OPERATION AND MAINTENANCE MANUAL FOR

139.2107 - 2B/PG Tool
139.3107 - 3B/PG Tool
139.2100 - 2B/PG Kit
139.3100 - 2B/PG Kit
Vacuum Shrouded
Needle Scalers
OPERATIONS AND MAINTENANCE
© Copyright 2011 by NOVATEK Corporation
All rights reserved printed in the United States of America. No part of this manual may be used or reproduced in any form or
by any means, stored in data base or retrieval system, without prior written permission from NOVATEK Corporation.
Making copies of this manual for any purpose other than your own personal use is a violation of the United States copyright
laws.
January 1, 2011 issue 1.0
Specifications subject to changes without notice!
If you have any questions, please contact us:
NOVATEK CORORATION
216 Philips Road
Exton, PA 19341
USA
www.novatekco.com
Toll Free 866 563-7800
Telephone: +1 610 363-7800
Fax +1 610 363-9620
Email: Sales@Novatekco.com
OPERATION AND MAINTENANCE MANUAL FOR
VACUUM SHROUDED NEEDLE SCALERS
NOTICE
FOR PROFESSIONAL USE ONLY
WARNING
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS PRODUCT.
IT IS YOUR RESPONSIBILITY TO MAKE THIS SAFETY INFORMATION
AVAILABLE TO OTHERS THAT WILL OPERATE THIS PRODUCT.
FAILURE TO OBSERVE THE FOLLOWING WARNING COULD RESULT IN INJURY.
PLACING TOOL IN SERVICE
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Always install, operate, inspect and maintain
this product in accordance with all applicable
standards and regulations (local, state, country,
federal, etc.).
Compressed air models always use clean, dry
air at 90 psi (6.2bar/620kPa) maximum air
pressure at the inlet. Higher pressure may
result in hazardous situations including
excessive speed, rupture, or incorrect output
torque or force.
Electric models must always utilize proper
gauge, and rated electrical cords with correct
connections.
Be sure all hoses and fittings are the correctly
sized and secured.
Ensure an accessible emergency shut off has
been installed in the air or electrical supply line.
Make others aware of its location.
Do not use damaged, frayed, or deteriorated air
hoses and fittings.
Always use proper gauge electrical cords with
correct connections. (When applicable.)
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Electric models must not use damaged, frayed, or
deteriorated electrical cords and connections.
Keep clear of whipping air hoses. Shut off the
compressed air before approaching a whipping
hose.
Always turn off and disconnect the tool from its
power supply before installing, removing or
adjusting any accessory, or before performing
any maintenance on the tool.
Do not lubricate tools with flammable or volatile
liquids such as kerosene, diesel or jet fuel. Use
only recommended lubricants.
Keep work area clean, uncluttered, ventilated and
illuminated.
Keep all electrical connections clear of water or
other liquids. (When applicable.)
Do not operate the machine while flammable or
volatile liquids such as gasoline, diesel or jet fuel
are present. Failure to do so can result in
explosion. (When applicable.)
Do not remove any labels. Replace any damaged
label.
USING THE TOOL
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Always wear protection when operating or
performing maintenance on this tool.
Always wear hearing protection when operating
this tool.
Always use Personal Protective Equipment
appropriate to the tool used and material
worked. This may include dust mask or other
breathing apparatus, safety glasses, ear plugs,
gloves, apron, safety shoes, hard hat and other
equipment,
Prevent exposure and breathing of harmful dust
and particles created by power tool use:
Some dust created by power sanding, sawing,
and grinding, drilling, and other construction
activities contains chemicals known to cause
cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
Lead from lead based paints,
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Crystalline silica from bricks and cement and
other masonry products, and
Arsenic and chromium from chemically treated
lumber
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are
specially designed to filter out microscopic
particles.
Keep others a safe distance from your work area,
or ensure they use appropriate Personal
Protective Equipment.
This tool is not designed for working in explosive
environments, including those caused by fumes
and dust, or near flammable materials.
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Electrically powered tools are not insulated
against electric shock.
Be aware of buried, hidden or other hazards in
your work environment. Do not contact or
damage cords, conduits, pipes, or hoses that
may contain electrical wires, explosive gases or
harmful liquids.
