears and/or bearings, which may not be immediately evident.
AIR VALVE LEVER
The valve lever controls the flow of air through the tool. It has two positions- ON or
OFF. Run the tool at the recommended range of 85-90 PSI, with the lever pointing
•
•
•
•
•
•

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to the ON position. This will produce 3,500 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.
WATER CONTROL VALVE
This valve lets you adjust the flow 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.
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 87 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; this helps prevent it from exceeding the recommended 3,500 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 lubricant dripping
on the work piece. The new Silencer System is designed to allow small particle of
contamination and dust to pass through, however if your air supply has particles
larger than 1mm you will need to clean out the Silencer.
Maintenance and Usage Tip:
The Silencer is located on the rear of the polisher under the air and water fittings.
A clogged Silencer would be indicated by a loss of power or lower RPM’s from the
tool. To clean the Silencer remove the air and water fittings, use a small screwdriver
or pick to remove the hard plastic silencer and blow it out with compressed air from
the outside (flat side of silencer). Reinstall the Silencer with the recessed side of
the Silencer toward the tool, the Silencer should fit into the encase tightly, leaving
a flat surface on the outside of the tool.
WARNING!
Tools sent in for repair, where the silencer is removed or modified, 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.

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MAINTENANCE AND USAGE TIPS:
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 lightweight
pressure. Applying excessive force or pressure may damage the disc and could
shorten the life of the tool.
WATER SUPPLY HOSE
This hose may be connected to any garden hose using a clamp. The hose is com-
posed of a special material to avoid kinks. Replacements are available should the
hose become damaged, Part # 133229.
SPLASH / SAFETY GUARD
The splash guard can be used for operator comfort and protection during all grinding
and polishing operations. (Part No. AWP-01)
CUSTOMIZING THE SPLASH GUARD
Using a pair of scissors or other cutting
instrument, follow the cut line to expose the
front opening for easy visibility.
1.
OPTIONAL ACCESSORIES
Cut Line for
Front Opening
Grooved Lines for
Height Adjustment

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Choose the desired height according to the application
to be performed and cut along the grooved cut lines to
adjust the height.
Install the rubber splash guard onto the tool so that
the lip on the splash guard fits into the groove on
the tool and the cutout is around the water fitting.
C-SHAPED HANDLE
When used with Alpha®Core Bits and Alpha®Profilers, the “C-Shape” handle
allows the operator to have better control and stability during operation. (Part No.
21A).
INSTALLING C-SHAPED HANDLE
2.
3.
Place flat washer
over hole pattern,
as shown above.
1. Slide C-Shaped
handle over flat
washer and align
holes.
2. Insert bolt and
lock washer into
hole and tighten
by hand.
3. Using a wrench,
tighten bolts to
securely attached
the C-shaped
handle. Repeat
steps for the
opposite side.
4.
C-shaped Handle during Drilling Application C-shaped Handle during Profiling Application
Groove
Water Fitting

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ALPHA®PNEUMATIC AIR POLISHER SCHEMATIC
Optional Accessories
78
4

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ALPHA®PNEUMATIC AIR POLISHER PARTS LIST (VERSION 3)
DRAWING NO. PART NO. DESCRIPTION QUANTITY
1 658-01 Screw M4x10 2
2 658-02 Pipe-joint Assembly 1
3 516-44 Oil Seal 1
4 AWP-21A C-shaped Handle for Air Tools*1
9 658-09 W-pipe 1
10 658-10 Head Packing 1
11 658-11 Body 1
12 658-12 Body Cover 1
13 658-13 Spring Washer M10 1
14 658-14 Grip 1
15 516-20 Bearing 608 ZZ 1
16 658-16 Snap Ring 1
17 658-17 Spiral Bevel Gear 1
18 516-48 Bearing 6302 ZZ 1
19 516-49 Oil Seal 1
20 516-50 44 Nut 1
21 658-21 Gear Shaft 5/8-11Thread 1
22 658-22 Half Moon Key 1
23 658-23 O-Ring 1
24 658-24 5/8 Nozzle 1
25 658-25 Spiral Bevel Pinion 1
26 516-18 Bearing 6001 ZZ 1
28 658-28 F-Bearing Case 1
29 658-29 Rotor Spacer 1
30 658-30 Cylinder (Inc. Part# 658-31) 1
31 658-31 Spring Pin 1
32 658-32 Rotor 1
33 516-25 Vane (4 Piece Set) 1
34 516-26 R-Bearing Case 1
35 516-27 Bearing 626 ZZ 1
36 516-28 Bearing Cap 1
37 658-37 Air Inlet Case 1
*(Optional / sold separately)

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ALPHA®PNEUMATIC AIR POLISHER PARTS LIST (VERSION 3)
DRAWING NO. PART NO. DESCRIPTION QUANTITY
43 658-43 Screw M4x10 1
45 658-45 Wave Washer 1
46 658-46 Nut M-14 1
47 658-47 O-Ring 2
50 658-50 Valve Lever 1
51 658-51 Screw M4x15 4
54 658-54 Nipple 1
55 133229 Water Hose 8mm ODx10ft (3m) 1
56 AWP-56 Compression Ring (Plastic) 1
57 AWP-57 Compression Nut 1
58 AWP-74 Hose Coupling 1
59 658-59 Clamp 1
60 AWP-75 Gasket 24x14x3 1
61 AWP-01 Rubber splash guard*1
62 658-62 Wrench 22mm 1
64 658-64 O-Ring 1
65 658-65 R-ring 1
66 658-66 Nut M8 1
67 658-67 Washer 05 1
70 658-70 Endcase w/Bushing
(inc. Part# 658-72 & 658-73) 1
71 516-79-2 Air hose Joint 1/4” BSPP 1
72 658-72 O-Ring 1
73 658-73 Bushing 07 1
74 658-74 Exhaust Hose (Leather) 1
78 658-78 Complete Endcase Assembly 1
79 516-79-1 Air hose 10mm ODx3M 1
80 658-80 Shim 01mm x 12mm OD 1
81 658-81 Shim 03mm x 12mm OD 1
82 658-82 Shim 05mm x 12mm OD 1
84 658-84 Shim 01mm x 84mm OD 1
85 658-85 Oval Key 10mm 1
*(Optional / sold separately)

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DRAWING NO. PART NO. DESCRIPTION QUANTITY
86 658-86 Water Valve 1
87 658-87 A-Valve 1
88 658-88 Needle Pin 1
89 658-89 Body Gasket 1
90 658-90 Silencer 1
Not Shown AIR-008 Air Polisher Lube Oil (8 oz) 1
Not Shown 516-50WRH 44- Nut Wrench 1
ALPHA®PNEUMATIC AIR POLISHER PARTS LIST (VERSION 3)
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®
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
Limited Warranty of Alpha®Air Polisher (AIR-658) for the USA and Canada ONLY!
Alpha Professional Tools®warrants this product against defects in material and
workmanship for a period of 90 days 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 tool accessories.
For Warranty Claims: Send complete tool with all your information and details
of the problem to the Alpha Professional Tools®, transportation prepaid. Do not
send tool accessories.
ACCESSORIES AND FACTORY SERVICE

15
PRODUCT REGISTRATION CARD
Model No. Serial No.
Company Name: ______________________________________________
Name: ______________________________________________________
Address: ____________________________________________________
City: _______________________State: ________Zip: ________________
Telephone: ___________________________________________________
Purchase Date: _______________________________________________
Dealer’s Name: _________________________________
Note: Serial & Model Number must be included for proper registration.
[phone]
Mail or Fax to:
Alpha Professional Tools®
103 Bauer Drive, Oakland, NJ 07436
Fax: [phone]
Photocopy of product registration form will be accepted.

Register online at:
www.alpha-tools.com/productregistration.aspx

Copyright ©2009 Alpha Professional Tools. All rights reserved.
103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: [phone]
www.alpha-tools.com
01/2010