Trelawny Vibro Lo Troubleshooting guide

OPERATION & MAINTENANCE
VL SINGLE SCALING HAMMERS

OPERATION
General Information
Before operating Trelawny Vibro-Lo
Scaling Hammers, this manual must be
read and understood by the operator, if
in any doubt, ask your supervisor before
using this e uipment. 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.
Trelawny SPT Ltd disclaims all
responsibility for damage to persons or
objects arising as a conse uence of
incorrect handling of the tool, failure to
inspect the tool for damage or other
faults that may influence it’s operation
prior to starting work, or failure to follow
the safety regulations listed or applicable
to the job site.
The Standard Vibro-Lo scaling tool is
fitted with taper fit cutter heads and is
primarily designed for the removal of
heavy rust and scale.
The Heavy-Duty Vibro-Lo one piece
piston with TCT cutter version is suitable
for concrete reduction and the removal of
laitance from concrete.
This tool must not be used in a fixture.
Note: Cruciform headed pistons are best
suited for the removal of heavy rust and
scale and also for the reduction of
concrete where a smoother finish is
re uired; these will reduce the aggregate
as well as the concrete surface.
Bush Hammer style headed pistons are
best suited to concrete reduction and for
laitance removal; these reduce the
damage caused to the aggregate using
the cruciform cutter head, ensuring that a
strong bond is created with the next
layer.
Air 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.
Always clear the air hose before
connection to the tool. Ensure that no
moisture (condensation) is present in the
air hose.
Ensure that a minimum 10mm (3/8”)
bore air hose is used and that all
couplings are secure, leak free and in
good condition.
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).
Corre t operating pressure is 6.2bar
(90 psi).
Do not let the operating pressure fall
below 5.5bar (80p.s.i.) or rise above
6.9bar (100 psi) absolute maximum.
The compressor must be able to supply
a minimum of 7.08 lps (15cfm), (Free air,
not displaced as uoted by some
compressor manufactures).
In particularly cold weather it is
recommended that a proprietary anti-
freeze lubricating oil is used.
Safety
Always, read instructions first before use.
Do wear Personal Protective E uipment
including safety goggles, footwear, ear
defenders and gloves. In some
environments it will be necessary to wear
facemasks or breathing apparatus.
Do be aware that this tool is not
electrically insulated.
Do keep hands and clothing away from
moving parts.
Do ensure that this tool is lubricated
daily.
Do be aware that the tool can create
dust and
flying debris.
Do be aware of others working around
you.
Do store this tool in a secure and dry
environment.
Alw a ys ob s e r ve safe -w o rki ng
pra ti es at all times.
Do not allow the tool to run unattended.
Do not use this tool in potentially
explosive environments.
Do not drag this tool by the air hose.
Do not use the Scaler as a lever.
Do not use petrol (gasoline), thinners or
any other high flash point solvent to
clean the tool.
Do not modify this tool in any way, as
this will invalidate the warranty and could
lead to serious injury.
Risk of Hand-arm
Vibration injury
These tools may cause Hand-arm
Vibration Syndrome injury if their use is
not ade uately 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 e uipment [PPE]
parti ularly gloves and lothing to
keep them warm and dry.
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 ‘Spe ifi ations’ se tion for
vibration emission data.
Further advice is available from our
Technical Department.
Re ommended
lubri ants
Oil the tool daily before use. Put a few
drops of one of the following zinc free air
tool lubricants through the air inlet.
SHELL S22 or R10
CASTROL Hyspin ZZ32
Cleaning
At intervals of no more than 40 hours or
if operation becomes unproductive and
the piston shows signs of sticking,
dismantle and clean with a highly refined
paraffin.
Immediately after cleaning, thoroughly oil
the tool with one of the recommended
lubricants .
Starting work
Prior to operating the tool check: -
That all fittings are secure, free from
leaks and air hoses are in good
condition.
That the air pressure is correct for this
tool 6.2 bar (90p.s.i.). Put a few drops of
recommended lubricant into the air inlet
of the tool. To operate the tool, which is
dependant on the type of lever fitted, for
those fitted with a safety lever, first push
thumb button forwards and then for both
styles of lever, pull the lever towards the
handle grip to start the tool, then apply
the cutter heads to the surface being
prepared.
To swit h off, simply release the
throttle lever.
Care must be taken to avoid damaging
or tripping over the air hose. Maintain
contact with the work surface with
sufficient pressure only to keep the tool
from bouncing off. Excessive pressure
can prevent the tool from working to its
full capacity. Handled correctly the
Scaler will work uickly and efficiently.
Ex essive operator pressure will not
improve the tool effi ien y but will
ause premature tool failure and
operator fatigue.

MAINTENANCE
Never allow the tool to run continuously
whilst not in contact with the surface
being prepared.
Please be aware: that this tool will
reduce in power or stop working if the
end cap (20) has become unscrewed.
Maintenan e
Maintenance must only be carried out by
a competent person.
Dis onne t the tool from the air
supply before arrying out any of the
following operations.
Clean all debris from the exterior of the
tool.
Head removal - Taper Fit (On site)
Lay the scaling hammer on a solid
surface with the cutter head (21) facing
uppermost. Place the head removal
washer (23) between the cutter head and
the body; insert the removal pin (22), into
cutter head hole (refer to diagram for
pictorial illustration). Wearing safety
glasses, using a medium size hammer
give a sharp blow to the head of the pin,
which will release the cutter head from
the piston.
One Pie e Piston & Piston/Cylinder
Assembly removal (Workshop)
Hold the single scaler body (14) in a
vice, using the flats provided and with
the end cap uppermost. Unscrew the
end cap (20). Remove spring cap (18)
and spring (19) from the end cap. From
the bottom of the body, push up the
cutter head to remove the piston
assembly.
Head removal - Taper Fit (Workshop)
Lay the piston and cylinder assembly on
a solid surface with the cutter head
facing uppermost. Place the head
removal washer (23) between the cutter
head and the cylinder; insert the removal
pin (22), into cutter head hole (refer to
diagram for pictorial illustration).
Wearing safety glasses and using a
medium size hammer, give a sharp blow
to the head of the pin, which will release
the cutter head from the piston.
Inspect all components for wear, replace
as necessary.
Valve body servi ing (Workshop)
Clamp the assembly firmly in a soft face
jawed vice, using the flats provided on
the valve body, with the throttle lever
upper most.
Using a 3mm diameter pin punch,
remove the throttle lever roll pin (8), and
then remove the throttle lever (7).
Rotate the tool 180 degrees in the vice to
access the valve. Unscrew the valve cap
(1) using a screwdriver, check the valve
cap’s 'O'Ring (2). Remove the spring (3).
Remove the valve stem (4) and the valve
seat 'O' Ring (5). Check the valve stem
and 'O'Ring for wear.
Assembly (Workshop)
Before any assembly takes place,
ensure all parts are clean and have a
film of air tool oil lubrication unless
otherwise stated. Avoid lubricating oil or
grease contaminating the threads of the
end cap (20), the threads within the bore
of the body (14) and also the taper of the
piston and cutter head. The end caps will
re uire securing with a thread-locking
adhesive. It is good practice to renew the
O’ Rings (2 & 5) and the brush seal (15).
Replace any parts showing signs of
wear; paying particular attention to the
small bore of the cylinder.
Valve Body assembly (Workshop)
Clamp the assembly firmly in a soft face
jawed vice, using the flats provided on
the valve body, insert new valve stem
'O'Ring (5) into valve body (6), followed
by the valve stem (4), spring (3), then the
valve cap (1) complete with its O'Ring
(2), tighten the valve cap with a
screwdriver. Rotate assembly 180
degrees in vice. Using a 3mm diameter
pin punch locate and align the throttle
lever (7) in position, then drive in the
throttle lever roll pin (8) into the pin
location.
