Avdel Genesis G3 HD Instruction Manual

3

Ferramenta Mecânica Hidro-Pneumática

Genesis

®

G3 HD

Hydro-pneumatisch Plaatsingsgereedschap

Genesis

®

G3 HD

Hydro-Pneumatic Power Tool

Genesis

®

G3 HD

Máquina Hidro-neumática

Genesis

®

G3 HD

In st ru ct io n Ma nu al Ma nu al d e In st ru cc io ne s Ma nu al d e In st ru çõ es Ha nd le id in g

3

Safety Rules 4

Speciﬁcations

Tool Speciﬁcations 5 Tool Dimensions 5

Intent of Use

Range of Fasteners 6 Part Numbering 6

Putting into Service

Air Supply 7 Operating Procedure 7

Nose Assemblies

Fitting Instructions 8 Servicing Instructions 8 Nose Tips 9-11

Accessories

Stem Deﬂector 12 Extension 12 Side Ejector 12 Swivel Heads 13 Preparing the Base Tool 14 Swivel Head Fitting Instructions 15 Swivel Head Servicing Instructions 16

Servicing the Tool

Daily / Weekly 17 Moly Lithium Grease EP 3753 Safety Data 17 MolyKote 55m & MolyKote 111 Safety Data 18 Annually 19 Service Kit 19 Head Assembly 19-20 Pneumatic Piston Assembly 20 Valve Spool Assembly 20 Trigger 20

General Assembly of Base Tool

General Assembly and Parts List 22-23

Priming

Oil Details 24 Hyspin VG 32 Oil Safety Data 24 Priming Kit 24 Priming Procedure 25

Fault Diagnosis

Symptom, Possible Cause & Remedy 26

Español 29

Português 55

Nederlands 81

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 UK Limited 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.

Contents Englis h

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 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 collector,it must be emptied when half full.

15 If the G3 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.

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.

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

5

Tool S p ecif i c atio n s

Specifications

Air Pressure Minimum - Maximum 5-7 bar (72.5 - 101.5 psi) Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cuft) Stroke Minimum 26 mm (1.02 in) Pull Force @ 5.5 bar 12.9 kN (2900 lbf) Cycle time Approximately 1.2 second Noise Level 75 dB(A) Weight Without nose equipment 2.35 kg (5.17 lb) Vibration Less than 2.5 m/s2 (8.2 ft/s2)

30

12°30'

134

128

152

150

316

145

116

70

3

Dimensions in millimetres.

Tool M e asur emen t s

Englis h

6

Intent of Use

G3 HD 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 below.

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 7, for adjustment instructions.

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 8.

FASTENER

NAME

MM

IN

FASTENER SIZE ( )

AVEX

®

STAVEX

®

AVINOX

®

AVIBULB

®

ETR

BULBEX

®

T-LOK

®

AVDEL® SR

MONOBOLT

®

INTERLOCK

®

TLR

®

AVTAINER

®

AVDEL

®

MBC

MBC/LC

AVSEAL

®

Q

™ RIVET

T

™ RIVET

CHERRYMATE™

KLAMPTITE™

3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10

–1/85/32 –3/16 – – –1/4 – – – –3/8 –

●

● ● ● ● ●

●

COMPLE TE TO OL

71221-00 . . .

*

BASE TOOL

1

2

3

1

NOSE A SSEMB LY

NOSE TIP

2

71221-02000

71210-15000

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 pages 22-23. 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 page 9 for selection table.

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, for aerospace and special fasteners. See tables pages 10-11. A nose assembly can be substituted by a swivel head (see pages 13-15). In this case the nose tip is part of the swivel head.

* ADD 3 DIGITS FROM THE LAST

COLUMN OF A NOSE TIP TABLE ON PAGE 9, 10 0R 11. FOR TOOLS WITH SWIVEL HEADS USE TABLE PAGES 13-14.

7

All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and automatic 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 servicing daily details page 17.

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

3

• Ensure that either the correct nose assembly or swivel head

suitable for the fastener is ﬁtted (see pages 8-11 and 13-15).

• Connect the tool to the air supply.

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

assembly, the fastener should remain held in by the vacuum system. If not, adjust the vacuum extraction rotary valve 60.

• If using a swivel head, the vacuum extraction is disabled but the

jaws themselves will grip the fastener.

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

protruding fastener enters squarely 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 .

ADJUSTING THE VACUUM EXTRACTION

• Using a screwdriver, turn rotary valve 60 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.

Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

Putting into Service

Ai r Supp l y

Op e ratin g Pro cedu re

Englis h

8

Nose Assemblies

I M P O R T A N T

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

A complete 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 9-11.

If your application presents no access restriction use a type ‘1’ nose tip unless you are placing aerospace fasteners which requires a type ‘3’ nose tip or Avtainer

®

fasteners a type 5 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 10. It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool.

The type 4 is an alternative to place

1

/4 in Monobolt®. See respective table. Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required. See page 1216 in the ‘Accessories’ section.

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.

• 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.

I M P O R T A N T

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

Item numbers in bold refer to nose assembly components in all 5 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 or chuck collet 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 G3 service kit. For complete list see page 19.

Fi t ting I nstru c t ions

Se r v ing I n struc t ions

9

1

In inches then in millimetres.

2

Head forming nose tips for use with countersunk heads

ONLY.

3

Long nose tip for deep placing

T Y P E 1

N O S E T I P S

N O S E A S S E M B L Y

part nº 71210-15000

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m )

see

belo w

PART Nº 'A' 'B'NAME

Al All oy Steel Al All oy Al All oy Al All oy Steel Al All oy Al All oy Al All oy Steel Al All oy Al All oy Any Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy Stainl ess S teel Stainl ess S teel Stainl ess S teel Steel Steel Steel Steel Steel Steel Any Any Any Any Any Any Steel Steel Steel Steel Steel Stainl ess S teel Stainl ess S teel Stainl ess S teel Any Any Any Any Any Any Any Any Al All oy Al All oy Al All oy/St eel Al All oy/St eel Al All oy Al All oy Al All oy/St eel Al All oy/St eel

1

/

8

1

/

8

1

/

8

–

5

/

32

5

/

32

5

/

32

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

5

/

32

3

/

16

– – – – – – – – – – – – – – – –

3

/

16

1

/

4

1

/

8

5

/

32

3

/

16

–

3

/

16

1

/

8

5

/

32

3

/

16

–

1

/

8

5

/

32

3

/

16

3

/

16

1

/

4

3

/

16

1

/

8

5

/

32

3

/

16

3

/

16

3

/

16

1

/

8

5

/

32

3

/

16

1

/

8

5

/

32

3

/

16

1

/

4

3

/

16

1

/

4

3

/

16

1

/

4

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

1

/

4

1

/

4

1

/

4

6.35

3.3

2.9

6.35

3.3

2.8

3.3

2.8

3.3

4.1

3.3

4.1

3.3

2.8

4.9

6.9

4.7

6.9

5.3

7.2

5.4

7.3

5.4

7.3

5.5

7.3

5.6

7.3

5.6

7.3

4.1

4.4

3.3

2.8

4.8

3.3

2.8

4.8

3.3

6.35

3.3

5.7

3.3

2.8

3.3

2.8

3.3

2.8

3.3

2.8

6.35

3.3

4.8

6.35

6.65

12.7

19.0

12.7

19.0

12.7

7121 0-05002 7121 0-16070

0734 0-06401

2

7121 0-05002 7121 0-16070 0738 1-04701

0734 0-06501

2

0738 1-04701 0734 0-04800 0749 0-04401

0734 0-06601

2

0761 2-02001 7121 0-16020 7121 0-16070 0738 1-04701 7121 0-16001

7121 0-16006

3

7121 0-16002

7121 0-16007

3

7121 0-16003

7121 0-16008

3

7121 0-16004

7121 0-16009

3

7121 0-16005

7121 0-16010

3

7122 0-16006

7122 0-16011

3

7122 0-16007

7122 0-16012

3

7122 0-16008

7122 0-16013

3

0760 5-00220 7122 0-16080 7121 0-16070 0738 1-04701 0749 8-01401 0734 0-06201 0734 0-06201 7121 0-16070 0738 1-04701 0749 8-01401 0761 2-02001 7121 0-05002 7121 0-16070 0734 8-07001 7121 0-16050 7122 0-60001 0738 1-04701 7121 0-16070 0738 1-04701 0738 1-04701 0734 0-04800 0738 1-04701 7121 0-16070 0738 1-04701 0738 1-04701 7121 0-05002 0734 0-06201 0734 0-06201 0761 2-02001 0734 0-06201 0761 2-02001 7122 0-16060 7122 0-16061 703- A-25-6TA

