Avdel Genesis G4 HD Heavy Duty Instruction Manual

Genesis®G4 HD Heavy Duty

Hydropneumatisk drevet verktøj

Genesis®G4 HD tyyppi Raskastyyppinen

Hydropneumaattinen työkalu

Genesis®G4 HD Ekstra kraftig

Hydro-Pneumatisk Trykluftsværktøj

Genesis®G4 HD För tyngre arbeten

Hydropneumatiskt verktyg

Instruction Manual Instruktionshåndbog Instruktionshandbok Brukerhåndbok Käyttöohje

Genesis®G4 HD Heavy Duty

Hy dro-P neu mat i c P owe r Too l

En g lish

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 Vacuum Extraction 7

Nose Assemblies

Nose Tips 8-10 Fitting Instructions 9 Fitting Instructions for Maxlok

and Avtainer

Servicing Instructions for all nose assemblies 11

Accessories

Stem Deﬂector 12 Extension 12 Side Ejector 12

Servicing the Tool

Daily / Weekly 13 Moly Lithium Grease EP 3753 Safety Data 13 MolyKote 55m & MolyKote 111 Safety Data 14 Annually 15 Service Kit 15 Head Assembly 15-16 Pneumatic Piston Assembly 16 Valve Spool Assembly 16 Trigger 16

General Assembly of Base Tool

General Assembly and Parts List 18-19

Priming

Oil Details 20 Hyspin VG 32 Safety Data 20 Priming Kit 20 Priming Procedure 21

Fault Diagnosis

Symptom, Possible Cause & Remedy 22-23

Dansk 25

Svenska 47

Norsk 69

Suomi 91

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.

Con tents

Saf ety 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 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 G4 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.

En g lish

Dimensions in millimetres.

12°30'

134

128

152

150

316

145

116

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 17 mm (0.7 in) Pull Force @ 5.5 bar 18.68 kN (4200 lbf) Cycle time Approximately 1.2 seconds 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)

Spe cifications

Too l S pe ci fi ca ti on s

Too l M ea su rem en ts

G4 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 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 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 PAGES 8-11.

FASTENER

NAME

FASTENER SIZE ( )

AVEX

STAVEX

AVINOX

AVIBULB

BULBEX

T-LOK

AVDEL® SR

INTERLOCK

HEMLOK

TLR

MAXLOK

AVTAINER

AVDEL

MBC

MBC/LC

AVSEAL

QTM RIVET T

RIVET

CHERRYMATE

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

/16 – – –1/4 – – – –3/8 –

● ●

●

● ●

●

● ●

●

● ●

●

● ● ●

● ●

COMPLETE TOOL

71231-00 . . .

BASE TOOL

NOSE ASSEMBLY

NOSE TIP

71231-02000

71210-15000

see note 3

+ + =

The part number of the base tool remains the same whichever nose assembly, or nose tip is ﬁtted. See the General Assembly pages 18-19. If a Maxlok

nose assembly is ﬁtted, the same base tool MUST be adapted. See details page 11.

The nose tip part number relates to a speciﬁc fastener. If access to the application is restricted, some extended nose tips are available. See ‘type 2 nose tip’ table page 9.

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 8-10.

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE TIP TABLE ON PAGE 8, 9 OR 10. FOR MAXLOK

, USE MAXLOK

TABLE PAGE 10 EVEN THOUGH THERE IS NO NOSE TIP.

Int ent of Use

En g lish

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 daily servicing details pages 13.

ADJUSTING THE VACUUM EXTRACTION

• Using a screwdriver, turn rotary valve 65 until the air ﬂow at

the rear of the tool ceases.

• With the nose of the tool pointing downwards, insert a

fastener other than Avtainer®or Maxlok®, into the nose and hold it into position.

• Turn the rotary valve either way until there is sufficient suction

to retain the fastener.

1 2

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

ALL FASTENERS EXCEPT AVTAINER®AND MAXLOK

• Ensure that a nose assembly suitable for the fastener is ﬁtted

(see pages 8-10).

• Connect the tool to the air supply.

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

should remain held in by the vacuum system. If not, adjust the vacuum extraction rotary valve 65 (see note below).

• 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 the broken stem will be projected to the rear of the tool.

AVTAINER®AND MAXLOK

• Ensure that the correct nose assembly is ﬁtted.

• Connect the tool to the air supply.

• Disable the vacuum extraction system by turning rotary

valve 65 until you feel or hear no air ﬂow out of the front of the nose assembly.

• Push the Maxlok

or Avtainer®stem through the application

hole.

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

• Keeping the head of the stem against the application, push

the tool onto the protruding stem.

• Fully depress the trigger. One cycle will ensure that the

collar is swaged into the lock grooves of the stem and that the stem breaks at the breaker groove.

• Release the trigger. The tool completes its cycle by pushing

itself off the collar and the spent stem will be pushed to the rear of the tool on insertion of the next fastener.

Item numbers in bold refer to the general assembly drawing and parts list on pages 18-19.

Placing AVTAINER

Placing MAXLOK

Put ting into Se rvice

Ai r Su pp ly

Op er at in g Pro ced ure

I M P O R T A N T

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

A tool must always be ﬁtted with the correct nose assembly and nose tip for your fastener and must be ordered separately, refer to the ‘NOSE TIPS’ tables below and pages 9-10.

If your application presents no access restriction use a type 1 nose tip unless you are placing aerospace fasteners which require a type 3 nose tip, Avtainer

a type 5, Hemlok®and 1/4” Interlock®a type 6. Maxlok®requires a special nose assembly which does not make use of any nose tip, see pages 10-11. Dimensions ‘A’ and ‘B’ will help you assess the suitability of a particular nose tip. You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted type 2 nose tips with extra reach, are available for some fasteners. Refer to the table on page 9. It is essential that a fastener-compatible nose assembly and nose tip are ﬁtted prior to operating the tool (no nose tip with Maxlok

I M P O R T A N T

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

See page 9, except for Avtainer®and Maxlok®see page 11.