Head Assembly - Taper Fit (On-Site)
Thoroughly clean the cutter head and
piston. Remove all traces of debris/oil
from the taper on the piston (17) and the
internal taper of the cutter head (21) by
cleaning with suitable oil free solvent.
Place the tool in a position where the
end cap is on a solid surface; Fit a new
and cleaned cutter head and place on to
the taper of the piston. Using a soft-
faced hammer deliver a sharp blow to
the cutter head. (Using a hard faced
hammer may cause the tungsten carbide
inserts to chip or shatter which could
cause a serious injury to you).
Head Assembly - taper fit (Workshop)
Remove all traces of oil and dirt etc, from
the taper on the piston (17) and cutter
head (21) by cleaning with suitable oil
free solvent. Fit the piston into the
cylinder (16) as shown in the service
layout.
Flexible Conne tor
If the Flexible Connector (12) re uires
replacement, return the tool to you local
distributor who will arrange for a new
connector to be fitted. These connectors
are fitted with uni ue retaining clips (13)
and a special machine is re uired to fit
them. Do not replace with a similar hose
or Jubilee type clips, this could be
dangerous to the operator and will not
produce the same vibration reduction
characteristics.
Place the assembly onto a solid surface;
fit a new brush-seal (15) over the piston
and into the recess of the cylinder.
Select one of the cleaned new cutter
head and place on to the taper of the
piston.
Using a soft-faced hammer deliver a
sharp blow to the cutter head.
Note: If you are re-fitting a used cutter
head to the piston it is essential that the
internal diameter of the cutter head is re-
surfaced using a medium grade of emery
cloth - this will ensure a good fit between
cutter head and piston, do not use
adhesive of any description on the taper.
If the taper has expanded to much on
the old cutter heads, they may not stay
on the piston, and replacements will be
re uired.
One Pie e Piston and Piston/Cylinder
assembly (Workshop)
Lubricate the piston (17a) and cylinder
bore(16a) and push the piston into the
cylinder bore.
FINAL ASSEMBLY
Both types (Workshop)
Lay the tool on a bench with the body
(14) on its side and insert the cylinder
assembly into the body and apply a few
drops of air tool lubricant to the top of the
piston.
Hold the body (14) in a soft fa ed vice
ensuring the screw cap threads are
uppermost.
Assemble the end cap (20), fit spring
(19) into the recess in the end cap and
then fit spring cap (18) into the end cap
as shown in the service layout.
Remove all traces of oil from the end cap
threads and the threads of the body by
cleaning with suitable oil free solvent.
Apply a bead of Loctite 243 sealant to
the first 3 threads of the end cap.
Screw end cap assembly into the body
until finger tight and using a suitable
spanner tor ue down to 55N.m.
(40 lbs.ft).
DISPOSAL
When the tool and its accessories are
taken out of service for disposal, it is
recommended that: -
They are rendered unusable to prevent
improper re-use.
They are dismantled into component
form, segregated according to material
composition and disposed of using waste
recycling processes specified by local
regulations.

EXPLODED DIAGRAM
Item Part Number Des ription Item Part Number Des ription
1 615.3021 Valve Cap 15 614.5301 Brush Seal 2 809.0139 O’Ring - Valve Cap 16 613.5301 Cylinder - (Standard Duty) 3 712.3022 Valve Spring 16a 613.5303 Cylinder - (Heavy Duty) 4 618.3022 Valve Stem 17 612.5301 Piston - (Standard Duty) 5 809.0089 O’Ring - Valve Seat 17a 612.5320 Piston One Piece (Heavy Duty) - TCT Cruciform 6 616.5321 Valve Body 612.5325 *Piston One Piece (Heavy Duty) - TCT Bush Hammer
423.5321 *Valve Body Assembly (inc 1-8) 18 615.5361 Spring Cap
7 716.3000 Throttle Lever 19 712.5301 Spring
716.1000 *Throttle Lever Safety 20 615.5341 Screwed Cap
8 813.0108 Roll Pin 21 426.5351 Cutterhead (Standard Duty) - TCT Cruciform 9 427.5361 Adapter 426.5352 *Cutterhead (Standard Duty) - TCT Bush
10 624.5350 Tube Handle 606.5303 *Cutterhead (Standard Duty) - Beryllium Cruciform 11 717.5301 Rubber Grip 22 827.0428 Taper fit Cutterhead Removal Pin 12 719.1380 Flexible Connector 23 633.5301 Taper fit Cutterhead Removal Washer 13 821.2000 Hose Clamp 14 411.5121 Body (Standard & Heavy Duty) *Items not shown on exploded diagram

TECHNICAL SPECIFICATIONS
Declared vibration emission value are in accordance with BS EN 12096: 1997
(K) E uals the factor of uncertainty, which allows for variations in measurement and production.
Vibration data figures are tri-axial, which gives total vibration emission.
Risk of Hand Arm Injury
Because of various factors, the range of vibration emission during intended use of these tools is expected to be between 3.7m/s² – 13.16m/s².
The vibration is dependent on the tool model, task, the operators grip, and feed force employed etc.
Noise level measured in accordance with: EN ISO 15744: 1999
Vibration measured in accordance with: EN ISO 28927 and EN ISO 20643
Ma hinery Dire tive Information
This machine has been designed and produced in accordance with the following directives: 2006/42/EC Ma hinery Dire tive
and applicable harmonised standard: EN ISO 1 1148-4:2010
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.
© Copyright 2009, Trelawny SPT Limited, CV31 1XT. UK All rights reserved. Any unauthorised use or copying of the contents or part thereof is
prohibited. This applies to trademarks, model denominations, part numbers and drawings.
Use only genuine Trelawny spares.
The use of non-Trelawny spare parts invalidates the warranty.
SURFACE PREPARATION TECHNOLOGY
Trelawny SPT Limited
Trelawny House, 13 Highdown Road, Sydenham Industrial Estate,
Leamington Spa, Warwickshire, CV31 1XT, United Kingdom
Telephone: [phone] Fax: [phone] Email: [e-mail]
General Industry Website: www.trelawnyspt.com
Dedicated Marine Website: www.trelawny-marine.com
© TSPT UK 2009 Part No: 735.5100 issue 7
Standard Duty (Repla eable Cutterheads) Heavy Duty (One Pie e Piston)
Piston Diameter 27mm (1.06)
Piston Length 68.8mm (2.70”) 111.75mm (4.4”)
Piston Stroke 26.0mm 1.023”)
Blows Per Minute 3000 2900
Air Consumption 3.3lps (7.0cfm) 4.25 lps (9 cfm)
Air Pressure 6.2 bar (90 psi)
Length 472mm (18.6”)
Working Height 140mm (5.5”) 160mm (6.3”)
Weight 2.46 (5.42lbs) 2.49kg (5.49lbs)
Noise Level L
pA
dB (A) 92.5 90.9
L
wA
dB (A) 106.3 104.5
Vibration Level (Trigger Hand) Primary 3.7m/s2 (k+ 0.0% +40%) 4.5m/s
2
(k= -0.0% +40%)
Se ondary 9.9m/s2 (k+ 0.0% +40%) 9.4m/s
2
(k= -0.0% +40%)
TROUBLE SHOOTING
Poor performan e or la k 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 and re-oil.
Tool worn out, can you feel side ways movement
between the piston and cylinder bore.
Replace the piston and cylinder, along with a new bush
seal.
Tool ontinues 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.
Do not use uick release couplings to switch tool off.
Tapered utterhead will not
stay on piston
To high an air pressure being used, piston hits bottom of
cylinder causing head to be jettisoned. Ensure that the air pressure is correct at 90psi, max 100psi.
Traces of oil remained on tapered surfaces when
replacing cutter head.
Ensure that the cutterhead and pistons tapers are
completely free of oil, use a good degreasing agent and
clean cloth prior to assembly.