Avdel Genesis G1 Instruction Manual

Hydro-Pneumatic Power Tool

Genesis®G1

Instruction Manual

3

Contents

Safety Rules 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 7
Adjusting the Vacuum Extraction 7

Nose Assemblies

Fitting and Servicing Instructions 8
Selection of Nose Tips 9

Accessories

Stem Deflector 10
Extension 10
Stem Collector 10

Servicing the Tool

Daily / Weekly / Monthly 11
Moly Lithium Grease EP 3753 Safety Data 11
MolyKote 55m & MolyKote 111 Safety Data 12
Annually 13
Service Kit 13
Head Assembly 13&14
Pneumatic Piston Assembly 14
Valve Spool Assembly 14
Trigger 14

General Assembly of Base Tool

General Assembly and Parts List 16-17

Priming

Oil Details 18
Hyspin VG 32 Oil Safety Data 18
Priming Kit 18
Priming Procedure 19

Fault Diagnosis

Symptom, Possible Cause & Remedy 20

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.

Warranty
Avdel installation tools carry a 12 month warranty against defects caused by faulty
materials or workmanship, the warranty period commencing from the date of delivery
confirmed by invoice or delivery note.

The warranty applies to the user/purchaser when sold through an authorised outlet, and
only when used for the intended purpose. The warranty is invalidated if the installation
tool is not serviced, maintained and operated according to the instructions contained in
the Instruction and Service Manuals.

In the event of a defect or failure, and at its sole discretion, Avdel undertakes only to
repair or replace faulty components.

4

Safety Rules

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 r

egular intervals for damage and function

by trained competent personnel. The Plastic Body and Base Cover must be changed after approximately 1 million cycles or whenever

there is evidence of impact damage, chipping or cracks. 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 collector,it must be emptied when half full.

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

in the vicinity.

16 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. Any

such sharp features must not be allowed to indent or otherwise damage the plastic body or End Cap of the tool - see Safety Rule 4. Do

not operate the tool if it is not fitted with a Rubber Base Cover.

17 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.

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

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

thoroughly.

20 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.

Specifications

Air Pressure Minimum - Maximum 5-7 bar

Free Air Volume Required @ 5.5 bar 1.2 litres

Stroke Minimum 14 mm

Pull Force @ 5.5 bar 5.3 kN

Cycle time Approximately 1 second

Noise Level Less than 75 dB(A)

Weight Without nose equipment 1.1 kg

Vibration Less than 2.5 m/s

2

Dimensions in millimetres

12° 30'

30

104

150

116

70

109

261

101

98.5

Tool Dimensions

5

6

Intent of Use

G1 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 light/medium industries where the plastic
components will not be subject to impact damage. It can
place all fasteners listed opposite.

The tool features an adjustable vacuum system for fastener
retention and trouble free collection of the spent stems
regardless of tool orientation. See the ‘Operating Procedure’
on page 8 for adjustment instructions.

COMPLETE TOOL

71200-00 . . .

*

BASE TOOL

1

1

2

3

1

NOSE ASSEMBLY

NOSE TIP

2

71200-02000

71200-15000

see note 3

2

3

++

3

The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
page 16.

The nose tip part number relates to a specific fastener. If access to the application is
restricted, some extended nose tips are available. See page 9 for selection tables.

This single nose assembly will allow placing of non-aerospace 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 for aerospace fasteners. See pages 8-9.

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE TIP
TABLE ON PAGE 9.

A complete tool, except the 71200-00039 (see note at bottom of page) is made up of three separate elements which will be supplied
individually. See diagram below.

If you wish to place most of the fasteners in the table above, you can order the 71200-00039 complete tool comprising of:

• 71200-02000 base tool

• 71200-15000 nose assembly

• Nose tips 71210-05002 and 71210-16070, one screwed into the base cover. Fit nose tip as indicated page 9.

You can order the above two nose tips and nose assembly as a nose assembly kit part number 71200-15100.

• For some fasteners the base tool and nose assembly and tip will be supplied separately.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGE 8.

FASTENER

NAME

MM

IN

FASTENER SIZE ( )

AVEX

®

STAVEX

®

AVINOX

®

AVIBULB

®

BULBEX

®

T-LOK

®

AVDEL® SR

MBC

MBC/LC

AVSEAL

®

3 3.2 4.0 4.3

–

1

/8

5

/32 –

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Range of Fasteners

Part Numbering

Air Supply

Putting into Service

7

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 working effective 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

1

/4 inch.

Read daily servicing details page 11.

• Using a screwdriver, turn rotary valve 57 until the air flow at the rear of the tool ceases.

• With the nose of the tool pointing downwards, insert a fastener into the nose and hold it into position.

• Turn the rotary valve either way until there is sufficient suction to retain the fastener.

8

6

4

2

0

1

0

1
2

14

1

6

TAKE OFF POINT
FROM
MAIN SUPPLY

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR OR LUBRICATION UNITS)

MAIN SUPPLY

DRAIN POINT

PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)

3 METRES MAXIMUM

• Ensure that a nose assembly suitable for the fastener is fitted as described on page 8.

• Connect the tool to the air supply.

• Insert the fastener stem into the nose of the tool.

• Insert the tool with the fastener squarely into the prepared hole of the application.

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

• Check that broken stems are being extracted to the rear of the tool. If not, adjust the vacuum extraction rotary valve 57.

Item numbers in bold refer to the general assembly drawing and parts list on pages 16-17.

Operating Procedure

Adjusting Vacuum Extraction

8

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 (see diagram page 6 and 9 for part numbers),
and apart from -00039 these items will be supplied separately, refer to tables opposite.

If your application presents no access restriction use a type ‘1’ nose tip unless you are placing an aerospace fastener which requires a
type ‘3’ nose tip.

Dimensions ‘A’ and ‘B’ will help you assess the suitability of a particular nose tip.
You should finally check that the dimensions of the nose casing, shown page 9, will not restrict access to your application.

If access is restricted type ‘2’ nose tips are available for some fasteners. Refer to type ‘2’ nose tip table.

It is essential that the correct nose assembly and correct nose tip are fitted prior to operating the tool.

IMPORTANT

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

* Item included in the G1 service kit. For complete list see page 13.

Item numbers in bold refer to nose assembly components in all 3 nose tip tables, see page 9.

• Lightly coat jaws 4 with Moly lithium grease*.

• Drop jaws 4 into jaw housing 3.

• Insert jaw spreader 5 into jaw housing 3.

• Locate buffer 6 on jaw spreader 5.

• Locate spring 7 onto jaw spreader 5.

• Fit locking ring 8 onto the jaw spreader housing of the tool.

• Holding tool pointing down, screw on the assembled jaw housing 3 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 and screw onto the tool, tightening with spanner*.

Nose equipment 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.

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

• Any worn or damaged part should be replaced.

• Particularly check wear on jaws.

• Check spring 7 is not distorted.

• Assemble according to fitting instructions.

Fitting Instructions

Servicing Instructions