Avdel GENESIS NG2 User Manual

Genesis

Hydro-Pneumatic Power Tool Druckluftgerät Outil oléo-pneumatique Attrezzo oleopneumatico

Instruction Manual Manuel d’instructions Betriebsanleitung Manuale d’istruzione

Safety Instructions 4

Specifications

Tool Specification 5 Tool Dimensions 5

Intent of Use

Range of Fasteners 6 Part Numbering 6

Putting into Service

Air Supply 7 Operating Procedure 7

Nose Assemblies

Fitting Instructions 8 Servicing Instructions 8 Nose Tips 9, 11 Type 1 9

Avseal

II 10 Type 2 12 Type 3 12

Accessories

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

Servicing the Tool

Daily / Weekly 18 Moly Lithium Grease EP 3753 Safety Data 18 Molykote

55m Grease Safety Data 19 Molykote®111 Grease Safety Data 19 Service Kit 20 Maintenance 20 Nose Equipment 20 Dismantling the Tool 21 Head Assembly 21 Pneumatic Piston Assembly 22 Air Valve 22 Rotary Valve 23 Trigger 23 Stop Plate Assembly (71213-03900) 24

General Assembly of Base Tool

General Assembly 26 Parts List 27

Priming

Oil Details 28 Hyspin

VG 32 Oil Safety Data 28 Priming Kit 28 Priming Procedure 29

Fault Diagnosis

Symptom, Possible Cause and Remedy 30

Français 33 Deutsch 63 Italiano 93

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.

LIMITED WARRANTY Avdel make the limited warranty that its products will be free of defects in workmanship and materials which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product being installed, maintained and operated in accordance with product literature and instructions and (2) confirmation by Avdel of such defect, upon inspection and testing. Avdel makes the forgoing limited warranty for a period of twelve (12) months following Avdel’s delivery of the product to the direct purchaser from Avdel. In the event of any breach of the forgoing warranty, the sole remedy shall be to return the defective Goods for replacement or refund for the purchase price at Avdel’s option. THE FORGOING EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.

Contents

English

Safety Instructions

1 Do not use outside the design intent.

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

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

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

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

by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel UK Limited procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel UK Limited with your training requirements.

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

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

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

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

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

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

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

11 The operating pressure shall not exceed 7 bar.

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

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

14 Vacuum Air MUST be turned off using the Trigger before removing the Stem Collector Bottle which MUST be emptied when half full.

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

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

working in the vicinity.

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

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

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

dry and clean for best possible grip.

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

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

thoroughly.

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

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

Tool Specification

Specifications

Air Pressure Minimum - Maximum 5-7 bar Free Air Volume Required @ 5.5 bar 2.1 litres Stroke Minimum 17 mm Pull Force @ 5.5 bar 9.34 kN Cycle Time Approximately 0.9 seconds Noise Level 75 dB(A) Weight Including nose equipment 2.1 kg Vibration Less than 2.5 m/s

Dimensions in millimetres

Tool Dimensions

English

Note: Stem collector short version bottle is an accessory part number 71213-03810

Intent of Use

nG2 is a hydro-pneumatic tool designed to place Avdel

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

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

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

If you wish to place most of the fasteners in the table opposite, you can order the 71213-00039 complete tool comprising of:

• 71213-02000 base tool

• 71213-15000 nose assembly

• Nose tips 71210-05002, 71210-16070 and 07381-

04701. Fit nose tip as indicated page 8 or 9.

You can order the above three nose tips and nose assembly as a nose assembly kit part number 71213-

15100.

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

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGE 8.

The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly pages 26-27. If a swivel head is fitted, the same base tool must be adapted. See details page 14.

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

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 table page 12. A nose assembly can be substituted by a swivel head (see pages 14-15). In this case the nose tip is part of the swivel head.

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE TIP TABLE ON PAGE 10 OR

12. FOR TOOLS WITH SWIVEL HEADS USE TABLE PAGES 14-

15.

Range of Fasteners

Part Numbering

FASTENER

NAME

AVEX

STAVEX AVINOX®II AVIBULB

ETR

BULBEX

AVDEL® SR MONOBOLT INTERLOCK

AVDEL

MBC

MBC®/LC

AVSEAL®II

KLAMPTITETMKTR

KLAMPTITE

FASTENER SIZE 3 3.2 4.0 4.3 4.8 5 5.2 6 6.5 7 –1/85/32 –3/16 –––––

●●

●

( )

●

●●●●

●

NOSE ASSEMBLY

BASE TOOL

71213-02000

71213-15000

NOSE TIP

see note 3

++=

COMPLETE TOOL

71213-00 . . .

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

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

/4 inch.

Putting into Service

Air Supply

English

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

fitted.

• Connect the tool to the air supply.

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

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

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

protruding fastener enters squarely into the hole of the application.

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

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

• A partial rotation and pull movement removes the collector bottle.

The Trigger should be lifted to cut-off the vacuum supply air prior to removing the collector bottle.

Operating Procedure

• To minimise air consumption, the trigger should be ‘lifted” to cut-off the vacuum air supply if the tool is not to be used for a period

of time.

Do not use tool when Stem Collector Bottle is removed

OF FILTER/REGULATOR OR LUBRICATION UNITS)

(USED DURING MAINTENANCE

3 METRES MAXIMUM

AIR LUBRICATION

PERMISSABLE

STOP COCK

TAKE OFF POINT FROM MAIN SUPPLY

MAIN SUPPLY

DRAIN POINT

PRESSURE REGULATOR AND FILTER (DRAIN DAILY)

Lift Trigger to cut-off the vacuum air supply.