Keep hands, loose clothing, long hair and
jewelry away from working end of tool.
Power tools can vibrate in use. Vibration,
repetitive motions or uncomfortable positions
may be harmful to your hands and arms. Stop
using any tool if discomfort, tingling feeling or
pain occurs. Seek medical advices before
resuming use.
Keep body stance balanced and firm. Do not
overreach when operating this tool. Anticipate
and be alert for sudden changes in motion,
reaction torques, or forces during startup and
operation.
Tool and/or accessories may briefly continue
their motion after throttle is released,
To avoid accidental starting – ensure tool in
“off” position before applying air pressure or
connecting to electricity. Avoid throttle when
carrying, and release throttle with loss of air or
electricity.
Ensure work pieces are secure. Use clamps or
vises to hold work piece whenever possible.
Do not carry or drag the tool by the hose or
power cord.
Do not use power tools when tired, or under the
influence of medication, drugs, or alcohol.
Never us a damaged or malfunctioning tool or
accessory,
Do not modify the tool, safety devices, or
accessories.
Do not use this tool for purposed other than
those recommended.
Use accessories recommended by Novatek
Corp.
Never operate a tool with an accessory unless it
is properly installed and the tool is held firmly
against the work,
Always use a retainer, when furnished, in
addition to proper barriers to protect persons in
surrounding or lower areas from possible
ejected accessories.
When wearing gloves and operating models
with inside trigger, always be sure that the
gloves will not prevent the trigger from being
released.
Refer All Communications to the Nearest
Novatek Corporation Office or Distributor.
Pr inted in U.S.A.
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Wear safety shoes, hard hat, safety goggles,
gloves, dust mask and any other appropriate
protective clothing while operating the tool.
Do no indulge in horseplay. Distraction can
cause accidents.
Keep hands and fingers away from the throttle
lever until it is time to operate the tool.
Never rest the tool on your foot.
Never point the tool at anyone.
Compressed air is dangerous. Never point an air
hose at yourself or others.
Never blow clothes free of dust with compressed
air.
Be sure all hose connections are tight. A loose
hose not only leaks but can come completely off
the tool and while whipping under pressure, can
injure the operator and other in the area. Attach
safety cables to all hosed to prevent injury in case
a hose is accidentally broken.
Never disconnect a pressurized air hose. Always
turn off the air supply and bleed the tool before
disconnecting a hose.
When applicable, the operator must keep limbs
and body clear of the chisel. If a chisel breaks,
the tool with the broken chisel projecting from the
tool will suddenly surge forward.
Do not ride the tool with one leg over the handle.
Injury can result if the chisel breaks while riding
the tool.
Know what is underneath the material being
worked. Be alert for hidden water, gas, sewer,
telephone or electric lines.
Use only proper cleaning solvents to clean parts.
Use only cleaning solvents which meet current
safety and health standards. Use cleaning
solvents in a well ventilated area.
Do not flush the tool or clean any parts with diesel
fuel. Diesel fuel residue will ignite in the tool
when the tool is operated, causing damage to
internal parts. When using models with outside
triggers or throttle levers, take care when setting
the tool down to prevent accidental operation.
Do not operate the tool with broken or damaged
parts.
Never start the tool when it is lying on the ground.
This tool is not designed for working in explosive
atmospheres.
TABLE OF CONTENTS
SECTION I
GENERAL ...........................................................................................................................................................6
SECTION II
PRIOR TO USE ..................................................................................................................................................6
IN USE ................................................................................................................................................................6
SECTION III
SELECTION OF NEEDLES ................................................................................................................................6
SELECTION OF CUFFS.....................................................................................................................................7
SECTION IV
SAFETY ..............................................................................................................................................................7
LUBRICATION ....................................................................................................................................................7
SECTION V
PARTS LIST A ....................................................................................................................................................8
PARTS LIST B ....................................................................................................................................................8
SERVICE LAYOUT A&B.....................................................................................................................................9
SECTION VI
SPECIFICATIONS ........................................................................................................................................... 10
NOVATEK CORPORATION LIMITED WARRANTY ....................................................................................... 11
SECTION I
GENERAL
This operation and maintenance manual is furnished with each “AAT” Shrouded Needle Scaler Tool/Kit. It outlines the
general operation and maintenance items critical to insure satisfactory, safe and long life of the Shrouded Needle Scaler
and Accessories. This manual also includes service layouts and parts list for all configurations (A-E) of the “AAT” Shrouded
Needle Scaler Tools and Kits.
READ ALL INSTRUCTIONS AND DATA IN THIS OPERATION AND MAINTENANCE MANUAL PRIOR TO OPERATION
OF THIS EQUIPMENT.
These instructions are for your protection and convenience. Please read them carefully since failure to follow the
precautions could result in injury. Whenever using electric powered equipment, basic safety precautions should be
followed.
If after reading this manual anything seems unclear, contact a NOVATEK authorized distributor or NOVATEK directly by
dialing 1-866-563-7800.
SECTION II
PRIOR TO USE
1.
Ensure that sufficient length of 3/8” diameter hose is available and compatible with the tool’s ¼” NPT air inlet.
2.
Tighten all hose connection fittings and blow out the air hose to insure that all debris is purged from the supply line.
3.
Put a few drops of lubricant in the air inlet of the tool on a daily basis prior to start up and shut down. (See
recommended air tool lubricants)
4.
Inspect the tool’s external parts, fittings and needle wear.
CAUTION: Do not inspect the tool without first disconnecting the air supply!
IN USE
1.
The tool must be supplied with clean, dry air for satisfactory service. A suitable filter is recommended.
2.
Maintain cuff and needle contact with the working surface with sufficient force to keep the tool from bouncing.
Excessive force will not improve tool production. Experience will soon indicate the proper force and “feel” for maximum
cleaning efficiency.
3.
Use the tool on a firm surface without running over edges for maximum needle life.
4.
Maintain specified air supple operating pressure for maximum tool efficiency. Refer to specification char for correct
pressure requirements.
5.
Always use a complete set of needles of the same length and end configuration to maximize the working capacity of the
tool.
SECTION III
SELECTION OF NEEDLES
1.
The kit contains the assembled needle scaler loaded with 3mm chisel tip needles. Additional 3mm chisel tip needles
and 2mm flat tip needles are supplied in the kits. The necessary conversion parts (needle holder and needles) to
convert to a 2mm flat tip configuration are also included in the kits.
2.
Additional needles are available in the 3mm pointed tip steel and 3mm flat tip beryllium copper spark resistant
configuration.
3.
The selection of the proper needle configurations is left to the user in accordance to the surface treatment required.
6
*www.novatekco.com * toll free 866.563.7800 * tele 610.363.7800 * fax 610.363.9620 * sales@novatekco.com*
SELECTION OF CUFFS
1.
Three cuff configurations are contained in the kit to support the “angle adjustable” (AAT) compatibility of the tool.
2.
The flat cuff is most efficiently utilized on surfaces generally flat or with small variations of contour or in hard to reach
places. The corner cuff is most effective on inside corners or hard to reach crevices. The outside edge cuff is designed
to work on outside corners and protruding surfaces (3B/PG only).
3.
Operator experience will develop skills in the operation of the tool with proper selection of needle configuration and cuff
selection to produce efficient removal of hazardous materials and desired surface for refinishing.
4.
Contact NOVATEK or your local TVS distributor to discuss specific problems you may encounter in tool selection for
coating removal and surface preparation.
SECTION IV
SAFETY
1.
Safe and efficient cleaning and surface preparation can only be achieved when the proper safe practices and safety
equipment are utilized.
2.
Eye protection must always be used by both the operator and others who are in the immediate area. The use of eye
protection during de-scaling operations is a mandatory requirement of OSHA. Casual eye were is NOT a substitute for
industrial safety eye protection.
3.
The tool should be operated using both hands to firmly position the cuff and needles against the work surface to be
cleaned.
4.
Always use the vacuum system when operating the tool to insure that all hazardous debris is picked up for proper
disposal.
5.
If the tool produces unusual sounds or vibrated excessively, shut down the tool and then inspect the tool after first
disconnecting the air supply. Resolve the problem prior to resuming normal production use.
6.
Due to fire hazards, do not use gasoline or volatile thinners to flush or clean the tool.
7.
Maintenance and repair records should be kept on all needle scalers. Frequency and nature of repair may reveal
unsafe operating conditions.
8.
Never allow the tool to be run continuously by “taping the throttle lever open.” This operating condition is very unsafe
and violates OSHA regulations.
9.
Do not operate the tool without front cuffs. Results will be unsatisfactory removal of contamination and containment of
hazardous waste.
LUBRICATION
1.
Oil the tool daily by inputting a few drops into the air inlet fitting. Do not allow oil to enter the air supply hose. Whenever
possible use clean oil from a sealed container.
2.
Use only lubricants specifically designed for air tool lubrication and marked “for air or pneumatic tool use.” Lubricants
meeting 150 VG 22 grade or equivalent are recommended.
3.
When tools are used in colder climates for prolonged periods under freezing conditions the air tool lubricant suggested
for use is an anti-freeze type similar to KILFROST™.
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*www.novatekco.com * toll free 866.563.7800 * tele 610.363.7800 * fax 610.363.9620 * sales@novatekco.com*
SECTION V
PARTS LIST – A
3B/PG SHROUDED PISTOL GRIP NEEDLE SCALER (Part No: 139.3107)
REF #
PART #
DESCRIPTION
1
2
3
4
5
6
6A
7
8
9
10
11
12
14
18
24
25
25A
26
615.3021
809.0139
712.3022
618.3022
809.0089
616.3521
423.3521
716.3021
813.0108
612.3001
613.3138
809.0289
809.0299
425.3138
717.3101
610.3011
601.3013
301.3012
445.2010
445.2015
445.3120
445.3125
712.3001
416.3138
418.3039
806.0830
731.4101
731.4102
731.4103
VALVE CAP
“O” RING - VALVE CAP (10pack)
VALVE SPRING
VALVE STEM
“O” RING - VALVE SEAT (10pack)
VALVE BODY
VALVE BODY ASSEMBLY (COMPRISES ITEMS 1-8 INCLUSIVE)
THROTTLE LEVER
ROLL PIN
PISTON
CYLINDER - AAT ONLY
“O” RING - CYLINDER/SMALL (10pack)
“O” RING - CYLINDER/LARGE (10pack)
COVER ASSEMBLY
RUBBER HANDLE GRIP
ANVIL
NEEDLE HOLDER 3mm
NEEDLE HOLDER 2mm
NEEDLES 2mm (100pack)
NEEDLES 2mm (250pack)
NEEDLES 3mm (100pack)
NEEDLES 3mm (250pack)
SPRING - COMPRESSION
INTERMEDIATE TUBE - 8TPI
FRONT TUBE WITH VACUUM TAKE OFF
CAP HEAD SCREW (10pack)
INTERNAL CORNER - FRONT CUFF
EXTERNAL EDGE - FRONT CUFF
FLAT SURFACE - FRONT CUFF
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31
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PARTS LIST - B
2B/PG SHROUDED PISTOL GRIP NEEDLE SCALER (Part No: 139.2199)
REF #
PART #
DESCRIPTION
1
2
3
4
5
6
6A
7
8
9
10
11
12
14
18
24
25
25A
26
615.3021
809.0139
712.3022
618.3022
809.0089
616.3521
423.3521
716.3021
813.0108
612.2001
613.2101
809.0249
809.0269
425.2100
717.3101
610.2091
601.2093
601.2092
445.2010
445.2015
445.3120
445.3125
712.2001
416.2099
418.2199
806.0830
731.2101
731.2103
VALVE CAP
“O” RING - VALVE CAP (10pack)
VALVE SPRING
VALVE STEM
“O” RING - VALVE SEAT (10pack)
VALVE BODY
VALVE BODY ASSEMBLY (COMPRISES ITEMS 1-8 INCLUSIVE)
THROTTLE LEVER
ROLL PIN
PISTON
CYLINDER - AAT ONLY
“O” RING - CYLINDER/SMALL (10pack)
“O” RING - CYLINDER/LARGE (10pack)
COVER ASSEMBLY
RUBBER HANDLE GRIP
ANVIL
NEEDLE HOLDER 3mm
NEEDLE HOLDER 2mm
NEEDLES 2mm (100pack)
NEEDLES 2mm (250pack)
NEEDLES 3mm (100pack)
NEEDLES 3mm (250pack)
SPRING - COMPRESSION
INTERMEDIATE TUBE - 8TPI
FRONT TUBE WITH VACUUM TAKE OFF
CAP HEAD SCREW (10pack)
INTERNAL CORNER - FRONT CUFF
FLAT SURFACE - FRONT CUFF
27
28
29
30
31
32
8
*www.novatekco.com * toll free 866.563.7800 * tele 610.363.7800 * fax 610.363.9620 * sales@novatekco.com*
SERVICE LAYOUT (A & B)
2 & 3B/PG SHROUDED NEEDLE SCALER w/ REFERENCE NUMBERS
Section VI
SPECIFICATIONS
(A)
(B)
CONFIG / MODEL
3B/PG
2B/PG
PART #
139.3107
139.2107
PISTON DIA. (IN.)
PISTON STROKE (IN.)
BLOWS (PER-MIN.)
AIR CONSUMPTION ( @ 90 PSI SCFM)
AIR PRESSURE REQUIRED (± 10) PSI
NOISE LEVEL DB (A)*
AIR INLET (IN) NPT
AIR SUPPLY HOSE DIA. (IN)
VACUUM HOSE, DIA. (IN)
NUMBER OF 3MM NEEDLES
NUMBER OF 2MM NEEDLES
1.125
1.54
2,200
8
90
92
¼
3/8
1½
28
65
.925
1.4
3000
5.5
90
89
¼
3/8
1½
19
51
* Under PNEUROP-CAGI test code conditions.
9
*www.novatekco.com * toll free 866.563.7800 * tele 610.363.7800 * fax 610.363.9620 * sales@novatekco.com*
NOVATEK CORPORATION LIMITED WARRANTY
The TOOLS manufactured by NOVATEK CORPORATION are warranted to be free from defects in
material and workmanship for a period of 180 DAYS from the date of purchase from NOVATEK
CORPORATION. This warranty does not apply to accessories. All electrical components of the tool
are also warranted to be free from defects in material and workmanship for a period of 180 DAYS.
This warranty applies only to TOOLS purchased new from NOVATEK CORPORATION. This
warranty does not apply to any TOOL which has been abused, misused, modified or repaired by
someone other than NOVATEK CORPORATION or its authorized repair center.
If a TOOL proves defective in material or workmanship within one year of purchase from NOVATEK
CORPORATION, it should be returned to NOVATEK CORPORATION, transportation pre-paid. The
return must be authorized by a RETURN MERCHANDISE AUTHORIZATION NUMBER (R.M.A. #)
obtained from NOVATEK CORPORATION prior to returning the UNIT. All packages must show
clearly on the outside the return merchandise authorization number. All packages received without
any R.M.A. # on the outside will be refused by NOVATEK CORPORATION receiving department.
Warranty claims will only be considered upon adequate proof of date of purchase. NOVATEK
CORPORATION will, at its option, REPAIR or REPLACE DEFECTIVE PARTS. Repairs or
replacements are warranted as above for the remainder of the original warranty period. The sole
liability of NOVATEK CORPORATION and the user’s exclusive remedy under this warranty is limited
to the repair or replacement of the defective product.
THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED AND NOVATEK
CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES OR ANY OTHER EXPENSES OR REPAIR OR REPLACEMENT AS DESCRIBED
ABOVE.
All warranty claims should be forwarded to:
NOVATEK CORPORATION
216 Philips Road
Exton, PA 19341
ATTENTION: CLAIM AND SERVICE DEPARTMENT
R.M.A. # ____________
CALL Toll Free at 1-866-563-7800 for your RMA number prior to shipping.
Also include a brief description of the problem as well as a phone number, contact name and return
address in case NOVATEK CORPORATION service personnel has to get in contact with you.
10
*www.novatekco.com * toll free 866.563.7800 * tele 610.363.7800 * fax 610.363.9620 * sales@novatekco.com*