Trelawny spt Vl203ex User manual

www.trelawny.co.ukwww.trelawny.co.uk

VL203ex NEEDLE SCALER

operations and maintenance manual

PAGE 2

VL203EX Needle Scaler

CONTENTS

Introduction ................................................................................................................................................................ 2

Declaration of Conformity..................................................................................................................................... 3

Foreword ...................................................................................................................................................................... 6

General Information ................................................................................................................................................ 6

Safety ............................................................................................................................................................................. 6

Risk of Hand Arm Vibration .................................................................................................................................. 7

Air Supply ..................................................................................................................................................................... 7

Starting Work ............................................................................................................................................................. 7

Maintenance ............................................................................................................................................................... 8

Assembly ...................................................................................................................................................................... 9

Disposal ........................................................................................................................................................................ 9

Exploded ...................................................................................................................................................................... 10

Parts List ....................................................................................................................................................................... 11

Technical Specication........................................................................................................................................... 12

INTRODUCTION

Your new Trelawny SPT 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 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.

ENVIRONMENTAL PROTECTION

The machine, accessories and packaging should be sorted for environmentally friendly

recycling. The plastic components are labelled for categorised recycling.

DISPOSAL

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

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

www.trelawny.co.uk

DECLARATION OF CONFORMITY

Adam Dickinson,

Managing Director

We,

Trelawny SPT Limited of

Trelawny House, 13 Highdown Road, Sydenham Industrial Estate, Leamington Spa, Warwickshire, CV31

1XT, United Kingdom,

Declare that under our sole responsibility for supply/manufacture of the product

Name of product Needle Scaler

Model VL203Ex

to which this document relates is in conformity with the provisions of the following Directive(s),

Normative Documents and their relevant Standards:

2006/42/EC MACHINERY DIRECTIVE

EN ISO 11148-4:2010 HAND HELD NON-ELECTRIC

(Non-Rotary Percussive Tools)

EN ISO 4414:2010 General rules and safety requirements

EN ISO 4414 SAFE PNEUMATIC EQUIPMENT OF MACHINERY

Conformity with the following relevant legislation:

2014/34/EU ATEX DIRECTIVE

Based on following harmonised standards:

EN 60079-0:2018

EN ISO 80079-36:2016

EN ISO 80079-37

II 2 G Ex h IIC T4 Gb

II 2 D Ex h IIIC T135°C Db

www.trelawny.co.uk

Email: sales@trelawny.co.uk

Tel: +44 (0) 1926 883781

Fax: +44 (0) 1926 450352

Year and place of issue,

2020

Leamington Spa, England

________________________

Registered Oce: Trelawny SPT Ltd, Trelawny House, 13 Highdown Road, Sydenham Industrial Estate, Leamington Spa, Warwickshire, CV31 1XT, United Kingdom

DOCUMENT No. Q:57/8

________________________________________________________________________________________________________

PAGE 4

VL203EX Needle Scaler

CZ Prohlášenl o přizpüsobení

My, společnost Trelawny SPT Limited

podajemy daňové přiznáni. že výrobek a dodávka výrobku

název výrobku

Model, výrobni čislo

Rok výroby

Pro které se průkaz týkajici, je přizpůsobeni s zásoby od následujici přikazov a jejich pohotovostni:

98/37/EC Přikaz soustroji

73/23/EC Přikaz nizkého napéti (upotřebitelne jediné do výrobku použiti elektnckej energie)

LT ATITIKTIES DEKLARACIJA’

Mes, Trelawny SPT Limite

Prisiimdami visą atsakomybę deklaruojame, kad tiekiamas / gaminamas produktas

Produkto pavadinimas

Modelis, serijos numeris

Pagaminimo

Kuriam taikoma ši deklaracija, atitinka šių direktyvų, norminių aktų ir su jais susijusių. standartų reikalavimus:

98/37/EC ļtrangos direktyva

73/23/EC Zemos įtampos direktyva (taikoma tik elektriniams įrengimams)

DE Ubereinstimmungserklarung

Wir, Trelawny SPT Limited

erklaren, dass unter unserer alleinigen Verantwortung fur die Lieferung und Herstellung des Produktes

Name des Produktes

Model, Seriennummer

Jahr der Herstellung

auf welches sich dieses Dokument bezieht. stimmt mit den Vorgaben der folgenden Direktive, normativen Dokumente und deren

jeweiligen Masstabe ein:

98/71/EC Maschineriedirektive

73/23/EC Niederspannungsdirektive (nur zutreffend auf Produkte, die Strom benutzen)

MT DIKJARAZZJONI TA KONFORMITA

Aħna, Trelawny SPT Limited

Niddikjaraw li aħna responsabbli kompletament għal provista / manifattura tal-prodott hawn 1msemmi:

lsem ll-Prodott

Mudell, Serial number

Sena Ia 'produzzjoni

Dan id-dokument magħmul għal prodott imsemmi hawn fuq, li huwa skond il-provizjonijiet imsemmija d-dokumenti tal-klassi tax-

xogħol:

98/37/EC Machinery Directive

73/23/EC Low Voltage Directive (tapplika biss għal prodotti li jaħdmu bl-eletrkiu)

DK Erklæring om overensstemmelse

Vi, Trelawny SPT Limited

Erklærer hermed at under vores ene forhandling ansvar for vores forhandling/produktion af produktet

Produkt navn

Model, serie nummer

Produktionsár

For hvilket delle dokument referer, at deler i overensstemmelse med bestemmelser af følgende direktiver, normative dokumenter

og deres relevante standart:

98/37/EC Machinery directive

73/23/EC Low voltage directive

NL EENVORMIGHEIDSVERKLARING

Wij. Trelawny SPT Limited

Verklaren dat wij de volledige verantwoordelijkheid dragen voor het leveren/fabriceren van het volgende product:

Naam van het product

Type, Serienummer

Productiejaar

En verklaren dat het product waarnaar dit document verwijst eenvormig is met de voorzieningen van de volgende Richtlijn(en),

Normatieve Documenten en hun relevante Standaarden:

98/37/CE MACHINERICHTLIJN

73/23/CE LAAGSPANNINGSRICHTLIJN (uitsluitend van toepassing bij producten die elektrische stroom gebruiken)

EE TOOTE VASTAVUSE DEKLARATSIOON

Meie, Trelawny SPT Limited

Deklareerime, et vastutame jägmise varustuse/toote müügi eest

Toote nimetus

Mudel, Seeria number

Aasta toodangu

Antud dokument töendab toote vastavust järgmistele direktiivi(de)le, normatiivaktidele ja nendega samaväärsetele standarditele:

98/37/EC MASINA DIREKTIIVID

73/23/EC MADALPINGE DIREKTIIVID (Kohandatakse vaid toodetele, mis kasutavad elektrivoolu

PL Deklaracja Zgodnosci

My, Firma Trelawny SPT Limited.

oświadczamy w naszej odpowiedzialności, ze produkcja i dostawa urzctdzenia

Nazwa produkta

Model, numer seryjny

Rok produkcji

do którego ten dokument należy, jest zgodne z klauzulami nastąpujacych zarządzen i ich istotnych standartów:

98/37/EC Zarządzenie mechaniczne

73/23/EC Zarządzenie niskiego napięcia elektrycznego (Zastosowanie tylko przy urządzeniach elektrycznoych)

ES Declaración de Conformidad

Nosotros, Trelawny SPT Limited

Declaramos que bajo nuestra completa responsabilidad de Ia fabricación/suministro del producto

Nombre del Producto

Modelo, No de Serie

Año de producción

A quién este documento se refiere, está de acuerdo con lo relacionado en Ia Directriz, Normativa Documentada y sus relevantes

standards:

98/37/EC Directorio de Maquinaria

73/23/EC Directorio de Bajo Voltaje (Aplicable solamente a productos que funcionen con electricidad)

PT DECLARAÇÄO DE CONFORMIDADE CE

A empresa TRELAWNY SPT LIMITED

Declara, sob sua inteira responsabilidade, que o fornecimento/fabrico do seguinte produto:

Designaçáo do produto

Modelo, Nümero de Série

Ano de produçáo

a que esta declaraçáo se refere. está em conformidade com o preceituado nas Directivas e Normas Comunitárias abaixo indicadas:

98/37/EC DIRECTIVA DE MÁQUINAS

73/23/EC DIRECTIVA DE BAIXA VOLTAGEM (Aplicável apenas a produtos que utilzi am energia eléctrica)

FI ILMOITUSVAHVISTUS

Me. Trelawny SPT Limited

Vahvistamme tuotteiden toimittamisesta/valmistamisesta

Tuotenimi

Malli, sarjanumero

Valmisttusvuosi

Tällä todistuksella vahvistamme säädökset seuraviin ohje/ohjesiin, Yleisiin papereihin ja niihin liittyvät vaatimukset:

98/37/EC KONEISTON OHJEET

73/23/EC PIENJÄNNITE OHJEET (tarvitaan ainoastaan tuotteille jotka käyttävät sähkovoimaa)

RU CBИдETEПЬCTBO O COOTBETCTBИИ

Mьι, Trelawny SPT Limited

3aявляем, что несем полную ответственость эа поставκу/производство нижеукаэанной

продуκцим

Hаименоване изделия

Mодель, серийньιй номер

Год вьιлуска

на котоеую вьιдано настящее Cвидетельство, и которая соответствует положениям слдующей(иx) директив(ьι),

нормативньιм доκументам и относящимся к ним стандартам:

98/37/EC ДИРЕКТИВА ПО MEXAHИ3MAM

73/23/EC ДИРЕКТИВА ПО HИ3KOBOЛЬTHOMУ OЪOPУДOBAHИЮ (распространяется только на изделия с

злектропитанием)

FR DÉCLARATION DE CONFORMITÉ

Nous, soussignés Trelawny SPT Limited

déclarons que le produit sous-nommé

Nom du produit

Modèle et Numéro de Serié

Année de production

et pour lequelnous prenons entière responsabilité pour sa fourniture et manufacture, est conforme aux clauses des directives

suivantes documents norminatifs et normes qui s'y appliquent:

98/37/EC DIRECTIVE POUR LA MACHINERIE

73/23/EC DIRECTIVE POUR BAS VOLTAGE (n'est applicable qu'aux produits utilisant l'énergie électrique)

SE FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

VI, TRELAWNY SPT LIMITED

FÖRKLARAR ATT VI MED ENSAMT ANSVAR ANSKAFFAT / TILLVERKAT PRODUKTEN PRODUKTNAMN

MODELL och SERlE NUMMER

Tillverkningsár

TILL VILKEN DETTA DOKUMENT HÄNVISAR ÄR I ÖVERENSSTÄMMELSE MED FÖLJANDE DIREKTIV, NORMATIVA

DOKUMENT OCH DERAS RELEVANTA STANDARDER

98/37/EC MASKINDIREKTIV

73/23/EC LÄGSTRÖMSDIREKTIV (TILLÄMPLIG PÄ ELEKTRISK DRIVNA PRODUKTER)

GR ΔΗΛΩΣΗ ΠΙΣΤΟΤΗΤΑΣ

Η εταιρεια Trelawny Spt Limited

Δηλωνει ότι έχει τη μονδικη ευθυνη ως κατασκευαστρια / προμηθευτρια του παρακατω προιοντος περιγραφη προιοντος

μοντελο, αριθμος σειρας

έτος παραγωγής

και στο οποιο αναφερεται αυτη η δηλωση, ειναι συμβατο με τις προδιαγαφες που οριϚονται στιϚ ακολουθεϚ Koινοτικες

OδηγιεϚ EλεγκτικεϚ ΔιαταξειϚ κι αλλεϚ σχετικες προδιαγραφεϚ

98/37/EC OΔHΓΙΑ ΠΕΡΙ ΜΗΧANHMATΩN

73/23/EC OΔHΓΙΑ ΠΕΡΙ XAMHΛHΣ TAΣHΣ (αφορα μονον προιοντα που λειτουργουν με ηλεκτρικο ρευμα)

SI IZJAVA O SKLADNOSTI

Trelawny SPT Limited

pod polno odgovornostjo izjavljamo, da so spodaj navedeni proizvodi, ki jih dobavljamolproizvajamo:

lme proizvoda

Model. serijska številka

Leto proizvodnje

na katere se ta dokument nanaša. proizvedeni v skladu z določili naslednjih direktiv, normativnih dokumentov in njihovih relevant-

nih standardov:

98/37/EC DIREKTIVA O STROJIH

73/23/EC DIREKTIVA O STROJIH Z NIZKO VOLTAŽO (nanaša se samo na proizvode na električni pogon)

HU MEGFELELŐSÉGI NYILATKOZAT

Mi. A "Trelawny SPT Limited" cég

Felelösségünk tudatában kijelentjük, hogy mint a termék szállitója/gyartója

Termék neve

Tipus, Sorozatszáma

Gyártási év

amelyre jelen dokumentum vonatkozik, megfelel az alábbi lrányelv(ek), lrányadó Dokumentumok elöirásainak, és az azokat

meghatározó szabvanyoknak:

98/37/EC GÉPÉSZETI IRÁNYELVEK

73/23/EC KISFESZÜLTSÉGÜ IRÁNYELVEK (Csak az elektromos meghajtásů gepeknél)

TR UYGUNLUK BEYANI

Trelawny SPT Limited

AÞaöýdaki, üretim ve tedarikinden tek baÞýna sorumlu olduöu ürünün

Ürün ady

Modei/Seri no

Üretim yili

bu belgenin ilgili olduöu apaöýdaki yönetmeliklerin, norm belgelerinin ve ilgili standartlarýnýn koÞullarýna uygun olduöunu beyan

eder:

98/37/EC MAKŶNALAR YÖNETMELŶDŶ

73/23/EC DÜÞÜK GERŶLŶM YÖNETMELŶDŶ (Yalnýýz elektrikle çalyÞan ürünlerde geçerlidir)

IT DICHIARAZIONE Dl CONFORMITA

La Società Trelawny SPT Limited

Dichiara, sotto Ia propria responsabilità, che Ia fornitura / produzione del prodotto

Nome prodotto

Modello, codice

Anno di produzione

a cui si riferisce tale documento è conforme aile seguenti Direttive, ai documenti della Normativa ed ai relativi standard:

98/37/EC DIRETTIVA SULLE APPARECCHIATURE

73/23/EC DIRETTIVA SUL BASSO VOLTAGGIO (applicabile esclusivamente peri prodotti che utilizzano energia elettrica)

DECLARATION OF CONFORMITY

www.trelawny.co.uk

DECLARATION OF CONFORMITY

Appendix 1 - Hazardous Area Certication

The VL203Ex Needle Scalers are certied compliant to the ATEX Directive (2014/34/EU) for safe use

within a hazardous area and has been assessed so by Element Materials Technology.

This product conforms to the Standards:

EN 60079-0:2018

EN ISO 80079-36:2016

EN ISO 80079-37

And is attributed with the product certication codes:

II 2 G Ex h IIC T4 Gb

II 2 D Ex h IIIC T135°C Db

With ATEX Certicate Number: EMT19ATEX0022X

Special Conditions of Safe Use

1. Air compressors used in conjunction with the Scaling Hammers shall incorporate means to prevent the

ingress of dust or other foreign material into the air supply i.e a lter on the compressor intake.

2. For air compressors used in conjunction with the Scaling Hammers, only lubricants that are resistant to

carbonisation shall be used.

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

stronger than manual rubbing.

4. Air supply hoses used in conjunction with the equipment must be manufactured from anti-static

material with a surface resistance no greater than 10°Ω.

5. Equipment is to be lubricated before as detailed in the Operations & Maintenance Manual.

6. Any lubricating oil used must have an auto ignition temperature of > 185°c.

7. The equipment must not be stored in an explosive acetylene atmosphere (to prevent the formation of

acetylides on the copper heads).

Equipment must only be installed & maintained by suitably qualied and competent personnel in

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

PAGE 6

VL203EX Needle Scaler

FOREWORD

GENERAL INFORMation

SAFETY

Thank you for your purchase of the VL203Ex Needle Scaler.

This manual contains the necessary maintenance information

for you to ensure proper operation and care for this machine.

It is essential for you to read through this manual thoroughly.

In the unlikely event that you experience problems with your

VL203Ex Needle Scaler, please do not hesitate to contact your

local Trelawny dealer or agent. We always welcome feedback

and comments from our valued customers.

Before operating, performing maintenance or repairing the

VL203Ex Needle Scalers, this manual must be read and

understood. If in any doubt, ask your supervisor before using

this equipment.

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, scale, and for the removal of laitance

from concrete, it can be used both indoors and out. This tool

must not be used in a xture.

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.

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.

- 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, 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.

We recommend using a suitable vacuum system connected

to the optional 38mm vacuum take o-port tted to the tool.

The Beryllium Copper spark resistant needles may create

airborne dust, which may be 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 VL203Ex, Vl223Ex or VL303Ex Needle

Scaler and also comes with an Anti-static 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

WARNING! Before operating, performing maintenance

or repairing the VL203Ex this manual must be read and

understood. If in any doubt, ask your supervisor before

using this equipment.

WARNING! Always observe safe-working practices at

all times.

www.trelawny.co.uk

RISK OF HAND-ARM VIBRATION INJURY

air supply

STARTING WORK

These tools may cause Hand-arm Vibration Syndrome injury

if their use is not adequately managed. We advise you to

carry out a risk assessment and to implement measures

such as; limiting exposure time [i.e. actual trigger time, not

total time at work], job rotation, ensuring the tools are used

correctly, ensuring the tools are maintained according to

our recommendations, and ensuring that the operators wear

personal protective equipment [PPE] particularly gloves and

clothing to keep them warm. Employers should consider

setting up a programme of health surveillance to establish

a benchmark for each operator and to detect any early

symptoms of vibration injury.

We are not aware of any PPE that provides protection

against vibration injury by attenuating vibration emissions.

See ‘Specications’ section for vibration emission data.

We strongly advise you to visit the Health & Safety

Executive website http://www.hse.gov.uk/vibration

This site provides excellent advice and information on HAV

and currently, includes a Hand-arm Vibration Exposure

Calculator that is easy to use to work out the daily vibration

exposure for each of your operators.

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.

For maximum e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 (80psi) or

rise above 6.9bar (100psi) 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.

Please note we recommend using a lanyard or strap attached

to the optional Drop Protection fall arrestor (39). This should

be attached to a belt or harness, but preferably to a xed and

secure mounting point.

Always use Trelawny Beryllium Copper Needles.

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 su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 eciently.

Excessive operator pressure will not improve the tool

e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 (7) 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 o the surface.

To switch o, simply release the throttle lever.

Gloves and personal protective equipment must be worn

when using this tool.

WARNING! VERY IMPORTANT

Only Trelawny Beryllium Copper Needles must be used

in this tool.

DO NOT substitute with any other needle.

PAGE 8

VL203EX Needle Scaler

MAINTENANCE

Removing Needles

Disconnect from air supply, hold the Cover (10) in a vice using

the ats provided, keeping the tool horizontal, unscrew by

hand, the Front Tube assembly (30,31,32,33,34) complete

with Return Spring (32), Needles (31), and Needle Holder (30).

Check the condition of the Front Tube Locking O’Ring (25).

Take care not to invert the Needle Scaler while removing

the Front Tube (34) or the Piston (26) may fall out of the

Intermediate Tube (22). 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 (25) to the

Intermediate Tube. Fit the Return Spring (32) 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 and ensure

ignition temperature is above 185Deg°.

Piston and Cylinder removal

Remove the Front Tube assembly (See Removing Needles)

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

Intermediate Tube (22), 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 anticlockwise.

Carefully remove the Intermediate Tube from the cover and

remove the Cylinder (15) from its location hole in the Cylinder

Guide Plate (12), which is tted in the cover (10). 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 will require replacing after

approximately 120 -160 hours use; this is dependent on the

cleanliness of the air supply and frequency of lubrication.

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

invalidate the ATEX certication. Remove the ball retaining

O’Ring (18) from its groove just inside the bore of the cylinder

stem using a suitable pointed implement. Remove the ball (17)

from the bore, replace and ret new O’Ring into groove.

Piston Valve Pin replacement

Hold the piston (26) in a vice by the stem, using a pair of pliers

break o the valve pin (28), 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 (1) with O’Ring (2), Valve Spring (3),

Valve Stem (4) and the Valve Seat O’Ring (5).

Valve Body removal

Remove the Front Tube assembly (30,31,32,33,34)

as per instructions for Removing Needles. Replace the Front

Tube (34) without the Needles etc, onto the Intermediate Tube

(22) and screw up until hand tight. Clamp the Valve Body (6)

with its 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. A vacuum shroud (42) is available (see parts list for

shroud and cu) which ts over the front tube. Position the

front of the cu (43) with the needle tips 15-20mm inside,

adjust as the needles wear. Tighten the caphead screw to

secure. Use a Trelawny recommended ATEX and HEPA

vacuum for 99.9% dust containment.

VERY IMPORTANT Before carrying out any dismantling,

ensuring the air supply is turned o,

www.trelawny.co.uk

ASSEMBLY

DISPOSAL

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

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). Replacement of

the Valve Body (6) onto the Cover assembly (10) 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 uppermost. Finally tighten

up clockwise by hand, holding the Front Tube (34) and Cover,

and align the Throttle Lever (7) with the front of the tool when

resistance is felt.

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 (12) 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 (15) by inserting the

cylinder stem into the bore of the Cylinder Guide Plate. With

the removal holes uppermost carefully slide the Intermediate

Tube (22) 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 rst into the Intermediate Tube, if resistance is

felt, turn the piston slightly until it is located in the cylinder.

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

front of the tool downwards, 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.

Dismantle into component form, segregate according to

material composition and dispose of using waste recycling

processes specied by local regulations.

VERY IMPORTANT

Only Trelawny Beryllium Copper Needles must be used

in this tool.

DO NOT substitute with any other needles.

WARNING! Maintenance must only be carried out by

a competent person, in a suitably equipped workshop.

Disconnect the tool from the air supply before carrying

out any of the following operations.

PAGE 10

VL203EX Needle Scaler

EXPLODED DIAGRAM

www.trelawny.co.uk

parts list

Item NO. PART NO. DESCRIPTION

1 615.3021 Valve Cap

2809.0139 Valve Cap O’Ring

3712.3022 Valve Spring

4618.3022 Valve Stem

5809.0089 Valve Seat O’Ring

6423.3021 Valve Body Assembly BSP Thread

(incl items 1-8)

7716.3000 Throttle Lever

8813.0108 Roll Pin

9717.3050 Rubber Handle Grip

10 425.2003 VL203 Cover Assembly

(Pistol Grip)

12 652.2003 Guide Plate

13 829.2003 Guide Plate Seal

14 809.0299 Guide Plate O’Ring

15 428.2003 Cylinder

17 816.3005 Plastic Ball 6mm diameter

18 809.0080 Ball Retaining O’Ring

19 809.2004 Piston Cushion

22 622.2031 Intermediate Tube

23 721.2003 Intermediate Tube

Outer Sleeve

25 809.0299 Front Tube Locking O’Ring

26 612.2003 Piston

28 636.3003 Valve Pin

29 829.2002 Piston Ring

30 601.2030 3mm Needle Holder

(19 Needles tted as standard)

31 403.1309 Needle set (1 x set

Beryllium Copper)

32 712.2003 Front Spring

33 620.2003 Front Tube Insert

33A 620.2003A Front Tube Spacer

34 622.2030 Front Tube

35 809.3005 Cylinder Stem Reaction Ring

39 512.2003 Fall Arrester Clamp Assembly

(Inc. 42, 43)

40 415.3003 Anti Static Lanyard

41 720.2003 VL203/223 Arrester Clamp Assembly

42 418.2003 Vacuum shroud assembly

(with at cu. 40)

43 731.2103 Flat Cu

446.2003X Service Kit (2,3,4,5,7,8,13,14,17,18,19,25,28,29,30,31,32)

819.2375 Connector 1/4” BSPT-3/8” Stem

843.0825 1/4’’ BSP to NPT Connector

735.3009 Fitting Instructions

453.1310 Box of 100 Beryllium Copper Needles

443.1307 Box of 500 Beryllium Copper Needles

PAGE 12

VL203EX Needle Scaler

Trouble Shooting Cause Action

Poor performance or lack of power.

Low air pressure. Ensure that the air pressure is correct at 90psi, max 100psi.

If tool has been left for some time without use, the oil may dry out

slightly, causing a sticky residue. Strip tool down, clean and re-oil.

Needles worn or some missing. Replace with new set of needles and new needle holder.

Piston seal worn. Remove seal from piston and t into bore of cylinder. If it drops to the

bottom of the bore, a replacement is required.

Valve pin broken. Replace valve pin and 6mm plastic ball.

Tool continues to run with trigger released. Valve seal may have become dislodged through the tool being

disconnected with the trigger in the open position.

Ensure that the trigger has not been taped or wired in the open

position, reposition or replace valve seat o’ring.

High vibration.

High air pressure. Ensure that the air pressure is correct at 90psi, max 100psi.

Lack of lubrication. Lubricate with the recommended air tool oil daily.

Low air pressure 70-80psi can also cause high vibration. Ensure that the air pressure is correct at 90psi, max 100psi.

Front return spring weak or broken. Replace return spring.

Guide plate seal worn. Replace guide plate seal.

Piston cushion failed. (This is a split o’ring) Replace with a new piston cushion.

Tool stopped working.

6mm plastic ball worn out. Check for and remove the remains of the ball, possibly in an exhaust

hole of cylinder and renew 6mm plastic ball.

Valve pin broken. Replace valve pin and 6mm plastic ball.

Model Piston Diameter Piston Stroke

(approximate) BPM Air Consumption @

6.2bar Overall Length Weight Noise LwA (Power

Level)

Vibration (AEQ)

Primary

Vibration (AEQ)

Secondary

VL203Ex Pistol

Grip Needle 23.5mm (0.925”) 11mm (0.43”) 2400 1.89lps (4.0cfm) 340mm (13.38”) 2.70kg (6.0lbs) 90.7 db(A) 2.75 m/s2

(k= 1.1)

3.26 m/s2

(k= 1.304m/s²)

Machinery Directive Information:

This tool has been designed and produced in accordance with the following directives: 2006/42/EC Machinery Directive

and applicable harmonised standard: EN ISO 1 1148-4:2012

EN ISO 11148-4: 2010 Hand Held Non-Electric (Non-Rotary

Percussive Tools)

This tool conforms with the following EC legislation: ATEX DIRECTIVE 2014/34/EU

Based on the following harmonised standards: EN60079-0:2018

EN ISO 80079-36:2016

EN ISO 80079-37

Notied Body: Element Material Technology LTD

Certicate Number: EMT19ATEX0022X

If your company has any problem with our products or would like to discuss the possibility of an improvement being made to them, then please do not hesitate to contact

us. Your comments are both important and appreciated.

Trelawny tools are thoroughly tested under specied conditions in accordance with applicable internationally recognised standards. When a tool is used on site the

conditions may not be the same as those used in our tests.

Trelawny Surface Preparation Technology operates a policy of continuous product development and renement and therefore reserves the right to change technical

specications and product designs without giving prior notice.

trademarks, model denominations, part numbers and drawings. Use only genuine Trelawny spares.

The use of non-Trelawny spare parts will invalidate the ATEX certication and also the warranty.

technical specication

Noise Levels: Noise level measured in accordance with: EN ISO 15744: 2008

Vibration Levels: Vibration measured in accordance with: EN ISO 28927-9:2012 and EN ISO 20643:2005. (k) Equals the factor of uncertainty, which allows for variations in

measurement and production. Vibration Data gures are tri-axial, which gives the total vibration emission. Because of various factors, the range of vibration from these

tools may vary between -0% +40% (3.26 m/s2 -4.56 m/s2). The vibration is dependent on the task, the operators grip and feed force employed etc.

NOTE: The above vibration levels were obtained from tri-axial measurements to comply with the requirements of “The Control of Vibration at Work Regulations 2005*” and

the revisions to the (8662) now EN ISO 28927-9:2012 and EN ISO 20643:2005 series of standards. These values are at least 1.4 times larger than the values obtained from