Nose Assemblies

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

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

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

• Any worn or damaged part should be replaced.

• Clean and check wear on jaws.

• Ensure that the jaw spreader is not distorted.

• Check Spring 7 is not distorted.

• Assemble according to fitting instructions above.

* Item included in the nG2 Service Kit. For complete list see page 20.

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 4 Nose Tip tables (pages 9, 10 and 12).

• 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.

• Insert Detent Sleeve 10 into Jaw Spreader Housing ‘T’ 9. Not applicable to Type 2 and 3 nose assemblies.

• Fit locking ring 8 onto the Jaw Spreader Housing “T’ 9.

• For tools converted to nose assemblies Type 2 and 3, fit Locking Ring 8 onto the Jaw Spreader Housing ‘T’ 9 attached to the tool.

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

• Utilising the ‘T’ section profiles assemble Nose Assembly onto the tool piston via the Male ‘T’ Adaptor 41 - pages 26-27.

Not applicable to Type 2 and 3 nose assemblies.

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

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

Fitting Instructions

Servicing Instructions

Nose Tips

Nose Assemblies

IMPORTANT

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

A tool (except part number 71213-00039) must always be fitted with the correct nose assembly and nose tip for your fastener but if you wish to order a nose assembly or a nose tip separately, refer to the ‘NOSE TIPS’ tables below and page 10 and 12.

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.

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 page 12.

It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a 71213-00039 complete tool, it is important that you check that the nose tip already fitted to the nose assembly is the correct one to place your fastener by sliding the fastener stem into the nose tip. No force should be required and play should be minimal.

Swivel heads are available as an alternative to nose assemblies when further reach is required. See pages 14-16 in the ‘Accessories’ section.

English

TYPE 1

NOSE TIPS

In inches then in millimetres.

Head forming nose tips for use with countersunk heads

ONLY.

Long nose tip for deep placing.

Dome head.

Countersunk.

Complete tool part number 71213-00039 does not only include the 71213-15000 nose assembly below but also the following three nose tips: 71210-05002, 71210-16070 and 07381-04701 making up a nose assembly kit part number 71213-

15100.

Use the nose tip listed in the table.

Items 3-11 available as cartridge assembly

71213-20320

NOSE ASSEMBLY

part nº 71213-15000

(+ 3 nose tips above = 71213-15100)

ITEM DESCRIPTION PART Nº

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

AVEX

Large flange

MONOBOLT BULBEX

AVINOX® II

T-LOK

AVIBULB

AVDEL® SR

INTERLOCK STAVEX

Large flange Countersunk

Q™RIVET

KLAMPTITE KTR KLAMPTITE

™ ™

FASTENER

3.2

–

3.0

4.0

4.8

4.0

4.8

3.2

4.0

4.8

–

4.3

4.8

3.2

4.0

4.8

3.2

4.0

4.8

1.8

4.8

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

MATERIAL

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

NOSE TIP (mm)

PART Nº 'A' 'B'NAME

71210-05002 71210-16070

07340-06401

71210-05002 71210-16070 07381-04701

07340-06501

07381-04701 07340-04800 07490-04401

07340-06601

71210-16020 71210-16070 07381-04701 71210-16070 07381-04701 07498-01401 07340-06201 07340-06201 71210-16070 07381-04701 07498-01401 71210-05002

71210-16070 07348-07001 71210-16050

07381-04701

71210-16070

07381-04701

07340-04800

07381-04701

71210-16070

07381-04701

71210-05002

07340-06201

71220-16060

07381-04701

4 5

12.7

19.0

12.7

19.0

12.7

4.8

3.3

2.9

4.8

3.3

2.8

3.3

2.8

3.3

4.1

3.3

2.8

3.3

2.8

4.8

3.3

2.8

4.8

3.3

5.7

2.8

3.3

2.8

3.3

2.8

3.3

2.8

4.8

3.3

4.8

2.8

see

below

…039* …039*

…003 …039* …039* …039*

…009 …039*

…016

…017

…015

…200 …039* …039* …039* …039*

…082

…120

…120 …039* …039*

…082 …039* …039*

…062

…064 …039* …039* …039* …039*

…016 …039* …039* …039* …039* …039*

…120

…430

…039

COMPLETE TOOL

PART NUMBER :

precede with 71213-00.

* See top left

Nose Tips

Nose Assemblies

AVSEAL®II

NOSE TIPS

FASTENER

MATERIAL

NAME

AVSEAL®II

– – – – – – –

– – – – –

Standard Al. Alloy - Flush Nose Tip

4.0 Standard Al. Alloy - 2mm Extended Nose Tip

4.0 Standard Al. Alloy - 8mm Extended Nose Tip

4.0 Standard Al. Alloy - Flush Nose Tip

5.0 Standard Al. Alloy - 2mm Extended Nose Tip

5.0 Standard Al. Alloy - 8mm Extended Nose Tip

5.0 Standard Al. Alloy - Flush Nose Tip

6.0 Standard Al. Alloy - 2mm Extended Nose Tip

6.0 Standard Al. Alloy - 8mm Extended Nose Tip

6.0 Standard Al. Alloy - Flush Nose Tip

6.5 Standard Al. Alloy - 2mm Extended Nose Tip

6.5 Standard Al. Alloy - 8mm Extended Nose Tip

6.5 Standard Al. Alloy - Flush Nose Tip

7.0 Standard Al. Alloy - 2mm Extended Nose Tip

7.0 Standard Al. Alloy - 8mm Extended Nose Tip

7.0

NOSE ASSEMBLY

part nº 71213-16100

ITEM DESCRIPTION PART Nº

1 TAPERED NOSE CASING 71213-00350 2 'O' RING 07003-00067 3 JAW HOUSING - TAPERED 71210-15902 * 4 JAW 71210-16101 * 5 JAW SPREADER 07498-04502 * 6 BUFFER 71210-05001 * 7 SPRING 07500-00418 * 8 LOCKING RING 07340-00327 * 9 JAW SPREADER HOUSING 'T' 71210-20321 * 10 DETENT SLEEVE 71210-20322 * 11 'O' RING 07003-00277 *

71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100 71213-16100

Items 3-11 available as cartridge

assembly 71213-16320

NOSE

ASSEMBLY

NOSE TIP (mm)

PART Nº

71210-16102 71210-16106 71210-16110 71210-16103 71210-16107 71210-16111 71210-16104 71210-16108 71210-16112 71210-16114 71210-16115 71210-16116 71210-16105 71210-16109 71210-16113

'A' 'B'

12.7

COMPLETE TOOL

PART NUMBER :

precede with 71213-00.

11.4

2.5

5.4

2.5

5.4

2.5

5.4

2.5

5.4

2.5

5.4

see

below

… 401 … 402 … 403 … 404 … 405 … 406 … 407 … 408 … 409 …413 …414 …415 …410 …411 …412

Nose Assemblies

Nose Tips

• Fit Jaw Spreader Housing 9* (71210-02101) together with ‘O’ Ring 10* or 11* (Jaw Spreader Housing 9* and ‘O’ Ring 10* or

11* are supplied with Type 2 and 3 Nose Assemblies)

• The Jaw Spreader Housing 9* must be tightened onto Piston 36 trapping Vacuum Tube 42 finally tighten

Locknut 40 against Jaw Spreader Housing 9*.

Items 9* and 10* or 11* refer to illustrations on pages 9, 10 and 12.

For other items refer to the general assembly drawing and parts list on pages 26 and 27.

English

To fit Nose Tips Type 2/3 or Nose Extension, the ‘T’ Adaptor 41 must be replaced with Jaw Spreader Housing 9*.

• Loosen Locknut 40 using 16mm AF Spanner.

• Unscrew and remove ‘T’ Adaptor 41 together with ‘O’ Ring 12.

10* or 11*

Nose Assemblies

Nose Tips

To fit Nose Tips Type 2 or 3 remove Male ‘T’ Adaptor 41 and replace with Jaw Spreader Housing 9* and ‘O’ Ring 10*.

Remove Male ‘T’ Adaptor 41 from the Tool (see page 11) and replace with Jaw Spreader Housing 9* (71210-02101) and ‘O’ Ring 10*.

9* and 10* refer to the illustrations on this page.

TYPE 2

NOSE TIPS

NOSE ASSEMBLY

part nº 71210-15200

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 9 JAW SPREADER HOUSING 71210-02101 10 'O' RING 07003-00277

FASTENER

MATERIAL

AVEX

BULBEX

T-LOK

STAVEX

AVIBULB

E.T.R

In inches then in millimetres.

3.2

Aluminium Alloy

–

3.2

4.0

4.8

4.0

4.8

4.3

4.8

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

5.2

Steel Aluminium Alloy Steel Aluminium Alloy Steel Aluminium Alloy Aluminium Alloy Steel Steel Steel Steel Steel Stainless Steel Stainless Steel Stainless Steel Steel Steel Steel/Brass

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

8 7 6 5 4239&10

NOSE TIP (mm)

PART Nº 'A' 'B'NAME

07340-02805 07340-02806 07340-02806 07340-02807 07340-02807 07340-07301 07340-02806 07340-02807 07241-07101 07241-07101 07340-02806 07340-02807 07340-02807 07340-02806 07340-02807 07340-02807 07340-02806 07340-02807 07340-02807

12.95

9.5

12.7

9.5

12.7

9.5

12.7

9.5

12.7

9.5

12.7

COMPLETE TOOL

PART NUMBER :

precede with

58.3

11.4

10.0

11.8

11.4

10.0

11.4

10.0

11.4

10.0

11.4

10.0

71213-00

see

below

…002 …008 …008 …014 …014 …018 …008 …014 …121 …121 …008 …014 …014 …008 …014 …014 …008 …014 …014

22.9

10 9

TYPE 3

NOSE TIPS

NOSE ASSEMBLY

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 9 JAW SPREADER HOUSING 71210-02101 10 'O' RING 07003-00277

8 7 6 5 4239&10

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

FASTENER

AVDEL

MBC

MBC L/C

In inches then in millimetres.

MATERIAL

3.2

Al Alloy

3.2

Al Alloy

3.2

Stainless Steel

4.0

Al Alloy

4.0

Al Alloy

4.0

Stainless Steel

4.8

Al Alloy

4.8

Al Alloy

3.2

Any

4.0

Any

4.8

Al Alloy

3.2

Any

4.0

Any

4.8

Al Alloy

56.3

Oversize

22.9

NOSE TIP (mm) see

PART Nº 'A' 'B'NAME

12.7

COMPLETE TOOL

PART NUMBER :

precede with

71210-16030 71210-16031 71210-16032 71210-16033 71210-16034 71210-16035 71210-16036 71210-16037 07340-06701 07340-06801 07340-06901 07344-04701 07344-04701 07344-04701

71213-00

2.5

3.3

2.5

3.3

2.5

4.8

5.0

5.1

4.6

below

…283 …284 …285 …288 …289 …290 …293 …294 …300 …305 …310 …320 …320 …320

10 9

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:

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

9* refers to illustrations on pages 9, 10 and 12.

STEM DEFLECTOR: 71213-20100

• Loosen Locknut 40 using

16mm AF Spanner.

• Unscrew and remove both ‘T’

Adaptor 41 and Locknut 40.

• Replace Locknut 40 with

‘Sealed’ Nut 71213-02200, screw ‘Sealed” Nut onto Piston

36 to disable Vacuum System.

• ‘T’ Adaptor 41 must be

tightened onto Piston 36, finally tightening ‘Sealed’ Nut against it.

• Remove the Stop Plate

Assembly (page 24) by unscrewing Screws 89 (2 off).

Fitted between the tool and the nose assembly the extension allows access into deep channels.

• The Tool must be fitted with Jaw Spreader Housing 9* (71210-

02101) and ‘O’ Ring before extension (71210-20300). See page 11.

• To fit the extension, remove any nose assembly components.

• Screw the inner extension to Jaw Spreader Housing 9*.

• Screw the outer onto Head Assembly 4.

• Fit the nose assembly onto the extension.

Stem Deflector

Accessories

Preparing the Base Tool for use with Stem Delector

Extension

English

The airline must be disconnected before any servicing or dismantling.

‘Sealed’ Nut 71213-02200 replaces Locknut 40 (to cut-off air supply to Vacuum System) as follows:

• Fit Stem Deflector (07340-00342) into Adaptor (71213-20101).

• Push the assembled Stem Deflector and Adaptor over Bottle

Adaptor 32 and align with the cut-out feature.

71213-20101

ADAPTOR

07340-00342

STEM DEFLECTOR

ADAPTOR 71213-20101

INNER

STEM DEFLECTOR

07340-00342

SEALED NUT

71213-02200

OUTER

EXTENSION - 'T' ADAPTOR 71213-12000

EXTENSION - NON QUICK RELEASE 71210-20300

Swivel Heads

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.

IMPORTANT

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

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

Swivel heads are supplied separately for fitting 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 page 15. For the ‘Constant Components’ table see page 17.

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

Remove Male ‘T’ Adaptor 41 from the Tool (see page 15) and replace with Jaw Spreader Housing (71210-02101).

STRAIGHT SWIVEL HEAD capability

FASTENER

AVEX

BULBEX

AVINOX® II

AVSEAL® II

AVDEL

MBC

MBC® L/C

STAVEX®

1 5 5 3

5 3

– – – –

1 5 5 3 3

1 5 3

1 5

5 3

/ / / / /

/ / / /

/ /

/ / /

/ /

3.2

4.0

4.8

4.0

4.8

3.2

4.0

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

8 32 /

8 32

In inches then in millimetres.

MATERIAL

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

Al Alloy

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

3.2 Steel

4.0 Stainless Steel

3.2 Stainless Steel

4.0

360° rotation

Long nose tip for deep placing.

PART Nº

07345-03000 07345-03100 07345-03100 07345-03200 07345-03200 07345-03100 07345-03200 07345-03100 07345-03200 71213-06000 71213-06600 71213-06100 71213-06700 07345-03300 07494-03600 07494-03000 07345-03400 07494-03700 07345-03500 07494-03800 07345-04000 07345-04100 07345-04200 07345-04700 07345-04700 07345-04800 07345-04800 07345-03100 07345-03200 07345-03100 07345-03200

NOSE TIP (mm)SWIVEL HEAD

PART Nº

07345-03600 07345-03700 07345-03700 07345-03800 07345-03800 07345-03700 07345-03800 07345-03700 07345-03800 71213-16401

71213-16402

71213-16403

71213-16404

07345-03301 07494-03601 07494-03011 07345-03401 07494-03701 07345-03501 07494-03801 07165-00701 07165-00702 07165-00703 07345-04701 07345-04701 07345-04701 07345-04701 07345-03700 07345-03800 07345-03700 07345-03800

Oversize

'A' 'B'NAME

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

1.95

6.35

7.62

5.08

6.6

8.13

4.75

6.35

7.92

7.87

4.11

2.00

4.11

1.17

3.81

0.84

0.25

1.9

2.36

2.46

2.03

3.81

PART Nº

07340-00213 07340-00213 07340-00213 07490-04602 07490-04602 07340-00213 07490-04602 07340-00213 07490-04602 07340-00213 07340-00213 07340-00213 07340-00213 07340-00229 07340-00229 07340-00213 07340-00229 07340-00229 07498-04401 07498-04401 07340-00229 07340-00229 07498-04401 07340-00229 07340-00229 07498-04401 07498-04401 07340-00213 07490-04602 07340-00213 07490-04602

…001 …004 …004 …010 …010 …004 …010 …004 …010 …160 …180 …161 …181 …283 …284 …285 …288 …289 …293 …294 …300 …305 …310 …320 …320 …327 …327 …004 …010 …004 …010

COMPLETE TOOL PART NUMBER :

precede with 71213-30

(the stop nut and safety cap are included)

IMPORTANT: in contrast to complete tools

with nose assemblies, those fitted with swivel heads

include the nose tip as a part of the head.

JAWS

see

below

• Disconnect the air supply.

• Remove any nose assembly items.

• Remove Stem Collector Bottle Assembly

25 (71213-03800).

• Replace assembly 25 with Safety Cap

(71213-20201)

• Unscrew Male ‘T’ Adaptor 41 and remove

with ‘O’ Ring 12, Locknut 40, ‘O’ Rings 19 and 15, and Seal Housing 52. Do not refit these items.

• Screw Stop Nut (71213-20200) onto the

front of Head Piston 36 as far as it will go by hand.

• Fit Jaw Spreader Housing (71210-02101)

and ‘O’ Ring 12, tighten onto Head Piston 36, finally tighten Stop Nut against Jaw

Spreader Housing.

The tool is now ready to be fitted with a swivel head. Instructions below.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26-

27.

Preparing the Base Tool for Right-Angle and Straight Swivel Head Attachment

Accessories

Remove Male ‘T’ 41 Adaptor from the Tool and replace with Jaw Spreader Housing (71210-02101) See ‘Preparing the Base Tool’ above.

English

Base tool to receive a nose assembly

Base tool to receive a swivel head

RIGHT-ANGLE SWIVEL HEAD capability

FASTENER

MATERIAL

AVEX

BULBEX

AVINOX

AVSEAL

STAVEX

AVDEL

MBC

MBC L/C

3.2

Aluminium Alloy

3.2

Steel

4.0

Aluminium Alloy

4.0

Steel

4.8

Aluminium Alloy

4.0

Aluminium Alloy

4.8

Aluminium Alloy

3.2

Stainless Steel

4.0

Stainless Steel

–

1 1

1 5 5 3 3

1 5 3

1 5

–

3.2

4.0

3.2

4.0

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Steel Steel Stainless Steel Stainless Steel Aluminium Alloy Aluminium Alloy Stainless Steel Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy Aluminium Alloy

41 12 40 52

19 15

71213-20200

STOP NUT

PART Nº

07346-03000 07346-03100 07346-03100 07346-03200 07346-03200 07346-03100 07346-03200 07346-03100 07346-03200 71213-04000 71213-04700 71213-04100 71213-04800 07346-03100 07346-03200 07346-03100 07346-03200 07346-03300 07495-03600

07495-03000 07346-03400 07495-03700

07346-03500 07495-03800

07346-04000 07346-04100 07346-04200 07346-04500 07346-04500 07346-04600

07346-04600

NOSE TIP (mm)SWIVEL HEAD

PART Nº

07345-03600 07345-03700 07345-03700 07345-03800 07345-03800 07345-03700 07345-03800 07345-03700 07345-03800 71213-16401

71213-16402

71213-16403

71213-16404

07345-03700 07345-03800 07345-03700 07345-03800 07345-03301 07494-03601 07494-03011 07345-03401 07494-03701 07345-03501 07494-03801 07165-00701 07165-00702 07165-00703 07345-04701 07345-04701 07345-04701 07345-04701

71213-20201 SAFETY CAP

View with 25 removed and stop nut replacing removed items 19, 15, 52, 40

'A' 'B'NAME

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

3.81

7.87

1.95

6.35

7.62

7.87

5.08

6.6

8.13

4.75

6.35

7.92

7.87

4.11

2.00

4.11

3.81

1.17

3.81

0.84

0.25

1.9

2.36

2.46

2.03

PART Nº

07340-00213 07340-00213 07340-00213 07490-04602 07490-04602 07340-00213 07490-04602 07340-00213 07490-04602 07340-00213 07340-00213 07340-00213 07340-00213 07340-00213 07490-04602 07340-00213 07490-04602 07340-00229 07340-00229 07340-00213 07340-00229 07340-00229 07498-04401 07498-04401 07340-00229 07340-00229 07498-04401 07340-00229 07340-00229 07498-04401 07498-04401

JAWS

see

below

…001 …004 …004 …010 …010 …004 …010 …004 …010 …160 …180 …161 …181 …004 …010 …004 …010 …283 …284 …285 …288 …289 …293 …294 …300 …305 …310 …320 …320 …327 …327

In inches then in millimetres.

360° rotation

7.6

Long nose tip for deep placing.

Oversize

COMPLETE TOOL PART NUMBER :

precede with 71213-40

(the stop nut and safety cap are included)

IMPORTANT: in contrast to complete tools

with nose assemblies, those fitted with swivel

heads include the nose tip as a part of the head.

Accessories

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

IMPORTANT

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.

STRAIGHT SWIVEL HEAD

RIGHT-ANGLE HEAD

A Fit Locking Ring 10 over Jaw Spreader Housing 41*

(71210-02101). *See pages 24 and 25.

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

out 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 11 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.

Swivel Head Fitting Instructions

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 18). When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.

9* refers to illustrations on pages 9, 10 and 12.

Swivel Head Servicing Instructions

Accessories

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

illustration 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.

Item numbers in bold refer to Swivel Head illustrations on this page. Guard 1 refers to illustration on page 16.

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 within the table on pages 14-15.

CONSTANT COMPONENTS

ITEM DESCRIPTION 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

07494-05000

07494-03026

07494-03015 07343-02207 07495-03900 07007-00039 07345-03001 07345-03003 07345-03002 07007-00038 07342-02207

07494-03028 07346-03101 07165-00305 07494-03027 07001-00368 07345-00401

07495-03003 07004-00105 07494-03026 07495-03004 07495-03002 07343-02207 07495-03900 07007-00039 07345-03001 07345-03003 07345-03002 07007-00038 07342-02207 07343-02207 07494-03028 07346-03101 07165-00305 07494-03027

– –

07210-00804

English

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 29 explains

how to measure the stroke.

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

• Check that base cover 31 is fully tightened onto body 30.

• Stem Collector bottle: 'O'Rings 20 & 28 to be checked for wear, cleaned and lubricated with Molykote

55m

• 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 20.

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 incineration 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 26-27.

IMPORTANT

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.

Daily

Weekly

Moly Lithium Grease EP 3753 Safety Data

Molykote®55m Grease Safety Data

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.

Molykote®111 Grease Safety Data

Servicing the Tool

English

Service Kit

For an easy complete service, Avdel offers the complete service kit below.

Servicing the Tool

Maintenance

The air line 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 29.

Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 8 to 12 or if a swivel head was fitted pages 14 to 16.

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.

(Annually 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.

IMPORTANT

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.

Nose Equipment

• Unscrew Nose Casing 1 and Nose Tip.

• Remove the Nose Equipment Cartridge by sliding in the same plane to the Piston.

• Unscrew Jaw Housing 3 from the Jaw Spreader Housing ‘T’ 9 and remove Jaws 4, Jaw Spreader 5, Spring 7, Buffer 6 and Detent

Sleeve 10.

• Inspect all components. Renew all damaged or worn parts.

• Clean all parts and apply Moly Lithium Grase EP 3753 (07992-00020) to taper bore of Jaw Housing.

• Reassemble in reverse order to above.

Item numbers in bold refer to Nose Tip Tables on pages 9 and 10.

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

PART N DESCRIPTIONPART N DESCRIPTION

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

07900-00164

2 MM PIN PUNCH

CIRCLIP PLIERS

07900-00008 07900-00012 07900-00015 07900-00686 PEG SPANNER 07900-00677 SEAL EXTRACTOR 07900-00698 STOP NUT 07900-00700 PRIMING PUMP 07992-00020 GREASE - MOLYLITHIUM E.P.3753

07992-00075 GREASE - MOLYKOTE 55M

07900-00755 07900-00850 07900-00898

716 1/ x /2 SPANNER 916 5/ x /8 SPANNER 58 11/ x /16 SPANNER

GREASE - MOLYKOTE 111 PIN SPANNER VALVE HOOK

Dismantling the Tool

Servicing the Tool

Before dismantling the tool the oil must be emptied from it.

• With the air supply switched OFF at ON/OFF Valve Assembly 62 remove Bleed Screw 1 and Bonded Seal 6.

• Insert tool over a suitable container, switch air supply ON and actuate tool.

• Oil will expel from bleed screw orifice into container.

• Switch air supply OFF after all oil is expelled.

Ensure the bleed screw orifice is facing away from the person performing this operation.

• Twist and pull off Stem Collector Bottle Assembly 25. See illustration on page 7.

• Remove Stop Plate Assembly 104 by unscrewing Screws 89 2 off.

• Unscrew Retaining Nut 50.

• Pull off Bottle Adaptor Assembly 32 together with ‘O’ Rings 20 and 28.

• Remove End Cap Assembly 35 together with ‘O’ Ring 97 and Lip Seal 9.

• Remove Spring 91.

• Loosen Locknut 40 with a spanner* and unscrew Male ‘T’ Adaptor 41 together with ‘O’ Ring 12.

• With draw Vacuum Sleeve 42.

• Remove Locknut 40 together with ‘O’ Rings 19 and 15.

• Push Head Piston 36 to the rear and out of Head Assembly 58 taking care not to damage the cylinder bore

• Using circlip pliers* remove Seal Retainer 43. Push Lip Seal 8 and Bearing Tape 26 to the rear and out of Head Assembly 58 taking

care not to damage the cylinder bore.

• Remove Seal Housing 52 and Lip Seal 2.

Assemble in reverse order noting the following points:

• Place Lip Seal 8 onto the insertion rod* ensuring correct orientation. Locate the guide tube* into the head of the tool and push the

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

• The chamfered edge of Seal Retainer 43 must face forward with the gap at the bottom.

• After fitting Lip Seals 11, 10, ‘O’ Ring 18 and Bearing Tape 27 onto the Head Piston 36 ensuring correct orientation, lubricate the

cylinder bore and place the piston sleeve* into the back of Head Assembly 58. Slide the bullet* onto the threaded part of Head Piston 36 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 piston sleeve*.

• Male ‘T’ Adaptor 41 must be fully tightened onto Head Piston 36 before tightening Locknut 40 against it.

• Reprime in accordance with the instructions on page 29.

* Item included in the nG2 Service Kit. For complete list see page 20. Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

Head Assembly

English

• Remove ‘ON/OFF’ valve assembly 62.

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

• Pull off Rubber Boot 48.

• Using the peg spanner* unscrew Base Cover 31.

• Unscrew Nyloc Nuts 67 (2 off) and remove Base Plate Assembly 65.

• Remove Cylinder Liner 37 together with Sealing Washers 29 (2 off) and ‘O’ Rings 66 (2 off).

• Remove Pneumatic Piston Assembly 57 together with ‘O’ Ring 75, Lip Seal 90 (3 off) and Guide Ring 51.

• Engage the Seal Extractor* into Seal Assembly 60 and withdraw Seal Assembly from intensifier tube of the Head Assembly 58.

Assemble in reverse order to dismantling.

* Seals should be checked for damage and replaced as necessary. Lubricate pneumatic seals with Molykote

55m and hydraulic seals with

Molykote®111.

Dismantling

•

Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Piston Assembly.

• Using Spanner (07900-00672), and Location Spigot (07900-00671). Unscrew Clamp Nut 39 and remove together with Top Plate Assy 44

together with Tie Rods 56, Transfer Tube Assembly 61, ‘O’ Rings 14 and Silencer Pads 53.

• Remove tool from vice and separate Body 30 from Handle 64. Remove ‘O’ ring 17.

• Push out the Valve Seat 34, from the Body 30, together with ‘O’ Rings 14.

• Pull out Valve Spool assembly 59 from Handle 64. Remove ‘O’ Ring 7 from handle counterbore.

Assembly

Assemble in reverse order to Dismantling Instructions

• Seals should be checked for damage and replaced if necessary, lubricated with Molykote

55m grease.

• Apply Loctite

243 to Clamp Nut 39 and tighten to torque 11ftlb (14.91 Nm)

IMPORTANT

Check the tool against daily and weekly servicing.

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

* Item included in the nG2 Service Kit. For complete list see page 20. Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

Pneumatic Piston Assembly

Servicing the Tool

Air Valve

Servicing the Tool

Dismantling

• Using a 4mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger Assembly 33.

• Remove Pneumatic Piston Assembly 57 as described in Pneumatic Piston Assembly.

• Using Spanner (07900-00672), and Location Spigot (07900-00671), unscrew Clamp Nut 39 and remove together with Top Plate

Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, Seperate Body 30 from Handle 64. Remove ‘O’ Rings 16 and 17.

• Seperate Head Assembly 58 from Handle 64. NOTE ORIENTATION OF ROTARY VALVE 38

• Push out Rotary Valve 38 together with ‘O’ Rings 5.

Assemble in reverse order to Dismantling Instructions noting the following:

• Seals should be checked for damage and replaced if necessary, lubricated with Molykote

55m grease.

• Ensure Rotary Valve 38 is assembled in correct orientation to align valve pins with forks on the Trigger 33.

See illustration below.

Rotary Valve

Dismantling

• Using a 4mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger 33.

• Unscrew Trigger Valve 21 using trigger valve extractor (0900-00692).

Assemble in reverse order to Dismantling Instructions noting the following:

• When assembling Trigger 33 the trigger forks locate on the pins each side of the Rotary Valve 38.

• Ensure Rotary Valve 38 is orientated correctly. See illustration below.

Trigger

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

English

Stop Plate Assembly (71213-03900)

Servicing the Tool

Assembly (see illustration below)

• Place ‘O’ Ring 2 into the recess in Housing 5 retain in position using grease Molykote

55m.

• Assemble ‘O’ Ring 4 onto Piston 1 and push assembly into Housing 5 making sure it is in as far as it will go.

• Position the slot in Piston 1 parallel to the step face in Housing 5.

• Slide Plate Shut Off 3 into the assembled parts 1, 2, 4, and 5. Retain parts in place using grease Molykote

55m.

• Place ‘O’ Ring 4 into the recess of Cover Plate 6 retain in position using grease Molykote

55m.

• Place spring 7 into position, locate using the recesses in both Plate Shut Off 3 and Bottle Adaptor Assembly 32*.

• Position the above assembled parts onto Bottle Adaptor Assembly 32*.

• Secure in position using two Screws 89*.

*see pages 26 and 27.

1 PISTON 2 ‘O’ RING 3 PLATE SHUT OFF 4 ‘O’ RING 5 HOUSING 6 COVER PLATE 7 SPRING

ITEM DESCRIPTION

89*

32*

CLOSED

OPEN

Notes

English

General Assembly of Base Tool 71213-02000

H - H

28 11 13 91

'X'

385

104 Assy

35 Assy

25 Assy

B - B

Ring

Suspension

8920

97 32

64 Assy

Assy 59

62 Assy

Detail 'X'

HH HH

A - A

90 67 29 66

65 Assy

Assy

26 2 8

41 12 40 1,6 4352

100

Assy 33

Assy 61

Assy 57

Parts List for 71213-02000

English

111111111221111111122112212111231121111

QTY SPARES

SEAL RETAINER

TOP PLATE ASSEMBLY

SUSPENSION RING

TRIGGER PIN

RUBBER BOOT

LABEL

RETAINING NUT

GUIDE RING

SEAL HOUSING

SILENCER

TIE ROD

PNEUMATIC PISTON ASSEMBLY

HEAD ASSEMBLY

VALVE SPOOL ASSEMBLY

SEAL ASSEMBLY

TRANSFER TUBE ASSEMBLY

ON/OFF VALVE ASSEMBLY

HANDLE ASSEMBLY

BASE PLATE ASSEMBLY

'O' RING

M6 NYLOC NUT

MODIFIED COUNTER

COUNTER MOULDING

MOULDING RETAINING NUT

SPECIAL M4 SCREW

'O' RING

WASHER

CENTRE POLE MAGNET

M5 X 19 COUNTERSUNK SCREW

M5 NYLOC NUT

SCREW

LIP SEAL

SPRING

'O' RING

71210-02019

71213-02010

71210-02022

71210-02024

71210-02055

71213-02027

71213-02028

71210-03205

71210-02104

71210-02031

71211-02004

71211-03200

71213-03320

71210-03400

71210-03800

71210-03600

71210-03700

71213-02013

71221-02014

07003-00027

07002-00108

71221-20105

71221-20101

71221-20103

71221-20102

07003-00280

07002-00163

07007-01993

71221-20104

07002-00098

07001-00677

07003-00274

07490-03002

07003-00268

07003-00398

07003-00042

43444546484950515253565758596061626465666771727374757677798089909196979899

VALVE BODY

LABEL BOOK SYMBOL

TOOL INSTRUCTION MANUAL

STOP PLATE ASSEMBLY

71210-03401

07007-01503

07900-00841

71213-03900

100

103

104

11121111111131121111112111121111111111111

QTY SPARES

M5x5 HEX SOCKET BUTTON HD SCREW

LIP SEAL

'O' RING

M5 BONDED SEAL

'O' RING

LIP SEAL

'O' RING

TRIGGER VALVE

1/8" BSP PLUG

6" FLEXIBLE HOSE

3mm DIAx10mm SPIROL PIN

STEM COLLECTOR BOTTLE ASSEMBLY

BEARING TAPE - PISTON ROD

BEARING TAPE - PISTON

'O' RING

SEALING WASHER

BODY MACHINED

BASE COVER

BOTTLE ADAPTOR ASSEMBLY

TRIGGER ASSEMBLY

VALVE SEAT

END CAP ASSEMBLY

HEAD PISTON

CYLINDER LINER

07001-00405

07003-00333

07003-00127

07003-00189

07003-00194

07003-00271

07003-00273

07003-00274

07003-00275

07003-00341

07003-00277

07003-00278

07003-00281

07003-00204

07003-00287

07003-00288

07003-00342

07003-00310

07003-00415

07005-00088

07005-01274

07008-00010

07007-00224

71213-03800

71213-02021

71213-02022

07003-00416

71221-02006

71213-02001

71211-02002

71213-03000

71213-02008

71210-02009

71213-02025

71213-02121

71211-02008

71213-02000 PARTS LIST * These are minimum recommended levels of spares based on regular servicing

0102040506070809101112131415161718192021222324252627282930313233343536373839404142

ITEM PART Nº DESCRIPTION ITEM PART Nº DESCRIPTION

ROTARY VALVE

CLAMP NUT

LOCKNUT

MALE 'T' ADAPTOR

71213-02012

71210-02014

71210-02103

71213-02020

VACUUM SLEEVE

71210-02102

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 have been reduced and fasteners are not now being fully placed by one operation of the trigger.

The recommended oil for priming is Hyspin®VG32 available in 0.5 litre (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.

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

Oil Details

Hyspin®VG 32 Oil Safety Data

Priming Kit

PRIMING KIT : 07900-00688

PART Nº DESCRIPTION

07900-00351 3mm ALLEN KEY 07900-00700 PRIMING PUMP 07900-00224 4mm ALLEN KEY 07900-00698 STOP NUT 07900-OO734 STOP NUT - MAXLOK

Priming Procedure

Priming

IMPORTANT

DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 62.

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.

• Switch OFF air supply at ON/OFF Valve Assembly 62.

• Remove all nose equipment. (see page 8)

• Remove Bleed Screw 1 and Bonded Seal 6.

• Invert tool over suitable container, switch ON air supply at ON/OFF Valve Assembly 62 and actuate tool.

• Residual oil in the tools hydraulic system will empty through bleed screw orifice.

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

• Switch air supply OFF at ON/OFF Valve Assembly 62.

• Screw priming pump (07900-00700) into bleed screw port, utilising Bonded Seal 6.

• Actuate Priming Pump by pressing down and releasing several times until resistance is evident and the Head Piston starts to move

rearward.

ENSURE PUMP IS KEPT ‘SQUARE’ TO BLEED SCREW PORT DURING PRIMING OPERATION TO PREVENT BREAKAGE OF BLEED NIPPLE ON PROMING PUMP.

• Remove the priming pump, surplus oil will expel from bleed screw port.

• Replace the Bleed Screw 1 together with Bonded Seal 6.

• Switch ON air supply at ON/OFF Valve Asembly 62.

• Check that the stroke of the head piston reaches specification. If not repeat above procedure.

• Switch OFF air supply and refit nose equipment. (see page 8).

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

English

* Pages 14 to 16 if a swivel head is used instead of a nose assembly. † Page 16 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 26 and 27.

SYMPTOM POSSIBLE CAUSE REMEDY PAGE REF

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

Symptom Possible Cause Remedy Page Ref

Fault Diagnosis

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 Worn or broken jaws Fit new jaws 8 place fastener Low oil level or air in oil Prime tool 28, 29

Build up of dirt inside the nose assembly Service nose assembly 8†

Tool will not grip Worn or broken jaws Fit new jaws 8, 9, 10, 12 stem of fastener Build up of dirt inside the nose assembly Service nose assembly 8

Loose jaw housing Tighten against locking ring 8 Weak or broken spring in nose assembly Fit new spring 8, 9, 10, 12 Incorrect component in nose assembly Identify and replace 9, 10, 12

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 9, 10, 12

Weak or broken spring in nose assembly Fit new spring 9, 10, 12 Air or oil leak Tighten joints or replace components Low oil level or air present in oil Prime tool 28-29

Cannot feed next Broken stems jammed inside tool Empty stem collector 7 fastener Check jaw spreader is correct 9, 10, 12

Adjust air pressure to within specification 5

Slow cycle Low air pressure Adjust air pressure to within specification 5

Build up of dirt inside the nose assembly Service nose assembly 8†

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

Damaged trigger valve 21 Replace 23

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 28-29

+ 94 hidden pages

Avdel GENESIS NG2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual