Trelawny VL203Ex, Operation And Maintenance Manual

Page: 9 / 16

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ASSEMBLY
DISPOSAL
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).
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 Chisel holder 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) 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
tighten). 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 fitting the Chisel holder, hold the tool horizontal when
completing this operation.
Fitting of Chisel Holder
The Chisel Holder assembly comprises of an Anvil, Spring,
Chisel Holder and the Chisel. 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 middle of the rebate on the shank of the Chisel
with the retaining ball and turn the 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.
Dismantle into component form, segregate according to
material composition and dispose of using waste recycling
processes specified by local regulations.
VERY IMPORTANT
Only Trelawny Aluminium Bronze Chisel must be used in
this tool.
DO NOT substitute with any other chisel.
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.