Alpha Tool.Com.HK Limited Polisher AIR680 ver 3 User Manual

							Part No: AIR-680Version 3
103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: 800-286-01 14
www.alpha-tools.com
Alpha® Pneumatic
Air Polisher
Instruction Manual
MANUAL  
						

							2
TAble of CoNTeNTs
Introduction  ........................................................................\
........ 3
About the Symbols  .................................................................... 3
Safety Instructions for Power Tools ........................................... 4
AIR-680 Overview  ..................................................................... 6
Specifications  ........................................................................\
.... 6
Equipment Included  ................................................................... 7
  Optional Accessories  ............................................................ 7
  Recommended Alpha
® Accessories  ..................................... 7 
Special Features ........................................................................\
 7
Tool Set-Up Information  ............................................................. 7
  Connection Fittings  ............................................................... 8
  Air Pressure and Volume  ...................................................... 9
  Rust Protection ..................................................................... 9
  How to Add the Rust Inhibitor Oil  ........................................10
Polishing and Using The Tool .................................................. 11  
  Spindle Size  ........................................................................\
 11
  Air Valve Lever  .................................................................... 11
  Filter/Regulator System  ...................................................... 12
  Water Control Valve ............................................................ 12
	 Silencer/Muffler  ................................................................... 13
  Reversible Side Handle  ...................................................... 13
  Air Supply Hose Assembly  .................................................. 13
  Water Supply Hose Assembly ............................................. 13
  Attaching the Exhaust Hose & Clamp  ................................. 14
AIR-680 Schematic .................................................................. 15
AIR-680 Parts List ................................................................... 16
Accessories and Factory Service  ............................................18
Product Registration  ................................................................ 19   
						

							3
 INTRoduCTIoN
Thank you for purchasing an Alpha
® Air Polisher. This polisher is 
the workhorse of a complete polishing system. A wide range of 
accessories help you perform many different tasks. This tool lets 
you grind, shape, bevel, contour and polish all kinds of natural stone 
and man-made materials. You can easily change from one type of 
disc to another in just a matter of seconds. The tool is used with 
water	 to	help	 you	get	the	best	 possible	 finish,	to	reduce	 the	health	
risks of dust, and to give the most savings in time and money. For 
your safety, please read this manual thoroughly before you start 
operating this polisher. 
 AbouT The symbols
According to the hazard level, all safety notes in this manual are 
classified	into	“DANGER”,		“WARNING”,	and	“CAUTION”.
		DANGER!	 Death	 or	serious	 personal	 injury	is	imminent	 when	
handling this polisher incorrectly.
		WARNING!	 There	 is	a	possibility	 of	death	 or	serious	 personal	
injury when handling this polisher incorrectly. 
		CAUTION!	 There	 is	a	possibility	 of	personal	 injury	or	property	
damage when handling this polisher incorrectly.
Note:			In	 some	situations,	 failing	to	observe	 WARNING	 notes	could	
result in death or serious personal injury.  Be sure to read 
and observe the safety notes to ensure safety and correct 
use of the polisher.  
for repair information call:
Headquarters,	Oakland,	NJ	—	(800)	648-7229	ext.505
Due to specially designed components this machine must be serviced only 
with genuine ALPHA® parts.   
						

							4
 sAfeTy INsTRuCTIoNs foR PoWeR T ools 
1. KNOW	 YOUR	 POWER	 TOOL.	 	Read	owner’s	 manual	carefully. 		
Learn	 its	applications	 and	limitations	 as	well	 as	specific	 potential	
hazards particular to this tool. 
2.  KEEP 	WORK	 AREA	CLEAN.	 Cluttered	 areas	and	benches	 invite	
accidents. 
3.  AVOID	 DANGEROUS	 ENVIRONMENTS.		 Keep	work	areas	 as	dry	
as	 possible.	 	 Do	not	 use	 tool	in	presence	 of	flammable	 liquids	or	
gases.  Keep the area well lit. 
4.  KEEP 	CHILDREN	 AND	VISITORS	 AWAY.		All	visitors	 should	be	kept 	
a safe distance from the work area. Keep out of reach of children.  
5.  DON’T 	FORCE	 TOOL.		It	will	 do	the	 job	better	 and	safer	 at	the	 rate	
for which it was designed. 
6.  WEAR	 PROPER	 APPAREL.		 Do	not	 wear	 loose	 clothing	 or	jewelry	
as it can get caught in moving parts. Rubber gloves and insulated 
non-skid footwear are recommended.  Wear protective covering to 
contain long hair. 
7.  WEAR	 PROPER	 EYE	PROTECTION.	 	 All	users	 and	bystanders 	
must always wear proper personal eye protection which conform with 
ANSI/ISEA 	Z87.1	 (CAN/CSA 	Z94.3).	 Also	use	a	face	 or	dust	 mask	 if	
operation	is	dusty.	 Always	wear	certified	safety	equipment.		
8.  WEAR	 PROPER	 EAR	PROTECTION.	 	 All	users	 and	bystanders	
must	 wear	 proper	 personal	 ear	protection	 which	conforms	 with	ANSI	
S12.6	(S3.19)	hearing	protection.  
9.  WEAR	 PROPER	 RESPIRATORY 	PROTECTION. 	All users and 
bystanders must wear proper personal respiratory protection. Always 
use	 NIOSH/OSHA 	approved	 respiratory	 protection	appropriate	 for	the 	
dust exposure.    
               
Warning:  Some dust created by power sanding, sawing, grinding, drilling, 
polishing and other construction activities contains chemicals known to the 
State of California to cause cancer, birth defects, or other reproductive harm. 
Some examples of these chemicals are:      
 - Lead from lead-based paints         
 - Crystalline silica from bricks, cement and other masonry products, an\
d    
 - 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, work in a well ventilated area, and    
						

							5
work with approved safety equipment, such as dust masks that are specially 
designed	to	filter	out	microscopic	particles.	 	 	 
         
To familiarize with the risks associated with a material, consult with your 
employer, manufacturer/supplier and government agencies regarding the 
hazards of the materials and their recommendations to protect yourself.
  
     
10.  DON’T 	ABUSE	 WATER	 SUPPLY 	HOSE.		 Don’t	carry	tool	by	supply	
hose	or	expose	to	traffic	areas	where	it	can	be	crushed.	
11.  ALWAYS SECURE WORK PIECE.  Use clamps or a vise to hold work.  
It’s	safer	 than	using	 your	hand	 and	it	frees	 both	hands	 to	operate	 tool.	
12.  DON’T 	OVERREACH.		 Keep	proper	 footing	 and	balance	 at	all	 times. 	
13.  DISCONNECT 	TOOLS	 WHEN	NOT	IN	 USE.	 	 Always	 disconnect	
tool before servicing; when changing accessories such as grinding 
wheels, backer pads, etc.
14.  REMOVE	 ADJUSTING	 KEYS	AND	WRENCHES.  Form a habit of 
checking to see that keys and adjusting wrenches are removed from 
tool before turning it on. 
15.  MAINTAIN	 TOOLS	WITH	CARE.			 Keep	tools	clean	 at	all	 times	 for	
best and safest performance.  Follow instructions for lubricating and 
changing accessories.  Keep handles dry, clean and free of oil or 
grease.  Inspect moving parts for alignment and binding as well as 
for breakage and improper mounting. 
16.  AVOID	 ACCIDENTAL 	STARTING.			 Do	not	 carry	 a	“connected”	 tool,	
or make adjustments, or change discs without making sure the tool 
is disconnected from the air supply.
17.  USE	 ONLY 	RECOMMENDED	 ACCESSORIES.	The	use	of	any 	
accessories other than what is listed or recommended for this 
particular tool may be hazardous. 
18.  KEEP 	HANDS	 AWAY	FROM	 ALL	MOVING	PARTS.	
19.  USE	SIDE	HANDLES.		Supplied	with	tool	for	control	and	safety.	
20.  USE	 RECOMMENDED	 GRINDING	WHEELS	ONLY.	 	 	Do	not	 use	
conventional abrasive grinding wheels with this tool. Only use 
diamond grinding wheels which are rated for wet usage. 
21.  STAY ALERT.   Watch what you are doing and use common sense.  
Do	not	 operate	 tool	when	 you	are	tired,	 or	under	 the	influence	 of	
medication or alcohol.       
            
						

							6
AIR-680 oVeRVIeW
Reversible Handle
15 ft Air Hose
15 ft Water Hose
Adjustable Air Valve
Adjustable Water Valve
Rubber Body Cover
Internal WaterLine
Oil PortScrew
Exhaust Hose With Clamp
sPeCIfICATIoNs
  Air Pressure  .................................................. 85 PSI
  Air Consumption .......................................... 15 CFM
	 No	Load	RPM .................................................. 4,000          
 Weight  ................................................. 2.64lbs/1.2kg
  Air Inlet .................................................... 1/4”	BSPP
  Water Inlet ................................................ 1/8”		BSPP
 Spindle  .......................................................... 5/8”-11	
 
1/4”	BSPP
1/8”	BSPP   
						

							7
 
 eQuIPmeNT INCluded
	 Air	hose	(15	ft	/	4.5m) .........................................1pc
	 Water	hose	(15	ft	/	4.5m) ................................... 1pc
	 Side	Handle	(reversible) .....................................1pc          
	 Double	End	Wrench	(19mm/22mm)  ................... 1pc
	 Rust	Inhibitor	Oil	(8oz	/	237ml)	(AIR-008)  ..........1pc
	 Screw	(w/	O-Ring	Seal	for	Oil	Port) ................... 1pc
  Exhaust Hose With Clamp  ................................. 1pc 
 
 oPTIoNAl ACCessoRIes 
	 Splash	Guard	(AWP-01) .................................... 1pc
	 C-Shaped	Handle	(AWP-21A) ........................... 1pc
 
 ReCommeNded AlPhA® ACCessoRIes
Ceramica	 EX		flexible	 diamond	 polishing	 discs,	waterproof	 Sandpaper 	
discs,	 Hook	and	Loop	 Backed	 Felt	Wheels,	 Core	Drill	Bits,	 Turboshine 	
and	Profilers.
sPeCIAl  feATuRes 
The Alpha® AIR-680 polisher was designed with user comfort in 
mind, for a full day of use. The silencer system will reduce the noise 
volume below 80 dBA and the rubber body cover will insulate the 
user from the cold and fatigue. The blue exhaust hose is designed 
to guide the cold exhaust air and rust inhibitor oil away from the user 
and the work area.
T ool seT -uP INfoRmATIoN
Unpack the tool carefully and study the helpful hints and warnings 
contained in this manual.  Please take time to familiarize yourself 
with	 the	features	 of	the	 tool.		 Be	sure	 to	fill	 out	 the	registration	 card	
enclosed, and mail it back to the distribution center today.
1/4”	BSPP
1/8”	BSPP   
						

							8
 CoNNeCTIoN fITTINGs
The	 air	and	 water	 hose	fittings	 on	the	 back	 of	this	 tool	 are	BSPP 	
(British	 standard	 parallel	pipe	or	“G”	 thread).	 These	fittings	 have	
parallel	 threads	 and	seal	 off	on	 the	 flat	surface	 on	the	 bottom	 of	
the	 thread.	 This	type	 of	fitting	 is	usually	 supplied	 with	an	“O”ring	 or	
sealing ring which we replaced with the silencer.
Parallel Thread Tapered Thread NPT   
						

							9
Trying	to	convert	 either	fitting	to	an	 American	 standard	pipe	thread	
(NPT),	 which	is	tapered,	 will	crack	 the	Endcase	 and	is	not	 covered	
under warranty.
 AIR PRessuRe ANd Volume
The recommended air pressure for this tool is 85 PSI. The most 
important factor in running this tool is the volume of air being sup-
plied to the tool. The volume is the air consumption needed to run 
this tool at a constant speed under light downward hand pressure. 
The	 volume	 is	measured	 in	CFM	 (cubic	 foot	per	minute	 (ft
3/min).	You	
need a minimum of 15 CFM per tool. 
When choosing a compressor to run an AIR-680 polisher, we recom-
mend a rotary screw type with a minimum of a 5hp motor/15-20 CFM 
and	 a	60	 gallon	 tank,	per	tool.	 (I.E. if you want to run four tools, you 
will need a compressor with a 20hp motor capability of 80+ CFM and 
an 80 to 100 gallon storage tank. )	
It is also very important to keep your air cool, dry, and clean, so look for a 
compressor	 with	a	refrigerated	 dryer	and	high-efficiency	 filter	built	in	or	
purchase	 a	separate	 air	dryer	 and	filter	 unit	rated	 for	your	 compressors 	  
CFM.
 RusT PRoTeCTIoN (A rust inhibitor oil is used to protect the 
tool from rusting when not in use)
PRoPeR CARe ANd mAINTeNANCe ARe ImPoRTANT 
f ACT oRs IN PReVeNTING ThIs T ool fRom RusTING oN The  
INsIde WheN NoT IN use.
At	 the	 end	 of	each	 workday,	 place	2-3	drops	 of	rust	 inhibitor	 oil	(in-
cluded	 with	each	 polisher)	 directly	into	the	OIL	PORT 	of	 the	 pneumatic 	
tool. After applying the rust inhibitor oil, turn the air valve slightly so 
that the oil atomizes into a mist and coats the internal components 
of the polisher. If the process is executed correctly, you should see 
a mist coming out of the end of the polisher. The Exhaust Hose 
(Part	 No.	658-95)	 and	Hose	 Clamp	 (Part	No.	1030-1104)	 need	to	be	
removed to see the mist effect. See the detailed steps on the next 
page for adding the oil to the pneumatic polisher.
  CAUTION!   
						

							10
When	you	remove	 the	screw	 (658-91)	 without	disconnecting	 the	
air supply, compressed air will start leaking out and push the screw 
while removing. When installing the oil port screw, install until the 
O-ring and screw head make contact with the Endcase. 
Warning: Over tightening of the oil port screw can strip the 
screw and/or internal thread of the Endcase.
 hoW T o Add The RusT INhIbIT oR oIl
1. Disconnect	the	tool	from	your	air	supply.
2.  Remove	the	screw	(Part	No.	658-91)	using	
a #1 phillips head miniature screw driver.  
(See	Fig.	1)
3. Add 2 -3 drops of the rust inhibitor oil into 
the	oil	port.	(See	Fig.	2)
4.  Reinstall	the	screw	(Part	No.	658-91).	
5.  Reconnect the tool to your air supply.
6.  Turn	the	valve	lever	(Part	No.	658-50)			
slightly so the air is leaking through the 
tool.		(Spindle	of	tool	should	not	spin	
during	this	process).	(See	Fig.	3)	
7.  Replacement Rust Inhibitor Oil can be 
purchased  from Alpha
® Professional Tools 
(Part	No.	 AIR-008).
Lubricating the tool before and during work is not needed. Excessive 
oil will turn to a tar-like substance inside the tool, causing the vanes 
to stick in the rotor and slow the tool down. This is the reason we do 
not recommend automatic oilers be used with this tool. Old or worn 
compressors,	 which	emit	oil	through	 the	air	lines,	 can	significantly	
shorten the life of the tool.
  WARNING!