Avdel Genesis 4 Instruction Manual

Genesis

Hydro-Pneumatic Power Tool

Instruction Manual

Safety Instructions 4

Speciﬁcations

Tool Speciﬁcation 5 Tool Dimensions 5

Intent of Use

Range of Fasteners 6 Part Numbering 6

Putting into Service

Air Supply 7 Operating Procedure - All fasteners except Avtainer® and Maxlok

Operating Procedure - Avtainer® and Maxlok

Nose Assemblies

Nose Tip Selection 9 Fitting Instructions - All Nose Assemblies except Avtainer® and Maxlok

9 Servicing Instructions 9 Nose Tips 10 - 13 Type 1 - Standard 10 Type 2 - Limited Access 11 Type 5 - Avtainer

11 Type 6 - Hemlok®- Stavex

11 Type 7 - Avibulb ® - Avinox

12 Maxlok

12 Fitting Instructions for Avtainer® and Maxlok

Nose Assemblies 13 Servicing Instructions for all Nose Assemblies 13

Accessories

Stem Deﬂector 14 Preparing the Base Tool for use with Stem Deﬂector 14 Extension 14

Servicing the Tool

Daily / Weekly 16 Moly Lithium Grease EP 3753 Safety Data 16 Molykote

55m Grease Safety Data 17

Molykote

111 Grease Safety Data 17 Service Kit 18 Maintenance 18 Nose Equipment 18 Dismantling the Tool 19 Head Assembly 19 Pneumatic Piston Assembly 20 Air Valve 20 Rotary Valve 21 Trigger 21

Base Tool

General Assembly of Base Tool 71234-02000 22 Parts List for 71234-02000 23

Priming

Oil Details 24 Hyspin®VG32 Oil Safety Data 24 Priming Kit 24 Priming Procedure 25

Fault Diagnosis

Symptom, Possible Cause and Remedy 26

Contents

LIMITED WARRANTY

Avdel makes the limited warranty that its products will be free of defects in workmanship and materials

which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product

being installed, maintained and operated in accordance with product literature and instructions, and (2)

conﬁrmation by Avdel of such defect, upon inspection and testing. Avdel makes the foregoing limited

warranty for a period of twelve (12) months following Avdel’s delivery of the product to the direct purchaser

from Avdel. In the event of any breach of the foregoing warranty, the sole remedy shall be to return the

defective Goods for replacement or refund for the purchase price at Avdel’s option. THE FOREGOING

EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES

AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY

ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.

Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the speciﬁcation of any product without prior notice.

Safety Instructions

1 Do not use outside the design intent.

2 Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.

3 Any modiﬁcation undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Avdel UK

Limited or their representatives, shall be the customer’s entire responsibility. Avdel UK Limited will be pleased to advise upon any

proposed modiﬁcation.

4 The tool/machine must be maintained in a safe working condition at all times and examined at regular intervals for damage and function

by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel UK Limited procedures.

Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel UK Limited with your

training requirements.

5 The tool/machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the U.K. the “Health and

Safety at Work etc. Act 1974” applies. Any question regarding the correct operation of the tool/machine and operator safety should be

directed to Avdel UK Limited.

6 The precautions to be observed when using this tool/machine must be explained by the customer to all operators.

7 Always disconnect the airline from the tool/machine inlet before attempting to adjust, ﬁt or remove a nose assembly.

8 Do not operate a tool/machine that is directed towards any person(s) or the operator.

9 Always adopt a ﬁrm footing or a stable position before operating the tool/machine.

10 Ensure that vent holes do not become blocked or covered.

11 The operating pressure shall not exceed 7 bar.

12 Do not operate the tool if it is not ﬁtted with a complete nose assembly or swivel head unless speciﬁcally instructed otherwise.

13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.

14 If the tool is ﬁtted with a stem deﬂector, it should be rotated until the aperture is facing away from the operator and other person(s)

working in the vicinity.

15 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against fastener

ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the application.

16 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be kept

dry and clean for best possible grip.

17 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.

18 Excessive contact with hydraulic ﬂuid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash

thoroughly.

19 C.O.S.H.H. data for all hydraulic oils and lubricants is available on request from your tool supplier.

This instruction manual must be read with particular attention to the following safety rules, by any person installing, operating, or servicing this tool.

Tool Specification

Specifications

Air Pressure Minimum - Maximum 5-7 bar

Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cu ft)

Stroke Minimum 17 mm

Pull Force @ 5.5 bar 18.68 kN (4200 lbf)

Cycle Time Approximately 1.2 seconds

Noise Level 75 dB(A)

Weight Including nose equipment 2.25 kg

Vibration Less than 2.5 m/s

22.9

12•

30'

140

128

156

150

320

145

116

Dimensions in millimetres

Tool Dimensions

Intent of Use

nG4 is a hydro-pneumatic tool designed to place Avdel

breakstem fasteners at high speed making it ideal for batch or ﬂow-line assembly in a wide variety of applications throughout all industries. It can place all fasteners listed opposite.

The tool features a vacuum system for fastener retention and trouble free collection of the spent stems regardless of tool orientation.

A complete tool is made up of three separate elements which will be supplied individually. See diagram below.

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGE 9.

FASTENER

NAME

FASTENER SIZE ( )

AVEX

STAVEX

AVINOX II

AVIBULB

BULBEX

T-L OK

AVDEL® SR

HEMLOK

MAXLOK

AVTAINER

AVSEAL

II Q RIVET T RIVET

AVDELMATE

KLAMP-TITE

KLAMPTITE KTR

LOCKBOLT

4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10 11 12

–

/16 – – – 1/4 – – – –3/8 – – –

COMPLETE TOOL

71234-00 . . .

BASE TOOL

NOSE ASSEMBLY

NOSE TIP

71234-02000

71210-15000

see note 3

++=

1 2 3

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE

TIP TABLE ON PAGES 10-12.

The part number of the base tool remains the same whichever nose assembly, or nose tip is ﬁtted. See the General Assembly pages 22 and 23.

The nose tip part number relates to a speciﬁc fastener. If access to the application is restricted, some extended nose tips are available. See table page 12.

This single nose assembly will allow placing of fasteners by simply selecting the appropriate nose tip from the range of Type 1 Nose Tips. Other nose assemblies are available for applications with restricted access and special fasteners see table page 12.

Range of Fasteners

Part Numbering

* For

/16” and 1/4” Lockbolt®equipment refer to separate Data Sheet 07900-00795.

** For Avseal

equipment refer to separate Data Sheet 07900-00840.

All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and ﬁltering systems on the main air supply. These should be ﬁtted within 3 metres of the tool (see diagram below) to ensure maximum tool life and minimum tool maintenance.

Air supply hoses should have a minimum effective working pressure rating of 150% of the maximum pressure produced in the system or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or

/4 inch.

TAKE OFF POINT FROM MAIN SUPPLY

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR OR LUBRICATION UNITS)

MAIN SUPPLY

DRAIN POINT

AIR LUBRICATION

PERMISSABLE

PRESSURE REGULATOR AND FILTER (DRAIN DAILY)

3 METRES MAXIMUM

• Ensure that the correct nose assembly suitable for the fastener is

ﬁtted.

• Connect the tool to the air supply.

• Insert the fastener stem into the nose of the tool. If using a

standard nose assembly, the fastener should remain held in by the vacuum system.

• Bring the tool with the fastener to the application so that the

protruding fastener enters squarely into the hole of the application.

• Fully actuate the trigger. The tool cycle will broach the fastener

and with standard nose assemblies the broken stem will be projected to the rear of the tool into the collector bottle.

• To minimise air consumption, the trigger should be ‘lifted’ to cut-off

the vacuum air supply if the tool is not to be used for a period of time.

Putting into Service

Air Supply

Operating Procedure -All fasteners except Avtainer®and Maxlok

Lift Trigger to cut-off the vacuum air supply.

Putting into Service

Operating Procedure

AVTAINER®and MAXLOK

• Ensure that the correct nose assembly is ﬁtted see pages 12 and 13.

• Connect the tool to the air supply.

• Push the Maxlok

or Avtainer®stem through the application hole.

• Place the collar on the stem (orientation as shown below).

• Keeping the head of the stem against the application, push the tool onto the protruding stem.

• Fully depress the trigger. One cycle will ensure that the collar is swaged into the lock grooves of the stem and that the

stem breaks at the breaker groove.

• Release the trigger. The tool completes its cycle by pushing itself off the collar and the spent stem will be pushed to

the rear of the tool on insertion of the next fastener.

Placing AVTAINER

Placing MAXLOK

Nose Tip Selection

Nose Assemblies

IMPORTANT

Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.

A tool must always be ﬁtted with the correct nose assembly and nose tip for your fastener and must be ordered separately, refer to the ‘NOSE TIPS’ tables on pages 10 to 13.

If your application presents no access restriction use a Type 1 nose tip. If you are placing Avtainer

a Type 5, Hemlok®and 1/4”

Interlock

a Type 6 must be used. Maxlok®requires a special nose assembly which does not make use of any nose tip, see pages 10 to 13. Dimensions ‘A’ and ‘B’ will help you assess the suitability of a particular nose tip. You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted Type 2 nose tips with extra reach, are available for some fasteners. Refer to the table on page 12. It is essential that a fastener-compatible nose assembly and nose tip are ﬁtted prior to operating the tool (no nose tip with Maxlok

Fitting Instructions - All Nose Assemblies except Avtainer® and Maxlok

IMPORTANT

The air supply must be disconnected when ﬁtting or removing nose assemblies.

Item numbers in bold refer to nose assembly components in all nose tip tables.

• Lightly coat Jaws 4 with Moly Lithium grease*.

• Drop Jaws 4 into Jaw Housing 3 or Chuck Collet 9 depending on which nose assembly you are using.

• Insert Jaw Spreader 5 into Jaw Housing 3 or insert Front Spring Guide 10 into Chuck Collet 9.

• Locate Buffer 6 on Jaw Spreader 5.

• Locate Spring 7 onto Jaw Spreader 5 or onto Front Spring Guide 10.

• Screw Rear Spring Guide 11 into Chuck Collet 9.

• Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool.

• Holding tool pointing down, screw the assembled Jaw Housing 3 or Chuck Collet 9 onto the Jaw Spreader Housing and tighten with

spanner*.

• Screw the nose tip into Nose Casing 1 and tighten with spanner*.

• Place Nose Casing 1 over Jaw Housing 3 or Chuck Collet 9 and screw onto the tool, tightening with spanner*.

* Item included in the nG4 Service Kit. For complete list see page 18.

Nose assemblies should be serviced at weekly intervals. You should hold some stock of all internal components of the nose assembly and nose tips as they will need regular replacement.

Use Spanner 07900-00849 (supplied with tool) to assist when servicing nose equipment.

• Remove the nose equipment using the reverse procedure to the ‘Fitting instructions’.

• Any worn or damaged part should be replaced.

• Clean and check wear on Jaws.

• Ensure that neither the Jaw Spreader nor the Front Spring Guide is distorted.

• Check Spring 7 is not distorted.

• Assemble according to ﬁtting instructions above.

Servicing Instructions

+ 19 hidden pages

Avdel Genesis 4 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual