Alpha Tool.Com.HK Limited Polisher AIR680 ver 2 User Manual

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POLISHING AND USING THE TOOL
This tool and the Alpha® accessories approved for use with this tool 
are designed to be used under light downward hand pressure. You 
need	to	allow	 the	polishing	 pads,	core	bits,	and	profilers	 to	do	 their	
job. Applying excessive downward pressure to the tool will cause the 
vanes to wear out in the middle and fail prematurely.
 SPINDLE SIZE 
The Alpha®	AIR-680	 air	polisher	 features	 a	5/8”-11	 spindle.		 This	tool	
has been designed for portable/shop production and uses all modern 
accessories.  It is very important that you do not run anything heavier 
than the recommended accessories on this machine.  A drop of oil 
should be applied to the outside threads whenever attachments are 
changed	 to	facilitate	 removal	and	prevent	 rust.		A	Double	 End	Wrench 	
(19mm/22mm)	is	provided	to	assist	in	changing	accessories.
 
Maintenance and Usage Tip:
•	Do	not	 leave	 the	tool	 submersed	 in	water.	 This	could	 expose	
the inner moving parts to moisture, which will shorten the life 
of the tool.
•	Do	not	 leave 	threaded	 accessories	 (backer	pads,	core	drill	
bits,	profilers) 	on	 the	 spindle	 of	tool	 for	extended	 periods	of	
time;	this	may	 result	 in	making	 it	difficult	 to	remove	 these	
accessories.
•	Excessive force or impact to the spindle may result in 
premature failure of gears, keyways and bearings, which may 
not be immediately evident.
 AIR VALVE LEVER 
The	valve	 lever	controls	 the	flow	 of	air	
through	 the	tool.		 It	has	 two	positions-	 ON	
or OFF.  Run the tool at the recommended 
pressure of 85 PSI, with the lever 
pointing	 to	the	 ON	 position.	 This	will	
produce	 4,000	RPM.	Do	not	 try	to	vary	
the speed.  The tool works best at full 
  CAUTION!  
						

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throttle	only.	Do	not	 attempt	 to	exceed	 the	recommended	 speed	by	
excess	 pressure.	 This	will	significantly	 shorten	the	life	of	the	 tool.	
When storing the tool overnight, disconnect from the air supply and 
open the valve.
   HELPFUL HINT: 
•	Air valve lever should be opened and closed slowly to allow 
the tool to accelerate and decelerate during all applications. 
Rapid acceleration and deceleration can wear out the ball 
bearings prematurely.
   HELPFUL HINT: 
•	Using a Filter Regulator System is 
Recommended
 FILTER/REGULATOR SYSTEM 
Having a Filter/Regulator helps prevent 
pressure drops when using a large 
volume of air, so you can set the 
pressure to the tools at 85 PSI, while the main system can run at 
125 PSI. The F/R unit will also remove any water from the air supply 
while	 also	filtering	 the	air	of	contamination	 down	to	five	 microns.	 By	
only using aluminum and brass after the F/R unit, you are eliminating 
any rust and contamination from getting into the air tools. 
The Alpha® F/R Manifold System comes in two sizes, 53 CFM & 106 
CFM	and	three	 adapter	 blocks:	3/8”,	1/2”	and	3/4”,	 and	is	designed	
for installation at the point of use.  All F/R manifolds are custom-
configured	 to	a	clients	 specific	 needs	and	are	available	 through	our	
distributor network, and via our website. 
 WATER CONTROL VALVE 
This	valve	 lets	you	 adjust	 the	flow	 of	water	
through the spindle. It may be used to shut 
off the water entirely when changing discs. 
When storing the tool overnight, open the 
valve and drain all water from the supply 
hose and tool.  
						

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 SILENCER / MUFFLER 
To	comply	 with	OSHA 	Occupational	 Noise	Exposure	 Standard	
Number	1926.52,	 this	polisher	 is	equipped	 with	an	internal	 Silencer	
System. When the polisher is operated correctly at 85 PSI, the sound 
level emitted should be less than 80 dBA. The internal Silencer 
System is also used to maintain a constant back pressure inside the 
tool, to prevent the rotor assembly from exceeding the max speed 
of the bearings; this helps prevent the polisher from exceeding the 
recommended 4,000 RPM. The exhaust hose for this tool also helps 
to reduce the noise level by venting the exhaust air and residual 
air-line, thus eliminating the risk of excess rust inhibitor oil dripping 
on the work piece. 
Tools sent in for repair, where the body gasket or silencer is removed 
or	modified,	are	not	covered	under	our	Limited	Warranty.
 REVERSIBLE SIDE HANDLE
Attach the handle into the threaded socket on either the left or right 
side of the tool.  A locknut is slipped onto the threads to keep the 
handle safely in position. 
Maintenance and Usage Tip:
Do	not	 apply	 more	force	or	pressure	 than	the	force	 created	 by	the	
weight of the polisher itself.  The polishing discs are designed to work 
properly under light downward hand pressure.  Applying excessive 
force or pressure may damage the vanes and could shorten the life 
of the tool.
 AIR SUPPLY HOSE ASSEMBLY
This new Flexzilla®  hose	 has	1/4”	 NPT	threads	 and	is	composed	 of	
a	special	 material	 to	avoid	 kinks	and	remain	 flexible	 down	to	-40°F.
Replacements	 are	available	 should	the	hose	 become	 damaged	 (Part	
No.	1030-0002).					
 WATER SUPPLY HOSE ASSEMBLY
This hose may be connected to any garden hose.  This new Flexzilla®  
hose is composed of a special material to avoid kinks and remain 
flexible	 down	to	-40°F.	 Replacements	 are	available	 should	the	hose	
become	damaged	(Part	No.	1030-0003).					  
						

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 PROCEDURE FOR CONNECTING EXHAUST HOSE AND HOSE 
CLAMP
1. Slide	the	Exhaust	 Hose	(Part	No.	
658-95) 	over	 the	water 	& 	air 	hoses 	
which should be already connected 
to	the	polisher.	(See	Fig.4)  
      
     
      
  
2. Exhaust Hose should be pulled up and 
wrapped around the bottom portion of the 
Endcase	 Assembly	 (Part	No.	658-94	 /	96). 	
(See	Fig.5)	 	 	 	
      
      
 
3. Slide	 the	Hose	 Clamp	 (Part	No.	1030-
1104)	 over	the	Exhaust 	Hose	 and	Endcase 	
Assembly.	(See	Fig.6)	 	 	 	
       
     
 
4. Using a screw driver, tighten to a snug 
fit.	(See	Fig.7)
     
						

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ALPHA® AIR-680 SCHEMATIC (VER.2)
43   
						

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 ALPHA® AIR-680 PARTS LIST (VER. 2)
DRAWING NOPART NO.ITEM DESCRIPTIONQUANTITY
1658-01Screw2
2658-92Pipe-Joint Assembly1
3516-44Oil Seal1
4658-09W-Pipe1
5658-10Head Packing1
6658-11Body1
7658-12Body Cover1
8516-20Bearing 2
9658-16Snap Ring1
10658-17Spiral Bevel Gear1
11516-48Bearing 1
12516-49Oil Seal1
13516-5044 Nut1
14658-93Spindle 5/8"-11 Thread1
15658-22Woodruff Key1
16658-23O-Ring (1.7mm x 2.75mm)1
17658-24Spray Nozzle1
18658-25Spiral Bevel Pinion1
19516-18Ball Bearing 1
20658-28F-Bearing Case1
21658-29Rotor Spacer1
22658-30Cylinder (inc. Part No. 658-31)1
23658-31Spring Pin1
24658-32Rotor1
25516-25Vanes (4pc set)1
26516-26R-Bearing Case1
27516-27Bearing 1
28516-28Bearing Cap1
29658-37Air Inlet Case1
30658-43Screw 1
31658-45Wave Washer1
32658-46Nut M-142
33658-47O-Ring (1.7mm x 6.75mm)1
34658-50Valve Lever1
35658-51Screw 4
36658-64O-Ring (1.0mm x 3.0mm)1
37658-65Retaining Ring E-Style1
38658-66Nut M81   
						

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 ALPHA® AIR-680 PARTS LIST (VER. 2)
DRAWING NOPART NO.ITEM DESCRIPTIONQUANTITY
39658-67Washer 051
40658-94Endcase Assembly (inc. Part No. 
658-72, 73, 91)
1
41658-72O-Ring (1.9mm x 3.8mm)1
42658-73Bushing 071
43658-96Complete Endcase Assembly1
44658-80Shim (0.10mm)1
45658-81Shim (0.03mm)1
46658-82Shim (0.05mm)1
47658-84Shim (0.20mm)1
48658-86Water Valve1
49658-87A-Valve  (inc. Part No. 658-88)1
50658-88Needle Pin1
51658-89Body Gasket (req. Part No. 658-90)1
52658-90Silencer (req. Part No. 658-89)1
53658-91Screw (w/O-Ring Seal  
(1pc in tool + 1 spare))
2
541030-1020Male Union for Water Hose Fitting1
551030-0003Water Hose Assembly1
561030-1021Male Union for Air Hose Fitting1
571030-0002Air Hose Assembly1
581030-1104Hose Clamp1
59658-95Exhaust Hose 1
601030-1103Double Open End Wrench 
(19mm/22mm)
1
61658-13Spring Lock Washer1
62658-14Side Handle1
63AIR-008Rust Inhibitor Oil 8 oz.(237ml)1
64AWP-01Splash GuardOptional
65AWP-21AC-Shaped HandleOptional  
						

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All the accessories can be purchased at a local distributor in your 
area.  For more information concerning Alpha® Air Polisher and factory 
service, please contact the Alpha® distribution centers listed below.
COMPANY	HEADQUARTERS:			 Alpha	Professional	 Tools® 
	 	 	 	 	 103	Bauer	Drive
	 	 	 	 	 Oakland,	NJ	07436
Hours	of	Operation:		 	 	 8:30	a.m.	–	5:00	p.m.	EST
Telephone	Number:		 	 	 201-337-3343
Toll-Free	Number:		 	 	 800-648-7229
or visit us on the web at: www.alpha-tools.com
Limited Warranty of Alpha® Air Polisher (AIR-680)Alpha Professional Tools® warrants this product against defects in material and workmanship for a period of 90 days from the date of original retail purchase (proof	of	purchase	 required).	 If	Alpha 	Professional	 Tools® receives notice of such defects during the warranty period, our obligation assumed under this warranty is limited to the repair or replacement of parts, without charge. This warranty does not apply to Alpha® accessories. Returns within the warranty period should be sent	in	freight	prepaid	to	one	of	 Alpha’s	Authorized	Warranty	Service	Centers.
The warranty does not apply in situations where:•	The tool has been misused, abused or improperly maintained•	Alterations or repairs were made by others•	Repairs due to normal wear and tear
Some States do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation	 may	not	apply.	 This	warranty	 gives	you	specific	 legal	rights	 and	you	may	also have other rights which vary from state to state.
For Warranty Claims:  Send complete tool with all your information and details of the problem to Alpha Professional Tools®,	transportation	 prepaid.	Do	not	 send	tool accessories.
  ACCESSORIES AND FACTORY SERVICE   
						

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PRODUCT REGISTRATION CARD
Model No.                  Serial No.
Company Name: ______________________________________________
Name: ______________________________________________________
Address: ____________________________________________________
City: _______________________State: ________Zip: ________________
Telephone: ___________________________________________________
Purchase Date: _______________________________________________
Dealer’s	Name:	_________________________________
Note:  Serial & Model Number must be included for proper registration.
(800) 648-7229
Mail	or	Fax	to:
Alpha Professional Tools®
103	Bauer	Drive,	Oakland,	NJ	07436
Fax:	800-286-0114
Photocopy of product registration form will be accepted.
Register online at: 
www.alpha-tools.com/productregistration.aspx   
						

							Copyright © 2015 Alpha Professional Tools. All rights reserved. 
103	Bauer	Drive,	Oakland,	NJ	07436	•	800-648-7229	•	Fax:	800-286-0114www.alpha-tools.com
03/2015