703- B-21

703- A-25-6T

703- B-26

743- A-25-8TA

703- B-21

743- A-25-8T

743- B-26

3.2

3

4.0

4.8

6.4

4.8

4.0

4.8

4 4 5 5 6 6

6.5

6.5 7 7 8 8 9 9

10 10

4.8

6.4

3.2

4.0

4.8

4.3

4.8

3.2

4.0

4.8

6

3.2

4.0

4.8

6.4

4.8

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

AVEX

®

Large flange

MONOBOLT

®

BULBEX

®

AVSEAL

®

TLR

®

AVINOX® II

T-LOK

®

AVIBULB

®

AVDEL® SR

Countersunk

INTERLOCK

®

STAVEX

®

Large flange Countersunk

Q™ RIVET

CHERRYMATE™

KLAMPTITE™

T™ RIVET

Large flange

… 0 0 1 … 0 0 4 … 0 0 3 … 0 0 1 … 0 0 4 … 0 1 0 … 0 0 9 … 0 1 0 … 0 1 6 … 0 1 7 … 0 1 5 … 0 2 1 … 2 0 0 … 0 0 4 … 0 1 0 … 1 6 0 … 1 8 0 … 1 6 1 … 1 8 1 … 1 6 2 … 1 8 2 … 1 6 3 … 1 8 3 … 1 6 4 … 1 8 4 … 1 6 5 … 1 8 5 … 1 6 6 … 1 8 6 … 1 6 7 … 1 8 7 … 1 4 0 … 1 4 1 … 0 0 4 … 0 1 0 … 0 8 2 … 1 2 0 … 1 2 0 … 0 0 4 … 0 1 0 … 0 8 2 … 0 2 1 … 0 0 1 … 0 0 4 … 0 6 2 … 0 6 4 … 0 6 3 … 0 1 0 … 0 0 4 … 0 1 0 … 0 1 0 … 0 1 6 … 0 1 0 … 0 0 4 … 0 1 0 … 0 1 0 … 0 0 1 … 1 2 0 … 1 2 0 … 0 2 1 … 1 2 0 … 0 2 1 … 4 3 0 … 4 3 5 … 3 8 0 … 3 8 1 … 3 8 3 … 3 8 4 … 3 8 5 … 3 8 6 … 3 8 7 … 3 8 8

A

B

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-00306 2 'O' RING 07003-00067 3 JAW HOUSING 07340-00304 4 JAWS 71210-15001 5 JAW SPREADER 07498-04502 6 BUFFER 71210-05001 7 SPRING 07500-00418 8 LOCKING RING 07340-00327

* In ADDITION to the nose assembly shown below, an extra long nose assembly is available to place

1

/4" Monobolt® in applications with restricted

access. See type 4 NOSE TIP table.

COMPLETE TOOL

PART NUMBER :

precede with

71221-00

8 7 6 5 4 23 1

61

22.9

Nose Assemblies

Englis h

10

Nose Assemblies

1

In inches then in millimetres.

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m )

see

bel o w

PART Nº 'A' 'B'NAME

Al All oy Steel Al All oy Steel Al All oy Steel Al All oy Al All oy Steel Steel Steel Steel Steel/ Brass Any Any Any

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

3

/

16

5

/

32

3

/

16

–

3

/

16

1

/

8

5

/

32

5

/

32

1

/

8

5

/

32

3

/

16

12. 95

11. 4

10. 0

11. 8

11. 4

10. 0

11. 4

10. 0

12. 95

11. 4

9.5

12. 7

9.5

12. 7

9.5

12. 7

9.5

073 40-0280 5 073 40-0280 6 073 40-0280 6 073 40-0280 7 073 40-0280 7 073 40-0730 1 073 40-0280 6 073 40-0280 7 072 41-0710 1 072 41-0710 1 073 40-0280 6 073 40-0280 7 073 40-0280 7 073 40-0280 5 073 40-0280 6 073 40-0280 7

3.2

4.0

4.8

4.0

4.8

4.3

4.8

3.2

4.8

5.2

3.2

4.0

4.8

AVEX

®

BULB EX

®

T-LO K

®

AVIB UL B

®

ETR T

™

RIVET

… 0 0 2 … 0 0 8 … 0 0 8 … 0 1 4 … 0 1 4 … 0 1 8 … 0 0 8 … 0 1 4 … 1 2 1 … 1 2 1 … 0 0 8 … 0 1 4 … 0 1 4 … 0 0 2 … 0 0 8 … 0 1 4

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-02804 2 'O' RING 07003-00067 3 JAW HOUSING 07340-00304 4 JAWS 71210-15001 5 JAW SPREADER 07498-04502 6 BUFFER 71210-05001 7 SPRING 07500-00418 8 LOCKING RING 07340-00327

COMPLETE TOOL

PART NUMBER :

precede with

71221-00

N O SE A S S E M B L Y

part nº 71210-15200

A

B

TYPE 2 NO SE T IP S AR E EXTENDED TO AL LO W AC CE SS I NT O APPLI CA TI ON S WH ER E TYPE 1 NOSE TI PS W IL L NO T REACH.

T Y P E 2

N O S E T I P S

8 7 6 5 4 23

1

58.3

22.9

T Y P E 3

N O S E T I P S

COMPLETE TOOL

PART NUMBER :

precede with

71221-00

1

56.3

22.9

1

In inches then in millimetres.

O

Oversize

N O SE A S S E M B L Y

part nº 71210-15300

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07344-02001 2 'O' RING 07003-00067 3 JAW HOUSING 07340-00304 4 JAWS 71210-15001 5 JAW SPREADER 07498-04502 6 BUFFER 71210-05001 7 SPRING 07500-00418 8 LOCKING RING 07340-00327

TYP E 3 N O S E T I P S A R E S P E C I F ICALLY FOR T H E A E R O S P A C E FAS T E N E R S L I S T E D B E L O W .

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m ) se e

bel o w

PART Nº 'A' 'B'NAME

Al All oy Al All oy

O

Stainl ess Steel Al All oy Al All oy

O

Stainl ess Steel Al All oy Al All oy

O

Stainl ess Steel Any Any Any Any Any Any

1

/

8

1

/

8

1

/

8

5

/

32

5

/

32

5

/

32

3

/

16

3

/

16

3

/

16

1

/

8

5

/

32

3

/

16

1

/

8

5

/

32

3

/

16

2.5

3.3

2.5

3.3

2.5

2.4

4.8

5.0

5.1

4.6

12. 7

712 10-1603 0 712 10-1603 1 712 10-1603 2 712 10-1603 3 712 10-1603 4 712 10-1603 5 712 10-1603 6 712 10-1603 7 712 20-1603 8 073 40-0670 1 073 40-0680 1 073 40-0690 1 073 44-0470 1 073 44-0470 1 073 44-0470 1

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

AV D EL

®

MB C

MB C L/ C

… 2 8 3 … 2 8 4 … 2 8 5 … 2 8 8 … 2 8 9 … 2 9 0 … 2 9 3 … 2 9 4 … 2 9 5 … 3 0 0 … 3 0 5 … 3 1 0 … 3 2 0 … 3 2 0 … 3 2 0

A

B

8 7 6 5 4 23

11

Nose Assemblies

T Y P E 5

N O S E T I P

COMPLETE TOOL

PART NUMBER :

precede with

71221-00

1

In inches then in millimetres

N O SE A S S E M B L Y part nº 71220-15500

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07498-00501 2 'O' RING 07003-00067 9 CHUCK COLLET 07498-00801 4 JAWS 07220-02302 10 FRONT SPRING GUIDE 07498-00803

ITEM DESCRIPTION PART Nº

7 SPRING 07500-02005 11 REAR SPRING GUIDE 07498-00503 8 LOCKING RING 07340-00327 12 SIDE EJECTION ADAPTOR 07498-00900

THERE IS ONLY ONE TYPE 5 NOSE TIP, SPECIFICALLY DESIGNED TO PLACE AVTAINER

®

FASTENERS WITH

THIS SPECIAL NOSE ASSEMBLY.

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m ) se e

bel o w

PART Nº 'A' 'B'NAME

Steel

3

/

8

4.119. 1

074 98-0080 2

9.6

AV T AIN E R

®

… 2 4 3

98.5

20.6

90

12 11 7 10 4 298

A

B

28.6

N O SE A S S E M B L Y

part nº 71230-15800

A

B

8 7 6 5 4 23 1

61

22.9

.. . 2 0 1 .. . 2 6 1

1

In inches then in millimetres

F A S T E N E R

MATERIAL

Ø

1

N O S E TI P ( m m ) s ee

a b o ve

PART Nº 'A' 'B'NAME

1

/

4

1

/

4

MONOBOLT

®

INTERLOCK

®

T Y P E 6

N O S E T I P S

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-00306 2 'O' RING 07003-00067 3 CHUCK COLLET 07612-02003 4 JAWS 07612-02002 5 JAW SPREADER 07498-04502 6 BUFFER 07498-03003 7 SPRING 07500-00418 8 LOCKING RING 07340-00327

Any Any

4.1

3.6

14. 3

712 20-1602 1 076 12-0200 1

6.4

COMPLETE TOOL

PART NUMBER

PRECEDED WITH:

71221-00

T Y P E 4

N O S E T I P

COMPLETE TOOL

PART NUMBER :

precede with

71221-00

1

In inches then in millimetres

N O SE A S S E M B L Y part nº 71220-15400

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07498-00501 2 'O' RING 07003-00067 9 CHUCK COLLET 07498-00502 4 JAWS 07497-03002

ITEM DESCRIPTION PART Nº

10 FRONT SPRING GUIDE 07498-00507 7 SPRING 07500-02005 11 REAR SPRING GUIDE 07498-00503 8 LOCKING RING 07340-00327

FIT TE D TO TH IS LO NG NO SE ASS EM BLY, TH E TYP E 4 N OS E TIP WIL L ALLOW T HE PL AC ING O F

1

/4 " MONOB OL T

®

FA ST ENERS IN AP PLICA TI ONS R EQ UIR IN G VER Y DEEP AC CESS.

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m ) se e

bel o w

PART Nº 'A' 'B'NAME

Steel

1

/

4

4.114. 3

712 20-1602 1

6.4

MONOBOLT

®

… 2 0 2

11 7 10 4 298

A

B

20.6

98.5

Englis h

12

St e m Def l ector

Accessories

ADAPTOR NUT 71210-20101

STEM DEFLECTOR

07340-00342

The stem deﬂector is a very simple alternative to the standard stem collector and allows access in restricted areas. To replace the stem collector with the stem deﬂector proceed as follows:

• Unscrew retaining nut 22 by inserting a 3 millimetre

diameter rod into one of the holes.

• Remove retaining nut 22 and the stem collector assembly,

items 18, 19, 20, 21, 45, 62 and 63.

• Screw the adaptor nut onto end cap 23.

• Push the boss end of the stem deﬂector into the internal

groove of the adaptor nut.

• Rotate the stem deﬂector until the aperture faces away

from the operator and other person(s) in the vicinity.

Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

INNER

71210-20301

OUTER 71210-20302

STEM DEFLECTOR: 71210-20100

EXTENSION: 71210-20300

INNER EXTENSION

OUTER CASING

8-32 x 1/4" SOCKET CAP HEAD SCREW

Part number: 07498-00900 for fasteners with a stem larger than 3.1 mm (1/8") Ø

Fitted between the tool and the nose assembly the extension gives an extra reach of 76mm, ideal for use in deep narrow applications.

• To ﬁt the extension, remove any nose assembly

components.

• Screw the inner extension to jaw spreader housing 1.

• Screw the outer onto head assembly 4.

• Fit the nose assembly onto the extension.

Fitted between the tool and the nose assembly, the side ejector forces fastener stems to eject at the front of the tool and gives an extra reach of 90mm.

It cannot be used in conjunction to a swivel head. Select the correct part number (below right) according to the stem diameter of the fastener.

For greater ease of use, it is recommended that the stem collector or deﬂector is replaced with safety cap part number 71210-20201 as used with swivel heads. See page 14 for ﬁtting instructions, but note that the stop nut is not ﬁtted in this case.

• To ﬁt the side ejector, remove any nose assembly

components.

• Remove the socket cap screw from the side ejector.

• Screw the inner extension onto jaw spreader housing 1.

• Screw the outer casing onto head assembly 4.

• Replace the socket cap screw securing with Loctite

Screwlock 222, part number 07900-00371.

• Screw the nose assembly onto the side ejector.

Ex t ensio n

Si d e Eje c tor

13

Sw i vel H e ad

Accessories

Instead of a nose assembly, a swivel head can be ﬁtted to a base tool. It allows 360° rotation of the tool about the nose tip and allows access into many applications otherwise too restrictive. There are two types of swivel heads: the straight swivel head with the nose tip slightly offset from the centre line of the tool head and the right-angle swivel head with the nose tip on a perpendicular axis to the head of the tool. See drawings below for dimensions and pages 15-16 for detail.

I M P O R T A N T

PRIOR to ﬁtting a swivel head, the base tool must be adapted. See Preparing the base tool on page 14.

In contrast to nose assemblies part numbers of swivel heads do INCLUDE a nose tip as shown below.

Swivel heads can be ordered on their own or ﬁtted to a base tool forming a complete tool. See table below for part numbers. Jaws and nose tips vary depending on the fastener to be placed but all other components remain the same within each type of swivel head. See the ‘capability’ tables below and ‘constant component table’ page 16.

'A’ and ‘B’ dimensions will help you assess the accessibility of your application.

1

In inches then in millimetres.

2

Long nose tip for deep placing.

O

Oversize

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m )S W I V E L H E A D

PART Nº

J A W S

see

bel o w

'A' 'B'NAME

Al All oy Steel Al All oy Steel Al All oy Al All oy Al All oy Stainl ess Steel Stainl ess Steel Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy

O

Stainl ess Steel Al All oy Al All oy

O

Al All oy Al All oy

O

Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy

O

Al All oy

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

5

/

32

3

/

16

1

/

8

5

/

32

– – – –

1

/

8

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

3

/

16

1

/

8

5

/

32

3

/

16

1

/

8

5

/

32

5

/

32

3

/

16

3.8 1

1.9 5

4.1 1

2.0 0

4.1 1

1.1 7

3.8 1

0.8 4

0.2 5

1.9

2.3 6

2.4 6

2.0 3

7.8 7

6.3 5

7.6 2

5.0 8

6.6

8.1 3

4.7 5

6.3 5

7.9 2

7.8 7

073 45-0300 0 073 45-0310 0 073 45-0310 0 073 45-0320 0 073 45-0320 0 073 45-0310 0 073 45-0320 0 073 45-0310 0 073 45-0320 0 074 94-0600 0 074 94-0660 0 074 94-0610 0 074 94-0670 0 073 45-0330 0 074 94-0360 0 074 94-0300 0 073 45-0340 0 074 94-0370 0 073 45-0350 0 074 94-0380 0 073 45-0400 0 073 45-0410 0 073 45-0420 0 073 45-0470 0 073 45-0470 0 073 45-0480 0 073 45-0480 0

PART Nº

073 40-0021 3 073 40-0021 3 073 40-0021 3 074 90-0460 2 074 90-0460 2 073 40-0021 3 074 90-0460 2 073 40-0021 3 074 90-0460 2 073 40-0021 3 073 40-0021 3 073 40-0021 3 073 40-0021 3 073 40-0022 9 073 40-0022 9 073 40-0021 3 073 40-0022 9 073 40-0022 9 074 98-0440 1 074 98-0440 1 073 40-0022 9 073 40-0022 9 074 98-0440 1 073 40-0022 9 073 40-0022 9 074 98-0440 1 074 98-0440 1

PART Nº

073 45-0360 0 073 45-0370 0 073 45-0370 0 073 45-0380 0 073 45-0380 0 073 45-0370 0 073 45-0380 0 073 45-0370 0 073 45-0380 0 074 94-0600 1

074 94-0660 1

2

074 94-0610 1

074 94-0670 1

2

073 45-0330 1 074 94-0360 1 074 94-0301 1 073 45-0340 1 074 94-0370 1 073 45-0350 1 074 94-0380 1 071 65-0070 1 071 65-0070 2 071 65-0070 3 073 45-0470 1 073 45-0470 1 073 45-0470 1 073 45-0470 1

3.2

4.0

4.8

4.0

4.8

3.2

4.0

4 4 5 5

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

AVEX

®

BULB EX

®

AVIN OX

®

AVSE AL

®

AV D EL

®

MB C

MB C L/ C

… 0 0 1 … 0 0 4 … 0 0 4 … 0 1 0 … 0 1 0 … 0 0 4 … 0 1 0 … 0 0 4 … 0 1 0 … 1 6 0 … 1 8 0 … 1 6 1 … 1 8 1 … 2 8 3 … 2 8 4 … 2 8 5 … 2 8 8 … 2 8 9 … 2 9 3 … 2 9 4 … 3 0 0 … 3 0 5 … 3 1 0 … 3 2 0 … 3 2 0 … 3 2 7 … 3 2 7

COMPLETE TOOL PART NUMBER :

precede with 71221-30

(the stop nut and safety cap are included)

IMPORTANT: by opposition to complete tools

with nose assemblies, those fitted with swivel heads

include the nose tip as a part of the head.

S TR A IG H T S WI V EL HE A D c ap a bi l it y

A

B

360

° r

otat

i

on

56

92

6

20

Englis h

14

Pr epar i n g th e Base To o l

Accessories

1

In inches then in millimetres.

2

Long nose tip for deep placing.

O

Oversize

F A S T E N E R

MATERIAL

Ø

1

N O S E T I P ( m m )SW IV E L H E A D

PART Nº

J A W S

see

bel o w

'A' 'B'NAME

Al All oy Steel Al All oy Steel Al All oy Al All oy Al All oy Stainl ess Steel Stainl ess Steel Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy

O

Stainl ess Steel Al All oy Al All oy

O

Al All oy Al All oy

O

Al All oy Al All oy Al All oy Al All oy Al All oy Al All oy

O

Al All oy

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

5

/

32

3

/

16

1

/

8

5

/

32

– – – –

1

/

8

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

3

/

16

1

/

8

5

/

32

3

/

16

1

/

8

5

/

32

5

/

32

3

/

16

3.8 1

1.9 5

4.1 1

2.0 0

4.1 1

1.1 7

3.8 1

0.8 4

0.2 5

1.9

2.3 6

2.4 6

2.0 3

7.8 7

6.3 5

7.6 2

5.0 8

6.6

8.1 3

4.7 5

6.3 5

7.9 2

7.8 7

073 46-0300 0 073 46-0310 0 073 46-0310 0 073 46-0320 0 073 46-0320 0 073 46-0310 0 073 46-0320 0 073 46-0310 0 073 46-0320 0 074 95-0400 0 074 95-0470 0 074 95-0410 0 074 95-0480 0 073 46-0330 0 074 95-0360 0 074 95-0300 0 073 46-0340 0 074 95-0370 0 073 46-0350 0 074 95-0380 0 073 46-0400 0 073 46-0410 0 073 46-0420 0 073 46-0450 0 073 46-0450 0 073 46-0460 0 073 46-0460 0

PART Nº

073 40-0021 3 073 40-0021 3 073 40-0021 3 074 90-0460 2 074 90-0460 2 073 40-0021 3 074 90-0460 2 073 40-0021 3 074 90-0460 2 073 40-0021 3 073 40-0021 3 073 40-0021 3 073 40-0021 3 073 40-0022 9 073 40-0022 9 073 40-0021 3 073 40-0022 9 073 40-0022 9 074 98-0440 1 074 98-0440 1 073 40-0022 9 073 40-0022 9 074 98-0440 1 073 40-0022 9 073 40-0022 9 074 98-0440 1 074 98-0440 1

PART Nº

073 45-0360 0 073 45-0370 0 073 45-0370 0 073 45-0380 0 073 45-0380 0 073 45-0370 0 073 45-0380 0 073 45-0370 0 073 45-0380 0 074 94-0600 1

074 94-0660 1

2

074 94-0610 1

074 94-0670 1

2

073 45-0330 1 074 94-0360 1 074 94-0301 1 073 45-0340 1 074 94-0370 1 073 45-0350 1 074 94-0380 1 071 65-0070 1 071 65-0070 2 071 65-0070 3 073 45-0470 1 073 45-0470 1 073 45-0470 1 073 45-0470 1

3.2

4.0

4.8

4.0

4.8

3.2

4.0

4 4 5 5

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

AVEX

®

BULB EX

®

AVIN OX

®

AVSE AL

®

AV D EL

®

MB C

MB C L/ C

… 0 0 1 … 0 0 4 … 0 0 4 … 0 1 0 … 0 1 0 … 0 0 4 … 0 1 0 … 0 0 4 … 0 1 0 … 1 6 0 … 1 8 0 … 1 6 1 … 1 8 1 … 2 8 3 … 2 8 4 … 2 8 5 … 2 8 8 … 2 8 9 … 2 9 3 … 2 9 4 … 3 0 0 … 3 0 5 … 3 1 0 … 3 2 0 … 3 2 0 … 3 2 7 … 3 2 7

COMPLETE TOOL PART NUMBER :

precede with 71221-40

(the stop nut and safety cap are included)

IMPORTANT: by opposition to complete tools

with nose assemblies, those fitted with swivel heads

include the nose tip as a part of the head.

R IG H T- A NG L E S WI V EL HE A D c ap a bi l it y

7

.

6

32

2

0

52

56

7

4

97

A

B

360

° rota tion

1

2

3

5

7

17

23

20

22

21

62

19

63

18

45

66

65

71210-20202

STOP NUT

71210-20201 SAFETY C AP

• Disconnect the air supply.

• Remove any nose assembly items.

• Remove retaining nut 22 and all

elements of the stem collector (items 18, 19, 20, 21, 45, 62, 63). Note that ‘O’ ring 17 remains.

• Replace the above with a safety cap as

shown in drawing opposite.

• Unscrew jaw spreader housing 1 and

remove with ‘O’ ring 2, locknut 3, ‘O’ rings 66 and 65, and seal housing 5.

• Screw stop nut 71210-20202 onto the

front of head piston 7 as far as it will go by hand.

• Re-ﬁt jaw spreader housing 1 and ‘O’ ring

2.

• Unscrew the stop nut until it locks

against jaw spreader housing 1 and tighten with spanner.

The tool is now ready to be ﬁtted with a swivel head. Instructions are on page 15.

Base tool to receive a nose assembly

Base tool to receive a swivel head

15

Sw i vel H e ad Fi t t ing I n stru c t ions

Accessories

The following procedure will allow you to assemble and ﬁt either of the swivel heads to the tool. If you order a complete swivel head

rather than individual components, you will only need to start at stage L.

All moving parts should be lubricated. Unless stated otherwise use Moly Lithium grease (details page 17). When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.

The ﬁtting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.

I M P O R T A N T

PRIOR to ﬁtting a swivel head, the base tool must be adapted. See Preparing the base tool opposite.

The air supply must be disconnected when ﬁtting or removing swivel heads.

16

1

3

12

14

13

16

6

5

21

22

11

7

9

8

10

17

18

19

20

STRAIGHT SWIVEL HEAD

2

1

15

9

8

10

7

11

17

23

18

19

20

3

16

4

12

14

13

6

5

RIGHT-ANGLE HEAD

A Fit locking ring 10 over jaw spreader housing 1. B Coat screw 13 with thread locking adhesive and use to

secure nose tip 14 onto body 5.

C Lightly lubricate items 17, 18, 19, 20 and insert into jaw

carrier 3 as shown. Secure with screws 16.

D Position lever 4 into body 5 and hold in place with pin 15

through the hole of body 5 (not a slot).

E Lubricate the sides of the jaw carrier assembly and insert

into body 5.

F Lubricate rollers 8 and ENSURE that they will freely rotate in

the holes of adaptor 9. If necessary ream the holes.

G Position spring clip 7 over adaptor 9 past the holes for the

rollers and rotate until the locating peg is aligned with the corresponding hole in adaptor 9 (smallest hole).

H Fit adaptor 9 over the end of body 5 and drop rollers 8 into

place. Push spring clip 7 over rollers 8.

I Insert spindle 11 through adaptor 9 into jaw carrier 3 until

the hole lines up with slot in body 5. Temporarily hold in place with pin 6.

J Insert pin 12 through the front slot of body 5 into jaw carrier

3.

K Hold the assembly vertical to prevent all pins dropping and

slide the jaw carrier assembly back and forth a few times to ensure free movement. Go to M.

L Remove screws 23 (4 off) and guard 1. On a straight swivel

head also remove screw 21 and platform 22.

M Push pin(s) 6 out and let spindle 11 drop out. Screw spindle

11 onto the jaw spreader housing of the tool, leaving the

small screw ﬁxing hole uppermost for straight swivel. Tighten gently with a tommy bar.

N Screw the assembly over spindle 11 onto the tool handle.

Replace pin(s) 6.

O On straight swivel heads attach platform 22 onto the top of

the spindle with screw 21. Deburr the back end of platform

22 so that it cannot catch on guard 1.

P Snap guard 1 over the assembly, align screw holes in guard

with tapped holes in body assembly.

Q Insert pivot pin 15 through slots in guard and hole in body.

Fit circlip 2 onto pivot pin so that the circlip seats in groove provided.

R Coat the thread of screws 23 (4 off) with thread locking

adhesive and screw into body assembly securing guard to body assembly.

Englis h

16

Sw i vel H e ad Se r v icing Instr u ction s

Accessories

5

7

17

18

19

20

Swivel heads should be serviced at weekly intervals.

• Remove the complete head using the reverse procedure to

the ‘Fitting instructions’ omitting step ‘L’.

• If guard 1 is at all damaged it must be replaced by a new

one.

• Any worn or damaged parts should be replaced.

• Pay particular attention to jaw carrier items in the upper il-

lustration opposite as follows: Check wear on jaws 17. Check that jaw spreader tube 18 is not distorted. Check that spring 19 is neither broken or distorted. Check that spring guide 20 is not damaged.

• Check that spring clip 7 is not distorted. When removing

spring clip 7, use two screwdrivers as shown in the lower illustration opposite.

• Check for excessive wear on slots of body 5.

• Assemble according to ﬁtting instructions.

While nose tips and jaws will vary for each swivel head, other components remain constant within each type of head. See table below. For nose tips and jaws part numbers see pages 9-11.

C O N S T A N T C O M P O N E N T S

ITEM STRAIGHT SWIVEL RIGHT-ANGLE SWIVEL

1 2 3 4 5 6 7 8

9 10 11 12 13 15 16 18 19 20 21 22 23

GUARD CIRCLIP JAW CARRIER LEVER BODY PIVOT PIN SPRING CLIP ROLLER ADAPTOR LOCKING RING SPINDLE DOWEL PIN SCREW PIVOT PIN SCREW JAW SPREADER SPRING SPRING GUIDE SCREW PLATFORM SCREW

0 7 49 4- 05 00 0

-

0 7 49 4- 03 02 6

0 7 49 4- 03 01 5 0 7 34 3- 02 20 7 0 7 49 5- 03 90 0 0 7 00 7- 00 03 9 0 7 34 5- 03 00 1 0 7 34 5- 03 00 3 0 7 34 5- 03 00 2 0 7 00 7- 00 03 8 0 7 34 2- 02 20 7

0 7 49 4- 03 02 8 0 7 34 6- 03 10 1 0 7 16 5- 00 30 5 0 7 49 4- 03 02 7 0 7 00 1- 00 36 8 0 7 34 5- 00 40 1

-

0 7 49 5- 03 00 3 0 7 00 4- 00 10 5 0 7 49 4- 03 02 6 0 7 49 5- 03 00 4 0 7 49 5- 03 00 2 0 7 34 3- 02 20 7 0 7 49 5- 03 90 0 0 7 00 7- 00 03 9 0 7 34 5- 03 00 1 0 7 34 5- 03 00 3 0 7 34 5- 03 00 2 0 7 00 7- 00 03 8 0 7 34 2- 02 20 7 0 7 34 3- 02 20 7 0 7 49 4- 03 02 8 0 7 34 6- 03 10 1 0 7 16 5- 00 30 5 0 7 49 4- 03 02 7

– –

0 7 21 0- 00 80 4

17

Servicing the Tool

• Daily, before use or when ﬁrst putting the tool into service, pour a few drops of clean, light lubricating oil into the air inlet of the tool

if no lubricator is ﬁtted on air supply. If the tool is in continuous use, the air hose should be disconnected from the main air supply and the tool lubricated every two to three hours.

• Check for air leaks. If damaged, hoses and couplings should be replaced.

• If there is no ﬁlter on the pressure regulator, bleed the air line to clear it of accumulated dirt or water before connecting the air

hose to the tool. If there is a ﬁlter, drain it.

• Check that the nose assembly or swivel head is correct for the fastener to be placed.

• Check the stroke of the tool meets the minimum speciﬁcation (page 5). The last step of the 'Priming Procedure' on page 23

explains how to measure the stroke.

• Either a stem collector or a stem deﬂector must be ﬁtted to the tool unless a swivel head is ﬁtted.

• Ensure that rotary valve 60 is correctly adjusted for fastener retention (see ‘Operating Procedure’ page 7).

• Dismantle and clean the nose assembly with special attention to the jaws. Lubricate with Moly Lithium grease before assembling.

• Check for oil leaks and air leaks in the air supply hose and ﬁttings.

Grease can be ordered as a single item, the part number is shown in the service kit page 19.

First Aid

SKIN: As the grease is completely water resistant it is best removed with an approved emulsifying skin cleaner.

INGESTION: Ensure the individual drinks 30ml Milk of Magnesia, preferably in a cup of milk.

EYES: Irritant but not harmful. Irrigate with water and seek medical attention.

Fire

FLASH POINT: Above 220°C. Not classiﬁed as ﬂammable.

Suitable extinguishing media: CO

2

, Halon or water spray if applied by an experienced operator.

Environment

Scrape up for burning or disposal on approved site.

Handling

Use barrier cream or oil resistant gloves

Storage

Away from heat and oxidising agent.

Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

I M P O R T A N T

Read Safety Instructions on page 4.

The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.

The operator should not be involved in maintenance or repair of the tool unless properly trained.

The tool shall be examined regularly for damage and malfunction.

Da i ly

Weekl y

Mo l y Lit h ium G reas e EP 3 7 5 3 Sa f e ty D a t a

Englis h

Specifications

First Aid

SKIN: Flush with water. Wipe off. INGESTION: No ﬁrst aid should be needed. EYES: Flush with water.

Fire

FLASH POINT: Above 101.1°C. (closed cup) Explosive Properties: No Suitable Extinguishing Media: Carbon Dioxide Foam, Dry Powder or ﬁne water spray. Water can be used to cool ﬁre exposed containers.

Environment

Do not allow large quantities to enter drains or surface waters. Methods for cleaning up: Scrape up and place in suitable container ﬁtted with a lid. The spilled product produces an extremely

slippery surface. Harmful to aquatic organisms and may cause long-term adverse effects in the aquatic environment. However, due to the physical

form and water - insolubility of the product the bioavailability is negligible.

Handling

General ventilation is recommended. Avoid skin and eye contact.

Storage

Do not store with oxidizing agents. Keep container closed and store away from water or moisture.

First Aid

SKIN: No ﬁrst aid should be needed. INGESTION: No ﬁrst aid should be needed. EYES: No ﬁrst aid should be needed. INHALATION: No ﬁrst aid should be needed.

Fire

FLASH POINT: Above 101.1°C. (closed cup) Explosive Properties: No Suitable Extinguishing Media: Carbon Dioxide Foam, Dry Powder or ﬁne water spray. Water can be used to cool ﬁre exposed containers.

Environment

No adverse effects are predicted.

Handling

General ventilation is recommended. Avoid eye contact.

Storage

Do not store with oxidizing agents. Keep container closed and store away from water or moisture.

Mo l ykote 55m G reas e Safe t y Dat a

Mo l ykote 111 G reas e Safe t y Dat a

18

19

An n ually

Servicing the Tool

PART Nº DESCRIPTIONPART Nº DESCRIPTION

SERVICE KIT : 71210-99990 Spanners are specified in inches and across flats unless otherwise stated

07900-00667 PISTON SLEEVE 07900-00692 TRIGGER VALVE EXTRACTOR 07900-00670 BULLET 07900-00672 'T' SPANNER 07900-00706 'T' SPANNER SPIGOT 07900-00684 GUIDE TUBE 07900-00685 INSERTION ROD 07900-00351 3 MM ALLEN KEY 07900-00469 2.5 MM ALLEN KEY 07900-00158 2 MM PIN PUNCH

07900-00164 CIRCLIP PLIERS 07900-00008

7

/16 x 1/2 SPANNER

07900-00012

9

/16 x 5/8 SPANNER

07900-00015

5

/8 x 11/16 SPANNER 07900-00686 PEG SPANNER 07900-00677 SEAL EXTRACTOR 07900-00698 STOP NUT 07900-00700 PRIMING PUMP 07992-00020 GREASE - MOLY LITHIUM E.P.3753 07992-00075 GREASE - MOLYKOTE 55M 07900-00755 GREASE - MOLYKOTE 111

(or every 500,000 cycles whichever is the soonest)

Annually or every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged or recommended. All ‘O’ rings and seals should be renewed and lubricated with Molykote 55m grease for pneumatic sealing or Molykote 111 for hydraulic sealing.

For an easy complete service, Avdel is offering a complete service kit.

The airline must be disconnected before any servicing or dismantling is attempted unless speciﬁcally instructed otherwise.

It is recommended that any dismantling operation be carried out in clean conditions.

Before proceeding with dismantling, empty the oil from the tool following the ﬁrst three steps of the 'Priming Procedure' on page 23.

Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose equipment section, pages 811 or if a swivel head was ﬁtted pages 13-15.

For a complete service of the tool, we advise that you proceed with dismantling of sub-assemblies in the order shown.

After any dismantling REMEMBER to prime the tool and to ﬁt an appropriate nose assembly or swivel head.

• Unscrew retaining nut 22 and remove stem collector assembly, items 20, 18, 19, 21, 62, 63 and 45.

• Remove bottle adaptor assembly 13.

• Using the ‘T’ spanner* remove end cap assembly 23 together with seal 15, ‘O’ ring 14 and lip seal 24.

• Remove spring 24 and spring centralising bush 25.

• Loosen locknut 3 with a spanner* then unscrew jaw spreader housing 1 and ‘O’ ring 2.

• Remove locknut 3 together with 'O' rings 65 and 66 and vacuum sleeve 46.

• Push head piston 7 to the rear and out of head assembly 4 taking care not to damage the head cylinder bore.

• Using circlip pliers* remove seal retainer 26. Push lip seal 8 to the rear and out of head assembly 4 taking care again not to damage the

head cylinder bore.

• Remove seal housing 5 and lip seal 6.

* Item included in G3 service kit. Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

I M P O R T A N T

Read Safety Instructions on page 4.

The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate

personnel.

The operator should not be involved in maintenance or repair of the tool unless properly trained.

The tool should be examined regularly for damage and malfunction.

He a d Ass e mbly

Englis h

Servicing the Tool

• Remove ‘ON/OFF’ valve assembly 55.

• Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice ﬁtted with soft jaws.

• Pull off rubber boot 72.

• Using the peg spanner* unscrew base cover 36.

• Unscrew locknuts 68 (2 off) and remove base plate 70.

• Remove liner 41 together with sealing washers 71 (2 off) and 'O' rings 69 (2 off).

• Remove pneumatic piston assembly 38 together with ‘O’ ring 35, lip seal 37 (3 off) and guide ring 31.

Assemble in reverse order.

• Remove pneumatic piston assembly 38 as above.

• Using the ‘T’ spanner* and ‘T’ spanner spigot* unscrew clamp nut 32 and remove it together with top plate 58, tie rods 39 and transfer

tube assembly 40.

• Release the tool from the vice and separate body 34 from handle assembly 28.

• Remove ‘O’ ring 29 from intensiﬁer tube and remove head assembly 4 from handle assembly 28.

• Push out valve seat 59 together with both ‘O’ rings 64 (2 off).

• Remove all components of valve spool assembly 49.

• Remove ‘O’ ring 54 from handle recess.

Assemble in reverse order noting the following points -

• Ensure valve seat is correctly orientated.

• Use Loctite 243 when reassembling Clamp Nut 32, torque to 11ft lb (14.91 Nm).

• Using the 2 millimetre diameter pin punch*, drive trigger pin 44 out and lift off trigger 43.

• Unscrew trigger valve 42 using the trigger valve extractor*.

Assemble in reverse order to dismantling.

I M P O R T A N T

Check the tool against daily and weekly servicing

Priming is ALWAYS necessary after the too has been dismantled and prior to operating.

* Item included in the G3 service kit. For complete list see page 19. Item numbers in bold refer to the General Assembly drawing and parts list on pages 22-23.

Assemble in reverse order to dismantling noting the following points:

• Place lip seal 8 onto the insertion rod* ensuring correct orientation. Push the guide tube* into the bore of the head assembly 4, push the

insertion rod* with lip seal 8 attached through the guide tube* to locate seal into recess. Withdraw insertion rod* and guide tube*.

• The chamfered edge of seal retainer 26 must face towards lip seal 8 orientated with the 'gap' of the retainer towards the bottom of the

bore, in line with the hydraulic inlet port to the head bore.

• After ﬁtting lip seal 11 and 'O' ring 12 (2 off) onto the head piston 7 ensuring correct orientation, lubricate seals and cylinder bore.

Assemble piston sleeve* into the head assembly bore 4. Attach bullet* to thread of head piston 7. Push the piston fully through the sleeve*. Remove the bullet* and the piston sleeve*.

• Jaw spreader housing 1 must be fully tightened onto head piston 7 'trapping' vacuum sleeve 46 before tightening locknut 3 against it.

• Use Loctite 932 when reassembling Retaining Nut 22.

He a d Ass e mbly

Pn e umati c Pist o n Ass e m bly

Valv e Spoo l Asse m b ly

Tr i gger

20

21

Notes

Englis h

General Assembly of Base Too l 71 22 1- 02 00 0

B - B

A - A

6160

33

34

36

35

27

29

30

A

38

40

41

37

32

58

31

B

1 2 3 480 9 105 6 8

26

27

28

42

44

43

46

66

65

23

25

37

24

13

14

1516

63

11

127

A

62

22

45

18

19

21

20

767778

79

74

75

70

57

64

57

59

64

54

53

52

49-51

50

47

48

64

56

55

67

39

72

37 68 71 69

73

22

Parts List for 71221-02000

23

010203040506070809101112131415161819202122232425262728293031323334353637383940

41

71210-02101

07003-00277

71210-02103

71210-03320

71210-02104

07003-00333

71220-02121

07003-00273

07001-00405

07003-00194

07003-00341

07003-00342

71403-02110

07003-00278

71210-02029

71210-02022

07640-00239

71210-02051

07340-00335

07640-00244

71210-02028

71403-02120

07490-03002

71403-02104

71210-02019

07003-00288

71221-02013

07003-00287

71210-03800

71210-03205

71210-02014

71221-02027

71221-02001

07003-00182

71221-02002

07003-00274

71221-03210

71221-02004

71230-03600

71221-02008

JAW SPREADER HOUSING

'O' RING

LOCKNUT

HEAD ASSEMBLY

SEAL HOUSING

LIP SEAL

HEAD PISTON

LIP SEAL

SOCKET BUTTON HEAD SCREW

BONDED SEAL

LIP SEAL

'O' RING

BOTTLE ADAPTOR ASSEMBLY

'O' RING

SEAL

SUSPENSION RING

STEM COLLECTOR OUTER

STEM COLLECTOR BODY

STEM COLLECTOR END CAP

SILENCER

RETAINING NUT

END CAP ASSEMBLY

SPRING

SPRING CENTRALISING BUSH

SEAL RETAINER

'O' RING

HANDLE ASSEMBLY

'O' RING

INTENSIFIER SEAL ASSEMBLY

GUIDE RING

CLAMP NUT

LABEL

BODY - MACHINED

'O' RING

BASE COVER - MACHINED

LIP SEAL

PNEUMATIC PISTON ASSEMBLY (INCLUDES 31/35/37)

TIE ROD

TRANSFER TUBE ASSEMBLY

LINER - MACHINED

111111111112111111111111121111111114121

1

-

1

-

-1-

1121211-1

-

-1-

-

121

-

-1-

-1-1---

-

424344454647484950515253545556575859606162636465666768697071727374757677787980

81

07005-00088

71210-02008

71210-02024

07003-00311

71220-02102

07003-00127

07005-01274

71210-03400

07003-00268

71210-03402

71210-03401

07003-00042

07003-00271

71210-03700

07008-00010

71210-02031

71221-02003

71210-02009

71210-02013

07003-00189

71210-02034

71210-02035

07003-00281

07003-00204

07003-00310

07007-00224

07002-00108

07003-00027

71221-02005

71221-02006

71221-02007

07007-01993

71221-20104

07002-00098

71221-20105

71221-20101

71221-20102

71221-20103

07007-01503

07900-00818

TRIGGER VALVE

TRIGGER

TRIGGER PIN

'O' RING

VACUUM SLEEVE

'O' RING

1

/8" BSP PLUG

VALVE SPOOL ASSEMBLY (50 to 53)

• 'O' RING

• VALVE SPOOL

• VALVE BODY

• 'O' RING

'O' RING

ON/OFF VALVE ASSEMBLY

FLEXIBLE HOSE

SILENCER

TOP PLATE

VALVE SEAT

ROTARY VALVE

'O' RING

SILENCER CAP#

SILENCER#

'O' RING

SPIROL PIN

M6 NYLOK NUT

'O' RING

BASE PLATE

SEALING WASHER

RUBBER BOOT

CENTRE POLE MAGNET

M5 X 19 COUNTERSUNK SCREW

M5 NYLOK NUT

COUNTER

COUNTER MOULDING

SPECIAL M4 SCREW

MOULD RETAINING NUT

LABEL BOOK SYMBOL

TOOL INSTRUCTION MANUAL

111111111111111211121131122212111111221

1

-----1-

-2-

-

2

1

-

-2---2-

131

1

-------------

-

1

ITEM PART Nº DESCRIPTION QTY SPARES ITEM PART Nº DESCRIPTION QTY SPARES

712 2 1 -02 0 0 0 P A RTS L IST * These a r e m i n i m u m r e c o m m e n d e d l evels of sp a r e s b a s e d o n r e g u l a r s e rvicing

Englis h

Priming

Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full stroke after considerable use, when the stroke may be reduced and fasteners are not fully placed by one operation of the trigger.

The recommended oil for priming is Hyspin VG32 available in 0.5l (part number 07992-00002) or one gallon containers (part number 07992-00006). Please see safety data below.

First Aid

SKIN: Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact requires no immediate attention. INGESTION: Seek medical attention immediately. DO NOT induce vomiting. EYES: Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact.

Fire

Flash point 232°C. Not classiﬁed as ﬂammable. Suitable extinguishing media: CO

2

, dry powder, foam or water fog. DO NOT use water jets.

Environment

WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation. SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material.

Handling

Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.

Storage

No special precautions.

To enable you to follow the priming procedure opposite, you will need to obtain a priming kit:

PART Nº DESCRIPTION

PRIMING KIT : 07900-00688

07900-00351 3mm ALLEN KEY 07900-00698 STOP NUT 07900-00700 PRIMING PUMP 07900-00224 4mm ALLEN KEY 07900-00734 MAXLOK

®

STOP NUT

Oi l Deta i ls

Hy s pin V G 32 O i l Saf e t y Da t a

Pr i ming K it

24

Priming

25

I M P O R T A N T

DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 55.

REMOVE NOSE ASSEMBLY OR SWIVEL HEAD COMPONENTS.

All operations should be carried out on a clean bench, with clean hands in a clean area.

Ensure that the new oil is perfectly clean and free from air bubbles.

Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result.

• Remove bleed screw 9 and seal 10.

• Connect air supply to tool and switch ON/OFF valve 55 to ‘ON” position.

• Invert tool over suitable container and actuate trigger. Waste oil will be ejected through the bleed screw hole.

CARE SHALL BE TAKEN TO ENSURE THAT THE BLEED HOLE IS NOT DIRECTED TOWARDS THE OPERATOR OR OTHER PERSONNEL.

• Screw stop nut 07900-00698 onto jaw spreader housing 1.

• Disconnect air supply to tool or switch ON/OFF valve 55 to ‘OFF” position.

• Fill the priming pump with oil.

• Screw priming pump 07900-00700 into the bleed screw hole with seal 10 in place.

• Actuate the priming pump by pressing down and releasing several times until resistance is felt.

• Remove the priming pump and the stop nut.

• Replace bleed screw 9 and seal 10.

• Connect air supply to tool and switch ON/OFF valve 55 to ‘ON” position.

• Check that the stroke of the tool meets the minimum speciﬁcation of 26 millimetres. To check the stroke, measure the distance

between the front face of jaw spreader housing 1 and the front face of the head, BEFORE pressing the trigger and when the trigger is fully actuated. The stroke is the difference between the two measurements. If it does not meet the minimum speciﬁcation, repeat the priming procedure.

Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

Pr i ming P ro c e dure

Englis h

Fault Diagnosis

* Pages 13-15 if a swivel head is used instead of a nose assembly † Page 15 if a swivel head is used instead of a nose assembly Item numbers in bold refer to the general assembly drawing and parts list on pages 22-23.

More than one Air leak Tighten joints or replace components operation of the Insufficient air pressure Adjust air pressure to within speciﬁcation 5 trigger needed to Lack of lubrication Lubricate tool at air inlet point 7 place fastener Worn or broken jaws Fit new jaws 8-11*

Low oil level or air in oil Prime tool 24-25 Build up of dirt inside the nose assembly Service nose assembly 8†

Tool will not grip Worn or broken jaws Fit new jaws 8-11* stem of fastener Build up of dirt inside the nose assembly Service nose assembly 8-11*

Loose jaw housing Tighten against locking ring 8-11* Weak or broken spring in nose assembly Fit new spring 8-11* Incorrect component in nose assembly Identify and replace 8-11* Rotary valve incorrectly adjusted Read ‘Operating Procedure’ 7

Jaws will not release Build up of dirt inside the nose assembly Service nose assembly 8† broken stem of Jaw housing, nose tip or nose casing fastener not properly seated Tighten nose assembly 8

Weak or broken spring in nose assembly Fit new spring 8-11* Air or oil leak Tighten joints or replace components Low oil level or air present in oil Prime tool 24-25

Cannot feed next Broken stems jammed inside tool Empty stem collector 4 (point 14) fastener Check jaw spreader is correct 8-11*

Adjust air pressure to within speciﬁcation 5

Rotary valve incorrectly adjusted Adjust as in ‘Operating Procedure’ 7

Slow cycle Lack of lubrication Lubricate tool at air inlet point 8

Low air pressure Adjust air pressure to within speciﬁcation 5 Build up of dirt inside the nose assembly Service nose assembly 9†

Tool fails to operate No air pressure Connect and adjust to within speciﬁcation 5

Damaged trigger valve 42 Replace 19-20 Loose base cover 36 Tighten 19-20 Loose stem collector Tighten retaining nut 22 19-20

Fastener fails to break Insufficient air pressure Adjust air pressure to within speciﬁcation 5

Fastener outside tool capability Use more powerful Genesis tool.

Contact Avdel UK Limited

Low oil level or air present in oil Prime tool 24-25

Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.

Sy mpt om Po s si b le Ca u se R eme dy Pa ge Ref

26

27

Declaration of Conformity

We, Avdel UK Limited, Mundells, Welwyn Garden City, Herts, AL7 1EZ declare under our sole responsibility that the product:

Model G3 HD

Serial No. ................................................

to which this declaration relates is in conformity with the following standards:

EN292 part 1 and part 2 ISO 8662 part 1 EN 60742/0695 ISO 3744 EN 50081-1 ISO PREN792 part 14 EN 55014

following the provisions of the Machine Directive 89/392/EC (as amended by Directive 91/368/EC, 93/44/EC) and 93/68/EC

Welwyn Garden City - date of issue

A R Dear - Design & Development Manager

This box contains a power tool which is in conformity with Machines Directive 89/392/EC. The ‘Declaration of Conformity’ is contained within.

29

Normas de seguridad 30

Especiﬁcaciones

Especiﬁcaciones de la máquina 31 Dimensiones de la máquina 31

Uso previsto

Gama de remaches 32 Números de pieza 32

Puesta en servicio

Suministro de aire 33 Procedimiento de funcionamiento 33

Boquillas

Instrucciones de montaje 34 Instrucciones de mantenimiento 34 Sufrideras 35-37

Accesorios

Deﬂector de vástagos 38 Extensión 38 Eyector lateral 38 Cabezales giratorios 39 Preparación de la máquina base 40 Instrucciones de montaje del cabezal giratorio 41 Instrucciones de mantenimiento del cabezal giratorio 42

Mantenimiento de la máquina

Diario / Semanal 43 Datos de seguridad de la grasa de Litio Moly EP 3753 43 Datos de seguridad de la grasa MolyKote 55m y MolyKote 111 44 Anual 45 Kit de mantenimiento 45 Conjunto de cabezal 45-46 Conjunto de émbolo neumático 46 Conjunto de manguito de válvula 46 Gatillo 46

Montaje general de la máquina base

Montaje general y lista de componentes 48-49

Cebado

Detalles del aceite 50 Datos de seguridad del aceite Hyspin VG 32 50 Juego para cebado 50 Procedimiento de cebado 51

Diagnóstico de averías

Síntoma, causa posible y solución 52

La política de Avdel Sistemas de Fijación es la de desarrollo y mejora continua del producto, reservándose el derecho de cambiar las especiﬁcaciones de cualquier producto sin previo aviso.

Garantía Las máquinas de colocación de Avdel Sistemas de Fijación poseen una garantía de 12

meses frente a defectos originados por componentes defectuosos o por mano de obra, iniciándose el período de garantía a partir de la fecha de entrega confirmada por la factura o nota de envio.

La garantía es aplicable al usuario / comprador cuando la venta se realice a través de un distribuidor autorizado, y únicamente con el propósito adecuado. La garantía quedará invalidada si no se lleva a cabo el servicio, el mantenimiento y el funcionamiento de la máquina de instalación de acuerdo a las instrucciones contenidas en los Manuales de servicio e instrucciones.

En caso de fallo o defecto, queda a la elección de Avdel Sistemas de Fijación el llevar a cabo la reparación o la sustitución de los componentes defectuosos.

Índice Españo l

30

Normas de seguridad

1 No la usen para otro propósito que no sea aquel para el que está diseñada.

2 No utilizar con esta máquina/herramienta ningún otro equipo más que el recomendado y suministrado por Avdel Sistemas de Fijación.

3 Cualquier modiﬁcación realizada por el cliente en la herramienta/máquina, las boquillas, accesorios o en cualquier equipo suministrado

por Avdel Sistemas de Fijación o por sus representantes, será de entera responsabilidad del cliente. Avdel Sistemas de Fijación aconsejará gustosamente sobre cualquier modiﬁcación propuesta.

4 La herramienta/máquina debe mantenerse en condiciones seguras de trabajo en todo momento y debe ser examinada a intervalos

regulares en cuanto a funcionalidad y existencia de posibles daños por personal con formación adecuada. Cualquier operación de desmontaje será únicamente llevada a cabo por personal con conocimiento en los procedimientos de Avdel Sistemas de Fijación. No desmontar esta máquina/herramienta sin consultar previamente las instrucciones de mantenimiento. Sírvanse contactar con Avdel Sistemas de Fijación haciendo mención a sus necesidades de formación.

5 La máquina/herramienta debe funcionar, en todo momento, de acuerdo con la legislación vigente en Seguridad y Salud. Cualquier

pregunta referente a la utilización correcta de la máquina y a la seguridad del operario, deberá estar dirigida a Avdel Sistemas de Fijación.

6 Las precauciones que deben observarse cuando se use esta herramienta/máquina, deben ser explicadas por el cliente a todos los

operarios.

7 Antes de intentar ajustar, adaptar o retirar una boquilla, debe desconectarse siempre la línea de aire de la entrada de la

herramienta/máquina.

8 No hacer funcionar una herramienta/máquina que se encuentre dirigida hacia cualquier persona(s) o hacia el propio operario.

9 Adoptar siempre una posición de apoyo ﬁrme y estable antes de hacer funcionar la herramienta/máquina.

10 Asegurarse de que los oriﬁcios de escape no se encuentran bloqueados ni tapados.

11 La presión de trabajo no debe superar los 7 bar.

12 No accionar la máquina sin que la boquilla o el cabezal giratorio se encuentren montados en su totalidad, a menos que se indique

especíﬁcamente lo contrario.

13 Deben tomarse las precauciones debidas para asegurarse que los vástagos gastados no constituyan un peligro.

14 Si la máquina lleva incorporado un colector de vástagos, éste deberá vaciarse cuando se encuentre a la mitad de su capacidad.

15 Si la máquina G3 incorpora un deﬂector de vástagos, éste deberá girarse hasta que la abertura se encuentre en dirección opuesta a

la posición del operario y de cualquier otra persona(s) que trabaje(n) en las proximidades.

16 Cuando se utilice la máquina, se hace necesaria la utilización de gafas de seguridad, tanto por parte del operario como de cualquier

persona que se encuentre en las proximidades, a ﬁn de protegerse de la proyección de cualquier remache, en el caso de que éste saliera despedido al aire. Se recomienda la utilización de guantes en el caso de que la aplicación presente bordes o esquinas aﬁlados.

17 Prestar especial atención para evitar posibles enredos de ropas, corbatas, cabellos, trapos, con las partes móviles de la máquina, las

cuales deberán mantenerse secas y limpias para favorecer en lo posible el agarre.

18 Cuando se transporte la máquina de un emplazamiento a otro, mantener las manos alejadas del gatillo para evitar que se produzca un

arranque inadvertido.

19 Deberá evitarse un contacto excesivo con aceite hidráulico. Para minimizar la posibilidad de erupciones cutáneas, deberá tomarse la

precaución de lavarse a fondo.

Este manual de instrucciones debe ser leído con una atención particular teniendo en cuenta las siguientes reglas de seguridad, por cualquier persona que instale, haga funcionar o que repare esta máquina.

Avdel Genesis G3 HD Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual