Trelawny Challenger vl203 Installation guide

VL203/223 & 303 CHALLENGER

NEEDLE & CHISEL SCALERS

OPERATION & MAINTENANCE

OPERATION

General Informat on

Before operating, performing maintenance or repairing

the Challenger VL203/223 & 303 Needle/Chisel 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

specification 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 influence 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 fixture

A r Supply

The compressed air must be free from water and dirt The

installation of a filter/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 air hose is used and

that all couplings are secure, leak free and in good

condition

For maximum efficiency, 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 a r pressure for th s mach ne s to 6.2bar

(90ps ).

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 a r not displaced as quoted by

some compressor manufactures, this will give 3cfm of

headroom, so that the compressor isn’t continually

running

NOTE:

If th s tool stops work ng, 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)

Safety

Always, read nstruct ons f rst before use.

Do -

Be aware that this tool is not electrically insulated

Be aware that the tool can create dust and flying debris

Keep hands and clothing away from moving parts

Be aware of others working around you

Ensure that this tool is lubricated da ly

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

Always observe safe-work ng pract ces at all t mes.

Do not -

Allow the tool to run unattended

Use the Scaler as a lever

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

warranty and could lead to serious injury

Use wire or any other fixing 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 flash

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

Start ng work

Please note,

The Carbon steel needles provided are not intended for

use in a potentially explosive atmosphere

Pr or to operat ng the tool check: -

That all fittings are secure, free from leaks and air hoses

are in good condition

That the a r pressure s correct for th s tool 6.2 bar

(90 p.s. .).

Put a few drops of a recommended lubricant into the air

inlet of the tool

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 sw tch off, s mply release the throttle lever.

Gloves and personal protective equipment must be worn

when using this tool

MAINTENANCE

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 firm and stable

position

Maintain contact with the work surface with sufficient

pressure only to keep the tool from bouncing

Excessive pressure can prevent the tool from working to

its full capacity

Handled correctly the Challenger VL203/223 & 303

Needle Scalers will work quickly and efficiently

Excess ve operator pressure w ll not mprove the tool

eff c ency but could cause premature tool fa lure and

operator fat gue.

Never allow the tool to run continuously whilst not in

contact with the surface being prepared

Maintenance must only be carried out by a competent

person, in a suitably equipped workshop

D sconnect the tool from the a r supply before

carry ng out any of the follow ng operat ons.

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 efficient running and at intervals of no more than

120 hours, dismantle and clean with highly refined

paraffin

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

Po nted t p needles

Sharpened to a nail point, these are most effective in

breaking through very hard scale on surfaces where

some surface indentation is permissible - or where keying

(i e profile) of the surface is desirable Pointed tip

needles are available in 3mm only

Ch sel t p needles

These are general purpose needles, flattened to a chisel

like blade and are most effective in the removal of thicker

material, while leaving a less pitted surface than the

Pointed tip needles but still giving some surface

indentation (i e profile) Chisel tip needles are available

in 3mm only

Flat t p needles

Machined to a flat tip, these needles will leave slight

marking (i e profile) on the surface; the 2mm needles

actually have a burnishing effect on steel

2mm Needles are recommended for use on thin gauge

steels and any softer surfaces such as cast iron and

aluminium where light treatment is desired

Flat tip needles are available in three sizes - 2mm, 3mm

and 4mm

Remov ng Needles

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

the flats 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-f tt ng 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 lubr cants

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 D smantl ng

After ensuring the air supply is turned off, remove the air-

line from the tool Clean all deposits from the outside of

the tool Service kits are available, see parts section

P ston and Cyl nder removal

Hold the Cover in a vice using the flats 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 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 on

VL203/223 only) Secure the Cover (10) 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 from its location hole in the

Cylinder Guide Plate, which is fitted in the cover The

Cylinder Guide Plate (12) can be pulled out of the cover

to gain access to the Guide Plate Seal (13)

MAINTENANCE

collar half a turn to lock the Chisel in place

To release the Chisel, rotate the knurled collar until the

retaining ball is fully visible and remove the Chisel

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), (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 flats 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 flat 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 film of the recommended lubricating oil Assembly

is the reverse of dismantling

Secure the Cover 10/10a vertically in a vice using the

flats provided, insert the Cylinder Guide Plate 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 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 t ghten).

Gently insert the Piston, small diameter first 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-fitting the Needles, hold the tool

horizontal when completing this operation

D sposal

Dismantle into component form, segregate according to

material composition and dispose of using waste

recycling processes specified by local regulations

Cyl nder 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 th s plast c ball w th a steel vers on),

as it will damage the cylinder valve seat and piston valve

pin)

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

refit new O’Ring into groove

Valve Body - Valve Stem removal

Hold the Valve Body (6) in a vice using the flats provided

and with the Valve Cap (1) uppermost, unscrew the Valve

Cap

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

(10/10a) 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

Throttle Lever removal

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)

F tt ng of Ch sel Holder

Before fitting the Chisel Holder disconnect the tool from

the air supply

The Chisel Holder assembly comprises of an Anvil,

Spring, Chisel Holder and the Chisel

Unscrew Needle Holder attachment and remove the

assembly complete with the needles etc, take care not to

allow the internal components to fall out of the

intermediate tube Separate the Needle holder assembly

and remove the spring, this will be required in assembling

the Chisel Holder

To fit the Chisel Holder, first fit the spring onto the Anvil

locating against the large shoulder

Fit this assembly into the intermediate tube and locate the

large flat face of the Anvil against the front face of the

piston Ensure that the pinch bolt on the Chisel Holder is

loose and screw the Chisel Holder fully on to the

intermediate tube Then unscrew slightly to position the

boss underneath the tool and tighten the pinch bolt using

a 6mm AF Allen key

Turn the knurled collar on the Chisel Holder until the

retaining ball is fully visible; insert the Chisel aligning the

rebate with the ball Position the midpoint of the rebate on

the shank of the Chisel with the retaining ball and turn the

EXPLODED VIEW

ITEM

No.

PART No. DESCRIPTION ITEM

No.

PART No. DESCRIPTION

Common Parts Common Parts

1 615 3021 Valve Cap 28 636 3003 Valve Pin

2 809 0139 Valve Cap O’Ring 38 704 3101 Chisel 1/2” Sq Shank 7” x 3/4” Blade

3 712 3022 Valve Spring 704 3103 Chisel 1/2” Sq Shank 7” x 2 1/2” Blade

4 618 3022 Valve Stem 704 3205 Chisel 1/2” Sq Shank 7” x 1 3/8” Blade

5 809 0089 Valve Seat O’Ring 704 3110 Chisel 1/2” Sq Shank Spark Resistant 2” Blade

6 616 3021 Valve Body 705 1102 Chisel 5/8” Hex Shank 8” x 4” Blade

423 3021 Valve Body Assembly (includes items 1-8) 705 1106 Chisel 5/8” Hex Shank 9” x 2” Blade

7 716 3000 Throttle Lever 705 1112 Chisel 5/8” Hex Shank Spark Resistant 4” Blade

8 813 0108 Roll Pin 708 1100 Comb Holder 5/8” Hex Shank (for 1 1/2” Comb)

9 717 3050 Rubber Handle Grip 431 3504 Scraper 5/8” Hex Shank c/w 4” Blade

17 816 3003 Plastic Ball 6mm diameter

18 809 0080 Ball Retaining O’Ring 819 2375 Connector 1/4” BSP-3/8” Stem

VL203/223 Components VL303 Components

10 425 2003 VL203 Cover Assembly (Pistol Grip) 10 425 3003 Cover Assembly (Pistol Grip)

10a 616 2003 VL223 Cover Assembly (Inline) 12 652 3003 Guide Plate

12 652 2003 Guide Plate 13 829 3003 Guide Plate Seal

13 829 2003 Guide Plate Seal 14 809 0299 Guide Plate O’Ring

14 809 0299 Guide Plate O’Ring 15 428 3003 Cylinder

15 428 2003 Cylinder 19 809 3004 Piston Cushion

19 809 2004 Piston Cushion 22 622 3031 Intermediate Tube

22 622 2031 Intermediate Tube 23 721 3003 Intermediate Tube Outer Sleeve

23 721 2003 Intermediate Tube Outer Sleeve 24 814 3003 Circlip VL303 only

25 809 0299 Front Tube Locking O’Ring 25 809 0299 Front Tube Locking O’Ring

26 612 2003 Piston 26 612 3003 Piston

29 829 2002 Piston Ring 29 829 3002 Piston Ring

30 601 2030 3mm Needle Holder (fitted as standard) 30 601 3030 3mm Needle Holder (fitted as standard)

601 2020 2mm Needle Holder 601 3020 2mm Needle Holder

31 413 2119 Needle 3mm Chisel set (fitted as standard) 601 3040 4mm Needle Holder

412 1151 Needle 2mm Flat set 31 413 2128 Needle 3mm Chisel set (fitted as standard)

413 1119 Needle 3mm Flat set 412 1165 Needle 2mm Flat set

413 3119 Needle 3mm Pointed set 413 1128 Needle 3mm Flat set

403 1309 Needle set (1 x set Beryllium Copper) 413 3128 Needle 3mm Pointed set

32 712 2003 Front Spring 403 1328 Needle set (1 x set Beryllium Copper)

33 620 2003 Front Tube Insert 413 3128 Needle 4mm Flat Tipped

33A 620 2003A Front Tube Spacer 32 712 3003 Front Spring

34 622 2030 Front Tube 33 620 3003 Front Tube Insert

35 809 3005 Cylinder Stem Reaction Ring 34 622 3030 Front Tube

36 610 2003 Anvil 35 729 3003 Cylinder Stem Reaction Ring

37 419 2003 Chisel Holder 36 610 3003 Anvil

37 419 3003 Chisel Holder

446 2003 Service Kit, (2, 5,13,14,17,18,19,28,29,30,31set & 32) 446 3003 Service kit, (2,5,13,14,17,18,19,28,29,30,31set & 32)

PARTS LIST

TECHNICAL SPECIFICATION

Mach nery D rect ve Informat on:

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

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 specified 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 refinement and therefore reserves the right to

change technical specifications and product designs without giving prior notice

prohibited This applies to trademarks, model denominations, part numbers and drawings Use only genuine Trelawny spares

The use of non-Trelawny spare parts nval dates the warranty.

Trelawny SPT Limited

Trelawny House, 13 Highdown Road, Sydenham Industrial Estate,

Leamington Spa, Warwickshire, CV31 1XT, United Kingdom

Telephone: +44 (0)1926 883781 Fax: +44 (0)1926 450352 Email: sales@trelawny co uk

General Industry Website: www trelawnyspt com

Dedicated Marine Website: www trelawny-marine com

SURFACE PREPARATION TECHNOLOGY

VL223 INLINE

NEEDLE

VL223 INLINE

CHISEL

VL203 PISTOL

GRIP NEEDLE

VL203 PISTOL

GRIP CHISEL

VL303 PISTOL

GRIP NEEDLE

VL303 PISTOL

GRIP CHISEL

P ston D ameter 23 5mm (0 925”) 23 5mm (0 925”) 23 5mm (0 925”) 23 5mm (0 925”) 34 4mm (1 35”) 34 4mm (1 35”)

P ston Stroke (approx mate) 11mm (0 43”) 11mm (0 43”) 11mm (0 43”) 11mm (0 43”) 20mm ( 787”) 20mm ( 787”)

BPM 2400 2400 2400 2400 3000 3000

A r Consumpt on @ 6.2bar 1 89lps (4 0cfm) 1 89lps (4 0cfm) 1 89lps (4 0cfm) 1 89lps (4 0cfm) 2 6lps (5 5cfm) 2 6lps (5 5cfm)

Overall Length 370mm (14 5”) 435mm (17 1”) 340mm (13 38”) 395mm (15 5”) 370mm (14 6”) 300mm (11 8”)

We ght 2 35kg (5 18lbs) 2 95kg (6 5lbs) 2 70kg (6 0lbs) 3 2kg (7 05lbs) 3 51kg (7 74lbs) 4 25kg (9 36lbs)

Needle/Ch sel 51 x 2mm

19 x 3mm

19mm (3/4”)

Fitted as

standard

19 x 3mm

51 x 2mm

19mm (3/4”)

Fitted as

standard

65 x 2mm

28 x 3mm

19 x 4mm

19mm (3/4”)

Fitted as

standard

No se LwA (Power Level) 90 7 db(A) 76 3 db(A) 90 7 db(A) 76 3 db(A) 109 5 db(A) 78 2 db(A)

V brat on (AEQ) Pr mary 2 56 m/s

(k) 3 69 m/s

(k) 2 75 m/s

(k) 3 33 m/s

(k) 2 3 m/s

(k) 3 7 m/s

(k)

V brat on (AEQ) Secondary 2 95 m/s

(k) 3 59 m/s

(k) 3 26 m/s

(k) 4 14 m/s

(k) 3 7 m/s

(k) 4 3 m/s

(k)

No se Levels

Noise level measured in accordance with: EN ISO 15744: 1999

V brat on Levels

Vibration measured in accordance with: EN ISO 28927 and EN ISO 20643

(k) Equals the factor of uncertainty, which allows for variations in measurement and production Vibration Data figures 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% 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 and EN ISO 20643 series of standards These values are at least 1 4 times larger than the values obtained from single axis

measurements

*Based on European Union Council Directive 2002/44/EC (Physical Agents (Vibration) Directive)

R sk of Hand Arm Injury

Because of various factors, the vibration from this range of tools may be between 2 3 m/s2 – 6m/s2

The vibration is dependent on the task, the operators grip, and feed force employed

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