In inches then in millimetres.

Head forming nose tips for use with countersunk heads

ONLY.

Long nose tip for deep placing.

Material of the body then of the stem. 'Al' is the

abbreviation for Aluminium.

T Y P E 1

N O S E T I P S

F A ST EN E R

MATERIAL

N O SE T I P ( mm )

see

bel ow

PART Nº 'A' 'B'NAME

Alumini um Alumini um Steel Alumini um Alumini um Steel Steel Stainle ss Steel Steel Steel Alumini um Alumini um Alumini um Alumini um Alumini um Alumini um Alumini um Alumini um Alumini um Stainle ss Steel Steel Steel Steel Steel Any Any Any Any Any Any Any Any Al/Al

Al/Al

Al/Stee l

Al/Al

Al/Stee l

– – – – – –

–

4 3/16 3/16 3/16 3/16

1/4 1/4 1/4 1/4

2.8

3.3

4.1

3.3

2.8

5.5

7.3

5.6

7.3

5.6

7.3

4.1

4.4

4.8

3.3

4.8

3.3

5.7

3.3

5.7

2.8

3.3

9.5

8.0

9.5

9.0

11. 2

8.0

10. 2

8.3

12. 7

19. 0

12. 7

19. 0

12. 7

15. 9

12. 7

15. 9

12. 7

17. 5

12. 7

16. 7

12. 7

073 81- 0470 1 073 40- 0480 0 074 90- 0440 1

073 40- 0660 1

076 12- 0200 1 073 81- 0470 1 073 81- 0470 1 073 81- 0470 1 073 40- 0480 0 076 12- 0200 1 073 81- 0470 1 712 20- 1600 6

712 20- 1601 1

712 20- 1600 7

712 20- 1601 2

712 20- 1600 8

712 20- 1601 3

076 05- 0022 0 712 20- 1608 0 074 98- 0140 1 073 40- 0620 1 073 40- 0620 1 074 98- 0140 1 076 12- 0200 1 073 48- 0700 1 712 20- 6000 1 712 10- 1605 0 073 81- 0470 1 073 40- 0620 1 076 12- 0200 1 073 40- 0620 1 076 12- 0200 1 703 -A- 25-6 TA

703 -B- 21

703 -A- 25-6 T

703 -B- 26

743 -A- 25-8 TA

743 -B- 21

743 -A- 25-8 T

743 -B- 26

4.8

6.4

4.8

6.4

4.8

8 8 9

9 10 10

4.8

6.4

4.8

4.3

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

AVEX

Large flange

STAVEX

Countersunk

Large flange

BULBEX

AVSEAL

TLR

AVINOX

T-LOK

AVIBULB

AVDEL

Countersunk

INTERLOCK

Q™ RIVET

CHERRYMATE

T™ RIVET

Large flange

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

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

COMPLETE TOOL

PART NUMBER :

precede with

71231-00

8 7 6 5 4 23 1

22.9

N O S E AS S E M BL Y

part nº 71210-15000

Fi tt in g In st ru ct ion s

Nos e Assemblies

En g lish

Item numbers in bold refer to nose assembly components in type 1,2, 3 and 6 nose tip tables.

• 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.

• Holding tool pointing down, screw the assembled jaw housing 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 with ‘O’ ring 2 over jaw housing 3 and screw onto the tool, tightening with spanner*.

* Item included in the G4 service kit. For complete list see page 15.

In inches then in millimetres.

F A ST EN E R

MATERIAL

N O SE T I P ( mm )

see

bel ow

PART Nº 'A' 'B'NAME

Alumini um Steel Alumini um Steel Steel

–

10. 0

11. 8

10. 0

12. 7

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

4.8

4.3

4.8

AVEX

BULBEX

T-LOK

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

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

71231-00

N O S E AS S E M BL Y

part nº 71210-15200

TYPE 2 NOSE TIPS ARE EXTENDED TO ALLOW ACCESS INTO APPLICATIONS WHERE TYPE 1 NOSE TIPS WILL NOT REACH.

T Y P E 2

N O S E T I P S

8 7 6 5 4 23

58.3

22.9

T Y P E 3

N O S E T I P S

COMPLETE TOOL

PART NUMBER :

precede with

71231-00

56.3

22.9

In inches then in millimetres.

Oversize

N O S E AS S E M BL 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

F A ST EN E R

MATERIAL

N O SE T I P ( mm ) se e

bel ow

PART Nº 'A' 'B'NAME

Alumini um Alumini um

Stainle ss Steel Any Any

2.5

2.4

5.1

4.6

12. 7

712 10- 1603 6 712 10- 1603 7 712 20- 1603 8 073 40- 0690 1 073 44- 0470 1

4.8

AV DEL

MB C MB C L/C

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

8 7 6 5 4 23

TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE FASTENERS LISTED ABOVE.

In inches then in millimetres.

T Y P E 6

N O S E T I P S

F A ST EN E R

MATERIAL

N O SE T I P ( mm )

see

abo ve

PART Nº 'A' 'B'NAME

Any Any

3.6

14. 3

076 12- 0200 1 076 12- 0200 1

6.4

HEMLOK

INTERLOCK

… 2 6 1 … 2 6 1

ITEM DESCRIPTION PART Nº

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

COMPLETE TOOL

PART NUMBER :

precede with

71231-00

8 7 6 5 4 3 1

22.9

N O S E AS S E M BL Y

part nº 71230-15800

Nos e Assemblies

T Y P E 5

N O S E T I P

COMPLETE TOOL

PART NUMBER :

precede with

71231-00

In inches then in millimetres

N O S E AS S E M BL Y part nº 71230-15600

ITEM DESCRIPTION PART Nº

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

ITEM DESCRIPTION PART Nº

10 FRONT SPRING GUIDE 07498-00803 7 SPRING 07500-02005 11 REAR SPRING GUIDE 07498-00503 8 LOCKING RING 07340-00327

F A ST EN E R

MATERIAL

N O SE T I P ( mm ) se e

bel ow

PART Nº 'A' 'B'NAME

Steel

4.119. 1074 98- 0080 2

9.6

… 2 4 3

98.5

20.6

11 7 10 4 298

AV TAINE R

M A X L O K®-

N O N O S E T I P

In inches then in millimetres

NOSE ASSEMBLY NOSE ASSEMBLY

part nº 07610-02000 for

" ø part nº 07610-02100 for 1/4 " ø

ITEM DESCRIPTION PART Nº

CHUCK COLLET 07610-02002 4 JAWS 07610-02003 10 SPRING GUIDE 07220-02104 7 SPRING 07610-02107 8 LOCKING RING 07610-02004 12 ANVIL

07610-02001

ITEM DESCRIPTION PART Nº

CHUCK COLLET 07610-02102 4 JAWS 07610-02103 10 SPRING GUIDE 07220-02104 7 SPRING 07610-02107 8 LOCKING RING 07610-02004 12 ANVIL

07610-02101

THE THREE COMPONENTS ILLUSTRATED LEFT ARE ESSENTIAL WHEN FITTING A MAXLOK® NOSE ASSEMBLY TO THE G4 TOOL. READ MAXLOK® 'FITTING INSTRUCTIONS' PAGE 11.

F A ST EN E R

MATERIAL

N O SE A S SE M BL Y see

bel ow

PART NºNAME

All All

076 10- 0200 0 076 10- 0210 0

4.8

6.4

MA XLOK

… 3 7 1 … 3 7 2

8 7 10 9410

64.5

COMPLETE TOOL PART NUMBER :

precede with 71231-00

The three adapting components

illustrated below left are not included in the nose

assembly part number. Each item must be ordered separately, using individual

part numbers.

MAXLOK

NOSE ASSEMBLIES

will place both the ordinary flange

collar and the large flange collars.

07610-00501 CHUCK COLLET ADAPTOR

CHUCK COLLET ADAPTOR

71230-02063 ANVIL ADAPTOR

ANVIL ADAPTOR

07610-00307 ANVIL NUT

ANVIL NUT

En g lish

I M P O R T A N T

The air supply must be disconnected when ﬁtting or removing any nose assembly unless speciﬁcally instructed

otherwise.

The air vacuum extraction system MUST be disabled before operating a G4 tool with a Maxlok®or Avtainer®nose

assembly.

Refer to the ‘Operating Procedure’ for Avtainer®and Maxlok®, page 7.

AVTAINER

Item numbers in bold refer to the general assembly and parts list pages 18-19. Other items numbers refer to the‘type 5 nose tip’ table page 10.

• Remove jaw spreader housing 1, ‘O’ ring 2, and vacuum

tube 51.

• Replace jaw spreader housing 1, ‘O’ ring 2.

• Lightly coat jaws 4 with Moly Lithium grease*.

• Drop jaws 4 into chuck collet 9.

• Insert front spring guide 10 into chuck collet 9.

• Locate spring 7 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.

• Screw the assembled 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 with ‘O’ ring 2 over chuck collet 9 and

screw onto the tool, tightening with spanner*

MAXLOK

When ﬁtting a Maxlok®nose assembly, the base tool must be adapted using three auxiliary components illustrated page 10.

Item numbers in bold refer to the general assembly and parts list pages 18-19. Other items numbers refer to the ‘Maxlok

nose tip’ table page 10.

• Remove jaw spreader housing 1, ‘O’ ring 2, and vacuum

tube 51.

• Substitute jaw spreader housing 1 with chuck collet adaptor

07610-00501. Tighten fully onto piston before tightening the locknut against it.

• Fit locking ring 8 onto the chuck collet adaptor.

• Lightly coat jaws 4 with Moly lithium grease.

• Drop jaws 4 into or chuck collet 9.

• Insert one spring guide 10 into chuck collet 9.

• Locate spring 7 onto the spring guide already in place.

• Drop the other spring guide 10 into spring 7.

• Holding tool pointing down, screw the assembled chuck

collet onto the chuck collet adaptor and tighten with spanner.

• Screw anvil adaptor 71230-02063 into the head assembly.

• Place anvil 12 over chuck collet 9 and lock into place with

anvil nut 07610-00307.

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 assembly 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 that the spring is not distorted.

• On nose assemblies for Maxlok

and Avtainer®check that the spring guides are not distorted.

• On nose assemblies for Maxlok

check that the anvil is neither cracked nor has any scoring or corrosion marks on the inside face

of the concave shape at the front end.

• Assemble according to ﬁtting instructions.

* Item included in the G4 service kit. For complete list see page 15.

Nos e Assemblies

Fi tt in g in st ru ct ion f or M ax lo k®an d Av ta in er®No se A ss em bl ie s

Se rv ic in g ins tr uc ti on s fo r al l N os e As se mb li es

Acc essories

St em D ef le ct or

Ex te ns io n

Si de E je ct or

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. It is easy to ﬁt to the tool as follows:

• Unscrew retaining nut 26 by inserting a 3 millimetre

diameter rod into one of the holes.

• Remove retaining nut 26 and the stem collector assembly,

items 18, 20, 21, 22, 23, 24, and 25.

• Screw the adaptor nut onto end cap 27.

• 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 18-19.

INNER EXTENSION

OUTER CASING

KIT PART NUMBER: 71210-20100

STANDARD EXTENSION PART NUMBER: 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

STEM DIAMETER

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

• To ﬁt the extension, remove any nose assembly

components.

• Screw the inner extension onto jaw spreader housing 1.

• Screw the outer casing onto head assembly 4.

• Screw 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 is not an option when placing Maxlok

fasteners.

• 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.

For greater ease of use, it is recommended that the stem collector or stem deﬂector is replaced with safety cap part number 71210-20201. ‘O’ ring 19 must remain.

/16" & 1/4" MAXLOK®EXTENSION: 71230-20300

En g lish

• 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 is correct for the fastener to be placed.

• Check that the stroke of the tool meets the minimum speciﬁcation (page 5). The last step of the Priming Procedure on page 19

explains how to measure the stroke.

• Either a stem collector or a stem deﬂector must be ﬁtted to the tool if the vacuum extraction is ‘ON’. If it is turned ‘OFF’ a safety

cap must be ﬁtted. See ‘side ejector’ opposite.

• Check that base cover 40 is fully tightened onto body 38.

• Ensure that rotary valve 65 is correctly adjusted for fastener retention or turned off for Avtainer

and Maxlok®(see ‘Operating

Procedure’ page 7).

• Dismantle and clean nose assembly, with special attention to the jaws. Lubricate with Moly Lithium grease EP 3753 before

assembling.

• Check for air leaks.

Grease can be ordered as a single item, the part number is shown in the service kit page 15.

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

, 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 18-19.

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.

Ser vicing the Tool

Da il y

Wee kl y

Mo ly L it hi um G re as e EP 3 75 3 Saf et y Da ta

Spe cifications

Mo ly Ko te 5 5m G re as e Sa fe ty D ata

Mo ly Ko te 1 11 G re as e Sa fe ty D ata

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

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.

En g lish

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 21.

Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose equipment section, pages 8-

11.

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.

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.

* Item included in the G4 service kit. Item numbers in bold refer to the general assembly drawing and parts list on pages 18-19.

• Unscrew retaining nut 26 and pull off stem collector assembly, items 15, (72) 18, 20, 21, 22, 23, 24, 25 and ‘O’ ring 19.

• Using the ‘T’ spanner*, remove end cap 27 (73) together with seal 17 ‘O’ ring 16 and lip seal 28 and spring 70.

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

• Remove locknut 3 together with ‘O’ rings 49 and 50.

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

• Remove seal retainer 30. Push lip seal 8 to the rear and out of head assembly 4 taking care again not to damage the cylinder

bore.

• Remove seal housing 5 and lip seal 67.

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

/16 x 1/2 SPANNER

07900-00012

/16 x 5/8 SPANNER

07900-00015

/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.

Ser vicing the Tool

An nu al ly

He ad A ss em bl y

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 head of the tool and push the

insertion rod* with the seal into place through the guide tube*. Pull the insertion rod* out then the guide tube.

• Drop seal retainer 30 against lip seal 8 large ﬂange ﬁrst.

• Fit seals 11 and 13 onto the piston.

• Lubricate the cylinder bore and place the piston sleeve* into the back of head assembly 4. Slide the bullet* onto the threaded part

of piston 7 and push the piston with the seals through the piston sleeve* as far as it will go. Slide the bullet* off the piston and remove the piston sleeve.

• Fit seal housing 5 and lip seal 67.

• Tighten jaw spreader housing 1 fully tightened onto head piston 7 BEFORE tightening locknut 3 against it.

• Use Loctite 932 when reassembling Retaining Nut 26.

• Remove ‘ON/OFF’ valve assembly 60.

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

• Pull off rubber boot 80.

• Using the peg spanner* unscrew base cover 40.

• Unscrew locknuts 76 (2 off) and remove base plate 77.

• Remove liner 45 together with sealing washers 75 (2 off) and 'O' rings 78 (2 off).

• Remove pneumatic piston assembly 42 together with ‘O’ ring 39, lip seal 41 (3 off) and guide ring 35.

Assemble in reverse order.

• Remove pneumatic piston assembly 42 and seal assembly 34 as described immediately above.

• Using the ‘T’ spanner* and ‘T’ spanner spigot* undo clamp nut 36 and remove it together with clamp plate 63, transfer tube

assembly 44, ‘O’ ring 6, valve rod 43 and silencer pads 62.

• Release the tool from the vice and separate body 38 with ‘O’ ring 31 from handle assembly 32.

• Remove ‘O’ ring 33 from the intensiﬁer tube and pull off head assembly 4 from handle assembly 32.

• Push out valve seat 64 with both ‘O’ rings 6.

• Pull out all the components of valve spool assembly 54.

• Finally remove ‘O’ ring 59 out of the handle counterbore.

Assemble in reverse order noting the following points -

• Ensure that the central port in valve seat 64 faces upwards.

• Use Loctite 243 when reassembling Clamp Nut 36, torque to 11ft lb (14.91 Nm).

• Using the 2 millimetre diameter pin punch*, drive trigger pin 48 out and lift off trigger 47.

• Unscrew trigger valve 46 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 G4 service kit. For complete list see page 15. Item numbers in bold refer to the general assembly drawing and parts list on pages 18-19.

Ser vicing the Tool

He ad A ss em bl y

Pn eu ma ti c Pi st on As se mb ly

Valv e S po ol A ss em bl y

Tr ig ge r

En g lishNot es

Gene ral Ass embly of Ba se Tool 712 31-0200 0

B - B

6665

848586

1 2 3 4 9 105 8

486747

72 16

20 21

8281

A - A

5958

54-56

76 7577

En g lish

010203040506070809101113141617182021222324252628303132333435363738394041424445

71210-02101

07003-00277

71230-02015

71230-03300

71210-02104

07003-00281

71231-02003

07003-00273

71230-02041

07003-00194

07003-00341

07003-00342

71210-02022

07003-00278

71210-02029

07003-00311

07640-00239

71210-02051

07640-00244

71210-02034

07340-00335

71210-02035

71210-02028

07003-00374

71230-02019

07003-00288

71221-02013

07003-00287

71230-03800

71230-03205

71210-02014

71231-02027

71221-02001

07003-00182

71221-02002

07003-00274

71231-03210

71230-03600

71221-02008

07005-00088

JAW SPREADER HOUSING

'O' RING

LOCKNUT

HEAD ASSEMBLY

SEAL HOUSING

'O' RING

HEAD PISTON

LIP SEAL

SCREW

BONDED SEAL

LIP SEAL

'O' RING

SUSPENSION RING

'O' RING

SEAL

'O' RING

STEM COLLECTOR OUTER

STEM COLLECTOR BODY

SILENCER

SILENCER CAP

STEM COLLECTOR END CAP

SILENCER

RETAINING NUT

LIP SEAL

SEAL RETAINER

'O' RING

HANDLE ASSEMBLY

'O' RING

INTENSIFIER SEAL ASSEMBLY

GUIDE RING

CLAMP NUT

LABEL

BODY

'O' RING

BASE COVER

LIP SEAL

PNEUMATIC PISTON ASSEMBLY (INCLUDES 41/35/39)

TRANSFER TUBE ASSEMBLY

CYLINDER LINER

TRIGGER VALVE

111113111112111111111111112111111113111

-3-

112121111

-1-

-1---

211

-1-1-1---

4748495051525354555657585960616263646566676869707273747576777879808182838485868788

71210-02008

71210-02024

07003-00310

07003-00204

71230-02102

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

07003-00333

07900-00707

07007-00224

07490-03002

71403-02110

71231-02001

71221-02004

71221-02006

07002-00108

71221-02005

07003-00027

71221-02003

71221-02007

07007-01993

71221-20104

07002-00098

71221-20105

71221-20101

71221-20102

71221-20103

07007-01503

TRIGGER

TRIGGER PIN

'O' RING

VACUUM SLEEVE

'O' RING

1/8" BSP PLUG

VALVE SPOOL ASSEMBLY (55 to 58)

• 'O' RING

• VALVE SPOOL

• VALVE BODY

• 'O' RING

'O' RING

ON/OFF VALVE ASSEMBLY

6" FLEXIBLE HOSE

SILENCER

TOP PLATE

VALVE SEAT

ROTARY VALVE

'O' RING

LIP SEAL

TOOL INSTRUCTION MANUAL

SPIROL PINS

SPRING

BOTTLE ADAPTOR ASSEMBLY

END CAP ASSEMBLY

TIE ROD

SEALING WASHER

M6 NYLOK NUT

BASE PLATE

'O' RING

TOP PLATE

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

11211111111111121112112111222121111111221

1-1

-2-

1–2-1

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

ITEM PART Nº DESCRIPTION ITEM PART Nº DESCRIPTION

71231 - 0 2 000 PARTS LI S T * Th ese are mini mum reco mme n ded lev e ls o f s pare s ba sed on r egul ar s ervi cing

QTY SPARES QTY SPARES

Par ts List for 71 231-020 00

Pri ming

Oi l De ta il s

Hy sp in V G 32 O il Sa fe ty D at a

Pr im in g Ki t

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

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

, 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.

En g lish

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 60 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 60 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 60 to ‘ON” position.

• Check that the stroke of the tool meets the minimum speciﬁcation of 17 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 18-19.

Pri ming

Pr im in g Pro ce dure

Fau lt Diagnosis

Sym pt o m P o ss ibl e C au s e Re me d y Pag e R ef

Item numbers in bold refer to the general assembly drawing and parts list on pages 18-19.

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 & 13 place fastener Worn or broken jaws Fit new jaws 8-11

Low oil level or air in oil Prime tool 20-21 Build up of dirt inside the nose assembly Service 11

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 11

Loose jaw housing or chuck collet Tighten against locking ring 9-11 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 11 broken stem of Jaw housing or chuck collet, nose tip and fastener nose casing not properly seated Tighten nose assembly 9-11

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 20-21

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 following ‘Operating Procedure’ 7

Slow cycle Lack of lubrication Lubricate tool at air inlet point 7 & 13

Low air pressure Adjust air pressure to within the speciﬁcation 5 Build up of dirt inside the nose assembly Service 11

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

Damaged trigger valve 42 Replace 16 Loose base cover 35 Tighten 16 Loose stem collector Tighten retaining nut 22 16

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 Low oil level or air present in oil Prime tool 20-21 Incorrect length of fastener (Maxlok®ONLY) Change to correct length

Tool fails to swage Insufficient air pressure Adjust air pressure to within speciﬁcation 5 collar (Maxlok®ONLY) Worn or damaged anvil Replace 10-11

Low oil level or air present in oil Prime tool 20-21 Incorrect length of fastener Change to correct length

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

Declaration of Conformity

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

Model G4 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.

Da n sk

Sikkerhedsregler 26

Speciﬁkationer

Værktøjsspeciﬁkationer 27 Værktøjsdimensioner 27

Anvendelsesformål

Nitter 28 Delnummerering 28

Værktøjets idriftsættelse

Lufttilførsel 29 Driftsvejledning 29 Justering af vakuumsuget 29

Næsekonstruktioner

Næsetipper 30-32 Monteringsvejledning 31 Monteringsvejledning for Maxlok

og Avtainer

Servicevejledning for alle næsekonstruktioner 33

Tilbehør

Dorndeﬂektor 34 Forlænger 34 Sideudstøder 34

Service af værktøjet

Dagligt / ugentligt 35 Moly Lithium smørefedt EP 3753 Sikkerhedsdata 35 Sikkerhedsdata til MolyKote 55m & MolyKote 111 36 Årligt 37 Serviceudstyr 37 Hovedkonstruktion 37-38 Trykluftsstempelkonstruktion 38 Ventilspolekonstruktion 38 Udløser 38

Generel konstruktion af grundværktøjet

Generel konstruktion og reservedelsliste 40-41

Smøring

Oplysninger om olie 42 Hyspin olie VG 32 sikkerhedsdata 42 Smøreudstyr 42 Smøreprocedure 43

Fejlsøgning

Symptom, mulig årsag og afhjælpningsmetode 44-45

Avdel UK Limited har en politik om konstant produktudvikling og forbedring, og der tages forbehold for ændringer af et produkt uden videre varsel.

Garanti Avdel installationsværktøjer leveres med 12 måneders garanti mod defekter, som skyldes mangelfulde materialer eller dårlig udførelse af produktet, og garantiperioden starter fra leveringsdatoen, som bekræftes på fakturaen eller følgesedlen.

Garantien gælder for brugeren/køberen, når værktøjet sælges af en autoriseret forhandler, og kun såfremt det bruges til det påtænkte formål. Garantien bortfalder, hvis installationsværktøjet ikke efterses, vedligeholdes eller benyttes i overensstemmelse med de instrukser, som findes i instruktions- og servicehåndbøgerne

Kun i tilfælde af defekter eller fejl og efter eget skøn påtager Avdel d sig at reparere eller udskifte de mangelfulde komponenter.

Ind holdsforteg nelse

Sik kerhedsregler

1 Bør ikke anvendes til andet end det påtænkte formål.

2 Værktøjet må ikke anvendes med andet udstyr end det, der anbefales og leveres af Avdel UK Limited.

3 Eventuelle ændringer af værktøjet/maskinen, næsekonstruktioner, tilbehør eller andet udstyr leveret af Avdel UK Limited eller

repræsentanter herfor, sker på kundens fulde ansvar. Avdel UK Limited rådgiver gerne ved eventuelle ændringer.

4 Værktøjet/maskinen bør til enhver tid vedligeholdes under sikre arbejdsforhold og gennemgås med regelmæssige intervaller for

skader og funktionalitet af faglært, kompetent personale. Eventuel afmontering må kun foretages af personale, trænet i Avdel UK Limited’ procedurer. Værktøjet/maskinen bør ikke adskilles, uden man først henviser til vedligeholdelsesvejledningerne. Kontakt venligst Avdel UK Limited med henblik på Deres uddannelsesbehov.

5 Værktøjet/maskinen bør til enhver tid betjenes i overensstemmelse med den relevante sundheds- og sikkerhedslovgivning.

Gældende love i UK er ”The Health and Safety at Work etc. Act 1974”. Spørgsmål vedrørende korrekt betjening af værktøjet/maskinen samt brugersikkerhed bør rettes til Avdel UK Limited.

6 Kunden har pligt til at forklare for alle brugere de sikkerhedsforanstaltninger, der gør sig gældende ved brug af værktøjet/maskinen.

7 Luftledningen bør altid kobles fra værktøjets indsugning, inden man gør forsøg på at justere, montere eller fjerne

næsekonstruktionen.

8 Værktøjet må ikke betjenes, når det er rettet mod andre person(er) eller operatøren selv.

9 Sørg altid for at have et godt fodfæste eller en stabil position, inden værktøjet betjenes.

10 Kontrollér, at ventilationsåbningerne ikke er blokeret eller dækket til.

11 Driftstrykket bør ikke overstige 7 bar.

12 Værktøjet må ikke betjenes, hvis det ikke er udstyret med en komplet næsekonstruktion, med mindre der gives instrukser om

andet.

13 Sørg omhyggeligt for, at brugte dorne ikke udgør en risiko.

14 Hvis værktøjet er udstyret med en dornopsamler, skal den tømmes, når den er halvt fuld.

15 Hvis G4-værktøjet er udstyret med en dorndeﬂektor, skal den drejes indtil åbningen vender væk fra operatøren og andre personer,

som arbejder i nærheden.

16 Når værktøjet anvendes, er det påkrævet for operatøren og andre personer i nærheden at bære sikkerhedsbriller for at beskytte

mod nitteudstødning, hvis en nitte skydes ud ‘i luften’. Det anbefales at bruge handsker, hvis der er skarpe kanter eller hjørner på applikationen.

17 Undgå indvikling af løsthængende tøj, slips, langt hår, rengøringsklude osv. i de bevægelige dele i værktøjet, som bør holdes tørre

og rene for at opnå det bedst mulige greb.

18 Når værktøjet transporteres, skal De holde hænderne væk fra udløseren/betjeningshåndtaget for at undgå uagtsom start af

værktøjet.

19 Overdreven kontakt med hydraulikolie bør undgås. For at mindske risikoen for udslæt skal man sørge for at vaske sig grundigt

ved evt. kontakt.

Denne instruktionshåndbog og følgende sikkerhedsregler skal læses af enhver person, som installerer, benytter eller yder service på dette værktøj.

Da n sk

Dimensioner i millimeter

12°30'

134

128

152

150

316

145

116

Lufttryk Minimum - Maksimum 5-7 bar (72,5 - 101,5 psi) Frit luftvolumenbehov v. 5,5 bar 4,3 litres (0,15 kubikfod) Slaglængde Minimum 17 mm (0,7 tommer) Trækkraft v. 5,5 bar 18,68 kN (4200 lbf) Omløbstid Cirka 1,2 sekunder Støjniveau 75 dB(A) Vægt Uden næseudstyr 2,35 kg (5,17 lb) Vibration Mindre end 2,5 m/s2(8,2 fod/s2)

Spe cifikationer

Væ rk tø js sp ec if ik ati on er

Væ rk tø js di me ns io ner

G4 er et hydropneumatisk værktøj, der er konstrueret til at anbringe Avdel®-nitter med afbrækkelig dorn ved høj hastighed. Dette gør det ideelt til montering i forbindelse med serie- og kontinuerlig produktion i en lang række områder inden for alle industrier. Det kan anbringe alle de typer nitter, der er vist på modsatte side.

Værktøjet har et justerbart vakuumsystem til fastholdelse af nitter og problemfri opsamling af brugte dorne uanset værktøjets orientering. Se 'Driftsvejledning' på side 29 for en vejledning af justering.

Et komplet værktøj består af tre separate elementer, som leveres enkeltvis. Se diagrammet nedenfor.

NÆSEUDSTYR SKAL MONTERES SOM BESKREVET PÅ SIDE 30-33.

AVEX

STAVEX

AVINOX

AVIBULB

BULBEX

T-LOK

AVDEL® SR

INTERLOCK

HEMLOK

TLR

MAXLOK

AVTAINER

AVDEL

MBC

MBC/LC

AVSEAL

QTM RIVET

TTM RIVET

CHERRYMATE

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

–

/16 – – – 1/4 – – – – 3/8 –

● ●

●

● ●

●

● ●

●

● ●

●

● ● ●

● ●

NAVN PÅ

NITTE

STØRRELSE PÅ NITTE ( )

KOMPLET VÆRKTØJ

71231-00 . . .

BASISVÆRKTØJ

NÆSEKONSTRUKTION

NÆSETIP

71231-02000

71210-15000

se bemærkning 3

+ + =

TILFØJ 3 CIFRE FRA DEN SIDSTE KOLONNE I NÆSETIPTABELLEN PÅ SIDE 30, 31 ELLER 32. I FORB. MED MAXLOK

ANVENDES MAXLOK

-TABELLEN PÅ SIDE 32, SELVOM DER IKKE ER NOGEN NÆSETIP.

Delnummeret på grundværktøjet forbliver det samme, uanset hvilken næsekonstruktion eller næsetip, der er sat på. Se den generelle konstruktion på side 40-41. Hvis værktøjet er udstyret med en Maxlok

-næsekonstruktion, SKAL det samme grundværktøj tilpasses.

Se detaljerne på side 33.

Næsetippens delnummer relaterer til en bestemt nitte. Hvis adgang til emnet er begrænset, ﬁndes der enkelte forlængede næsetipper. Se tabellen for ‘Næsetipper af type 2’ på side 31.

Denne næsekonstruktion vil gøre det muligt at sætte standard nitter (ikke ﬂy-industri) ved ganske enkelt at vælge den korrekte næsetip fra udvalget af næsetipper af type 1. Der ﬁndes andre næsekonstruktioner til emner med begrænset adgang, til ﬂy-industri og særlige nitter. Se tabellerne på side 30-32.

Anv endelsesform ål

Da n sk

Alle værktøjer drives med trykluft ved et optimalt tryk på 5,5 bar. Vi anbefaler brug af trykregulatorer og automatisk oliering/ﬁltrering på hovedlufttilførslen. Disse monteres indenfor 3 meters afstand fra værktøjet (se nedenstående diagram) for at sikre maksimal levetid og minimal vedligeholdelse af værktøjet.

Lufttilførselsslangernes minimumskapacitet bør være et effektivt arbejdstryk på 150% af det maksimale tryk, der produceres i systemet, eller 10 bar, alt efter hvilket af disse udgør det højeste tryk. Luftslanger bør være oliebestandige med slidbestandig yderside og armering, såfremt slangen udsættes for skadevoldende drift. Alle luftslanger SKAL have en minimumshuldiameter på 6,4 mm eller

Vedrørende daglig vedligeholdelse, se side 35.

JUSTERING AF VAKUUMSUGET

• Drej ventilen 65 ved brug af en skruetrækker, indtil

luftstrømmen ved værktøjets bagende stopper.

• Indfør en nitte, som ikke er en Avtainer

eller Maxlok®, i næsen med værktøjsnæsen pegende nedad, og hold den på plads.

• Drej ventilen den ene eller den anden vej, indtil der er

tilstrækkeligt sug til at fastolde nitten.

STARTPUNKT FRA HOVEDTILFØRSLEN

STOPHANE

(ANVENDES UNDER SERVICE

AF FILTER/REGULATOR ELLER SMØREKOP)

UDTØMNINGSPUNKT FOR HOVEDTILFØRSLEN

TRYKREGULATOR OG FILTER (TØMMES DAGLIGT)

MAKSIMALT 3 METER

ALLE NITTER BORTSET FRA AVTAINER®OG MAXLOK

• Sørg for at en næsekonstruktion, der passer til nitten, er sat på

(se side 30-32).

• Tilslut værktøjet til lufttilførslen.

• Indfør nittedornen i næsen på værktøjet. Nitten bør fastholdes af

vakuumsystemet. Hvis ikke, justeres vakuum ventilen 65 (se bemærkningen nedenfor).

• Før værktøjet med nitten hen til emnet, således at den

fremspringende nitte trænger lige ind i hullet på emnet.

• Aktivér udløseren helt. Værktøjscyklussen vil antrække nitten, og

den afbrækkede dorn vil blive skudt tilbage i værktøjets bagende.

AVTAINER®OG MAXLOK

• Sørg for at den rigtige næsekonstruktion er sat på.

• Tilslut værktøjet til lufttilførslen.

• Kobl vakuumsystemet fra ved at dreje ventilen 65, indtil De

ikke kan høre eller føle luft strømme ud forrest fra næsekonstruktionen.

• Skub Maxlok

- eller Avtainer®-skaftet gennem hullet i emnet.

• Anbring kraven på skaftet (orienteringen vises nedenfor).

• Skub værktøjet hen på det fremspringende skaft, mens De

holder bottens hoved mod emnet.

• Tryk udløseren helt i bund. En cyklus vil sikre, at kraven

sænkes ned i låserillerne, og at skaftet brækkes af i afbrækningsrillen.

• Giv slip på udløseren. Værktøjet fuldfører dets cyklus ved at

skubbe sig selv af kraven, og det afknækkede skaft vil blive skubbet til værktøjets bagende ved indføring af den næste bolt.

Delene med fed skrift refererer til den generelle konstruktion og reservedelslisten på side 40-41.

Anbringelse af AVTAINER

Anbringelse af MAXLOK

Vær ktøjets idri ftsættelse

Lu ft ti lf ør se l

Dr if ts ve jl ed ni ng

V I G T I G T

Næsekonstruktioner omfatter IKKE næsetipper. Næsetipper skal bestilles separat.

Et værktøj skal altid være udstyret med en korrekt næsekonstruktion og næsetip til Deres nitte og skal bestilles separat. Se ‘NÆSETIP’ tabellerne nedenfor og på side 31-32.

Hvis der ikke er nogen adgangsbegrænsning i Deres applikation, skal De bruge en næsetip af type 1, med mindre De anbringer ﬂynitter, som kræver en næsetip af type 3, en Avtainer

af type 5, en Hemlok®og en 1/4" Interlock®af type 6. Maxlok®kræver en særlig næsekonstruktion, som ikke gør brug af en næsetip. Se side 32-33. Dimensionerne ‘A’ og ‘B’ vil hjælpe Dem med at vurdere, hvor passende en bestemt næsetip er. De bør også checke, at dimensionerne på næsehuset ikke vil begrænse adgangen til Deres emne. Hvis der er begrænset adgang, ﬁndes der en næsetip af type 2 med ekstra rækkevidde til visse nitter. Henvis til tabellen på side 31. Det er absolut nødvendigt, at en passende næsekonstruktion og næsetip sættes på, før De bruger værktøjet (ingen næsetip i forbindelse med Maxlok®).

V I G T I G T

Lufttilførslen skal afbrydes ved montering eller aftagning af næsekonstruktioner.

Se side 31, og for Avtainer®og Maxlok®se side 33.

'A' 'B'

Aluminium Aluminium Stål Aluminium Aluminium Stål Stål Rustfrit stål Stål Stål Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Rustfrit stål Stål Stål Stål Stål Alle Alle Alle Alle Alle Alle Alle Alle Al/Al

Al/Al

Al/Stål

Al/Al

Al/Stål

– – – – – –

–

4 3/16 3/16 3/16 3/16

1/4 1/4 1/4 1/4

2.8

3.3

4.1

3.3

2.8

5.5

7.3

5.6

7.3

5.6

7.3

4.1

4.4

4.8

3.3

4.8

3.3

5.7

3.3

5.7

2.8

3.3

9.5

8.0

9.5

9.0

11. 2

8.0

10. 2

8.3

12. 7

19. 0

12. 7

19. 0

12. 7

15. 9

12. 7

15. 9

12. 7

17. 5

12. 7

16. 7

12. 7

073 81- 0470 1 073 40- 0480 0 074 90- 0440 1

073 40- 0660 1

076 12- 0200 1 073 81- 0470 1 073 81- 0470 1 073 81- 0470 1 073 40- 0480 0 076 12- 0200 1 073 81- 0470 1 712 20- 1600 6

712 20- 1601 1

712 20- 1600 7

712 20- 1601 2

712 20- 1600 8

712 20- 1601 3

703 -B- 21

703 -A- 25-6 T

703 -B- 26

743 -A- 25-8 TA

743 -B- 21

743 -A- 25-8 T

743 -B- 26

4.8

6.4

4.8

6.4

4.8

8 8 9

9 10 10

4.8

6.4

4.8

4.3

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

AVEX

Stor flange

STAVEX

Forsænket

Stor flange

BULBEX

AVSEAL

TLR

AVINOX

T-LOK

AVIBULB

AVDEL

Forsænket

INTERLOCK

Q™ RIVET

CHERRYMATE

T™ RIVET

Stor flange

8 7 6 5 4 23 1

22.9

DEL. BESKRIVELSE VARENR.

1 07340-00306 2 07003-00067 3 07340-00304 4 71210-15001 5 07498-04502 6 71210-05001 7 07500-00418 8 07340-00327

N Æ S E T I P P E R

T Y P E 1

N I TT E

MATERIALE

N Æ SE TI P ( mm )

nedenfor

VARENR.NAVN

I tommer, derefter i millimeter.

Hovedformningsnæsetipper er KUN til brug ved

undersænkede nitter.

Lang næsetip til dyb placering.

Materiale-Nittekroppens, derefter dornen. 'Al' er en

forkortelse for aluminium.

NÆSEK O N S TRUKTION

Varenr. 71210-15000

NÆSEHUS

'O'-RING

KÆBEHUS

KÆBER

KÆBEÅBNER

BUFFER

FJEDER

LÅSERING

KOMPLET

VÆRKTØJS

DELNUMMER:

71231-00 står foran

Mo nt er in gs ve jl ed nin g

Næs ekonstruktio ner

+ 86 hidden pages

Avdel Genesis G4 HD Heavy Duty Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual