Avdel Genesis G1 71204, Genesis G1 71203 Instruction Manual

G1

Hydro-Pneumatic Power Tool

71203 Removable Bottle and 71204 Fixed Bottle

Genesis

®

Instruction Manual

Original Instruction

1

71204 Tool

71203 Tool

3

Safety Instructions 4

Specifications

Tool Specification 5
71203 and 71204 Tool Dimensions 5

Intent of Use

Range of Fasteners 6
Part Numbering 6

Putting into Service

Air Supply 7
71203 Tool (Removable Bottle) 7
71204 Tool (Fixed Bottle) 7
Adjusting the Vacuum Extraction 7
Operating Procedure 8
Removable Stem Collector 71213-05100 8

Nose Assemblies

Fitting Instructions 9
Servicing Instructions 9
Nose Tips 10 to 12
Type 1 10

Type 1A 11
Type 2 11

Jaw Spreader Housing 12

Accessories

Stem Deflector 13
Preparing the Base Tool for use with Stem Deflector 13
Extension 13
Swivel Heads 14
Straight Swivel Head capability 14
Preparing the Base Tool for Straight and Right-Angle 15
Swivel Head Attachment
Right-Angle Swivel Head capability 15
Swivel Head Fitting Instructions 16
Swivel Head Servicing Instructions 17
Constant Components 17

Servicing the Tool

Daily 18
Weekly 18
MolyLithium Grease EP 3753 Safety Data 18
Molykote

®

55m Grease Safety Data 19
Molykote®111 Grease Safety Data 19
Service Kit 20
Maintenance 20
Nose Equipment 20
Dismantling the Tool 21
Head Assembly 21
Pneumatic Piston Assembly 22
Air Valve 22
Rotary Valve 23
Trigger 23

Common Parts

General Assembly of Common Parts 71203-02000 24
Parts List for Common Parts 71203-02000 25

Stem Collector Bottles Removable and Fixed

71203 Tool Removable Stem Collector Bottle 26
71204 Tool Fixed Stem Collector Bottle 26

Priming

Oil Details 27
Hyspin®VG32 Oil Safety Data 27
Priming Kit 27
Priming Procedure 28

Fault Diagnosis

Symptom, Possible Cause and Remedy 29

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.

4

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 air line 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 The Tool MUST NOT be operated with the Stem Collector Bottle removed.

16 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.

17 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.

18 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.

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

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

thoroughly.

21 C.O.S.H.H. data for all hydraulic fluid 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

5

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 6.0 kN

Cycle Time Approximately 0.9 seconds

Noise Level 75 dB(A)

Weight Including nose equipment 1.7 kg

Vibration Less than 2.5 m/s

2

30.00 DIA

104.00

282.00

104.00

127.00 (71203 Tool)

145.00 (71204 Tool)

105.00

(71203 Tool)

116.00

(71204 Tool)

150.00

54.00 DIA

70.00 DIA

82.30

22.80 DIA

93.00 DIA

Dimensions in millimetres

71203 and 71204 Tool Dimensions

6

Intent of Use

nG1 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.

If you wish to place most of the fasteners in the table
opposite, you can order the 71203-00039 complete tool
comprising of:

• 71203-02000 base tool

• 71203-15000 nose assembly

• Nose tips 71210-05002 and 71210-16070. Fit nose tip
as indicated on pages 9 and 10.

You can order the above two nose tips and nose
assembly as a nose assembly kit part number 71203-

15100.

• For some fasteners the base tool, nose assembly
and nose tip must be ordered separately.

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON
PAGE 9.
To assist with nose equipment maintenance spanner
07900-00849 is supplied with the base tool.

FASTENER

NAME

MM

IN

FASTENER SIZE ( )

AVEX

®

STAVEX

®

AVINOX®II
AVIBULB

®

BULBEX

®

T-LOK

®

AVDEL® SR

ETR
N RIVET
Q RIVET

*AVSEAL

®

II

3 3.2 4.0 4.3 4.8 5 5.2 6 6.5 7

–1/8

2.4

3

/

5

/3232 –3/16 –––––

COMPLETE TOOL

71203-00 . . .
71204-00 . . .

*
*

BASE TOOL

NOSE ASSEMBLY

NOSE TIP

71203-02000
71204-02000

71203-15000
71213-15000

see note 3

++=

1

1 2 3

1

2

2

3

3

*

ADD 3 DIGITS FROM THE
LAST COLUMN OF A NOSE
TIP TABLE ON PAGES 10 OR 11.
FOR TOOLS WITH SWIVEL
HEADS USE THE TABLES ON
PAGES 14 AND 15.

1

n

1

n

The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 24-25. If a swivel head is fitted, the same base tool must be adapted. See details page 14.

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 11.

These nose assemblies will allow placing of fasteners by simply selecting the appropriate nose tip from
the range of Type 1 or 1A Nose Tips. Other nose assemblies are available for applications with restricted
access and special fasteners. See table page 11. A nose assembly can be substituted by a swivel head
(see pages 14-15). In this case the nose tip is part of the swivel head.

Range of Fasteners

Part Numbering

* For Avseal

®

equipment refer to separate Data Sheet 07900-00840.

7

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

AIR LUBRICATION

PERMISSABLE

PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)

3 METRES MAXIMUM

G1

Putting into Service

Air Supply

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

1

/4 inch.

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

AIR LUBRICATION

PERMISSABLE

PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)

G1

3 METRES MAXIMUM

71203 Tool Removable Stem Collector Bottle

71204 Tool Fixed Stem Collector Bottle

• Using a screwdriver, turn rotary valve 37 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.

Adjusting the Vacuum Extraction

8

• 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.

Quarter turn to Assemble
or Remove

• A quarter turn rotation removes or replaces the collector bottle.

Do not use tool when Stem

Collector Bottle is removed

Putting into Service

Operating Procedure

Removable Stem Collector Bottle 71213-05100

Nose Assemblies

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 the tool) to assist when servicing the 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 the jaw spreader is not distorted.

• Check Spring 7 is not distorted.

• Assemble according to ‘Fitting Instructions’ above.

* Item included in the Service Kit. For complete list see page 20.

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 3 Nose Tip tables (pages 10 and 11).

• Lightly coat Jaws 4 with MolyLithium 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.

• Insert Detent Sleeve 10 into Jaw Spreader Housing ‘T’ 9. Not applicable to Type ‘2’ Nose Assemblies.

• Fit Locking Ring 8 onto the Jaw Spreader Housing “T’ 9.

• For tools converted to nose assembly Type ‘2’, fit Locking Ring 8 onto the Jaw Spreader Housing ‘T’ 9 attached to the tool.

• Tighten Jaw Housing 3 and assembled components onto Jaw Spreader Housing ‘T’ 9.

• Utilising the ‘T’ section profiles assemble Nose Assembly onto the tool piston via the Male ‘T’ Adaptor 40 - page 12.

Not applicable to Type ‘2’ Nose Assemblies.

• 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*.

Fitting Instructions

Servicing Instructions

9

10

Nose Tips

Nose Assemblies

IMPORTANT

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

A tool (except part number 71203-00039) must always be fitted with the correct nose assembly and nose tip for your fastener but if you wish to
order a nose assembly or a nose tip separately, refer to the ‘NOSE TIPS’ table below and on page 11.

If your application presents no access restriction use a Type ‘1’ Nose Tip.

Dimensions ‘A’ and ‘B’ below 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
are available for some fasteners. Refer to the table on page 11.

It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a 71203-00039
complete tool, it is important that you check that the nose tip already fitted to the nose assembly is the correct one to place your fastener by sliding
the fastener stem into the nose tip. No force should be required and play should be minimal.

Swivel heads are available as an alternative to nose assemblies when further reach is required. See pages 13-17 in the ‘Accessories’ section.

1

In inches then in millimetres.

2

Head forming nose tips for use with countersunk heads

ONLY.

TYPE 1

NOSE TIPS

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Steel
Any
Any
Steel
Stainless Steel
Any
Any

1

/

8

1

/

8

1

/

8

–

5

/

32

5

/

32

5

/

32

1

/

8

1

/

8

1

/

8

5

/

32

1

/

8

1

/

8

1

/

8

3

/

32

4.8

3.3

2.9

4.8

3.3

3.3

3.3

3.3

3.3

4.8

3.3

3.3

3.3

4.8

3.3

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

71210-05002
71210-16070

07340-06401

2

71210-05002
71210-16070

07340-06501

2

71210-16070
71210-16070
71210-16070
71210-05002
71210-16070
71210-16070
71210-16070
71210-05002
71200-16051

3.2

3.2

3.2

3.0

4.0

4.0

4.0

3.2

3.2

3.2

4.0

3.2

3.2

3.2

2.4

AVEX

®

BULBEX

®

AVINOX® II
AVIBULB

®

AVDEL® SR

STAVEX

®

Q RIVET
N RIVET

…039*
…039*

…003
…039*
…039*

…009
…039*
…039*
…039*
…039*
…039*
…039*
…039*
…039*

…033

A

B

*Complete tool part number 71203-00039 or

71204-00039 does not only include the
71203-15000 nose assembly below but also the
following two nose tips:
71210-05002 and 71210-16070 making up a
nose assembly kit part number 71203-15100.
Use the nose tip listed in the table.

Note:

Alternative spring 07498-04301 should be fitted if
stem jammin g occures whe n installing small
diameter fasteners.

*

Items 3-11 available as cartridge assembl y

71203-20320

COMPLETE TOOL

PART NUMBER :

precede with 71203-00

or 71204-00

* See top left

NOSE ASSEMBLY

part nº 71203-15000

(+ 2nose tips above = 71203-15100)

ITEM DESCRIPTION PART Nº

1 TAPERED NOSE CASING 71213-00350
2 'O' RING 07003-00067
3 JAW HOUSING TAPERED 71210-15902*
4 JAWS 71200-15001*
5 JAW SPREADER 07498-04502*
6 BUFFER 71210-05001*
7 (See Note:) SPRING 07500-00418*
8 LOCKING RING 07340-00327*
9 JAW SPREADER HOUSING 'T' 71210-20321*
10 DETENT SLEEVE 71210-20322*
11 'O' RING 07003-00277*

1

2

3

4

5

6

7

10

11

9

8