Genesis nG1 Instruction Manual

G1

Hydro-Pneumatic Power Tool

Genesis

®

Instruction Manual

Original Instruction

1

3

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 to 12
Type 1 9

Type 1A 10
Jaw Spreader Housing 11
Type 2 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
MolyLithium Grease EP 3753 Safety Data 18
Molykote

®

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

General Assembly of Base Tool

General Assembly 26
Parts List 27

Priming

Oil Details 28
Hyspin

®

VG32 Oil Safety Data 28
Priming Kit 28
Priming Procedure 29

Fault Diagnosis

Symptom, Possible Cause and Remedy 30

Contents

LIMITED WARRANTY

Avdel makes the limited warranty that its products will be free of defects in workmanship and materials

which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product

being installed, maintained and operated in accordance with product literature and instructions, and (2)

confirmation by Avdel of such defect, upon inspection and testing. Avdel makes the foregoing limited

warranty for a period of twelve (12) months following Avdel’s delivery of the product to the direct purchaser

from Avdel. In the event of any breach of the foregoing warranty, the sole remedy shall be to return the

defective Goods for replacement or refund for the purchase price at Avdel’s option. THE FOREGOING

EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES

AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY

ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.

Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.

4

Safety Instructions

1 Do not use outside the design intent.

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

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

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

proposed modification.

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

by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel UK Limited.

procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel UK Limited.

with your training requirements.

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

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

directed to Avdel UK Limited.

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

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

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

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

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

11 The operating pressure shall not exceed 7 bar.

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

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

14 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 fluid oils and lubricants is available on request from your tool supplier.

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

Tool Specification

Specifications

5

Air Pressure Minimum - Maximum 5-7 bar

Free Air Volume Required @ 5.5 bar 1.2 litres

Stroke Minimum 14 mm

Pull Force @ 5.5 bar 6.0 kN

Cycle Time Approximately 0.9 seconds

Noise Level 75 dB(A)

Weight Including nose equipment 1.7 kg

Vibration Less than 2.5 m/s

2

30.00 DIA

104.00

282.00

104.00

123.30

120.61

90.61

150.00

54.00 DIA

82.30

22.80 DIA

93.00 DIA

SCRAP VIEW SHOWING BOTTLE

STEM COLLECTOR (SHORT VERSION)

NOTE: Stem Collector Short
Version Bottle is an accessory
part number 71213-03810

Dimensions in millimetres

Tool Dimensions

6

Intent of Use

nG1 is a hydro-pneumatic tool designed to place Avdel

®

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

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

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

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

• 71203-02000 base tool

• 71203-15000 nose assembly

• Nose tips 71210-05002 and 71210-16070. Fit nose tip
as indicated on page 8 or 9.

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

15100.

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

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON
PAGE 8.
To assist with nose equipment maintenance spanner
07900-00849 is supplied with the base tool.

FASTENER

NAME

MM

IN

FASTENER SIZE ( )

AVEX

®

STAVEX

®

AVINOX®II
AVIBULB

®

BULBEX

®

T-LOK

®

AVDEL® SR

ETR
N RIVET
Q RIVET

*

AVSEAL®II

3 3.2 4.0 4.3 4.8 5 5.2 6 6.5 7

–1/

8

2.4

3

/

5

/

3232

–3/16–––––

COMPLETE TOOL

71203-00 . . .

*

BASE TOOL

1

1

2

3

1

NOSE ASSEMBLY

NOSE TIP

2

71203-02000

71203-15000

or 71213-15000

see note 3

2

3

++=

3

1

n

1

n

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

These nose assemblies will allow placing of fasteners by simply selecting the appropriate nose tip from the
range of Type 1 or 1A Nose Tips. Other nose assemblies are available for applications with restricted
access and special fasteners. See table page 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

* For Avseal

®

equipment refer to separate Data Sheet 07900-00840.

7

8

6

4

2

0

10

12

14

16

TAKE OFF POINT
FROM
MAIN SUPPLY

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR OR LUBRICATION UNITS)

MAIN SUPPLY

DRAIN POINT

AIR LUBRICATION

PERMISSABLE

PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)

3 METRES MAXIMUM

G1

• 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 air supply prior
to removing the collector bottle.

Putting into Service

Air Supply

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.

Lift Trigger to
cut-off the
vacuum air
supply.

Do not use tool when Stem

Collector Bottle is removed

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

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

1

/4 inch.

8

Nose Assemblies

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

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

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

• Any worn or damaged part should be replaced.

• Clean and check wear on jaws.

• Ensure that the jaw spreader is not distorted.

• Check Spring 7 is not distorted.

• Assemble according to ‘Fitting Instructions’ above.

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

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 3 Nose Tip tables (pages 9, 10 and 12).

• Lightly coat Jaws 4 with MolyLithium grease*.

• Drop Jaws 4 into Jaw Housing 3.

• Insert Jaw Spreader 5 into Jaw Housing 3.

• Locate Buffer 6 on Jaw Spreader 5.

• Locate Spring 7 onto Jaw Spreader 5.

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

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

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

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

• Utilising the ‘T’ section profiles assemble Nose Assembly onto the tool piston via the Male ‘T’ Adaptor 40 - pages 26-27.

Not applicable to Type ‘2’ Nose Assemblies.

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

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

Fitting Instructions

Servicing Instructions

Nose Tips

Nose Assemblies

9

IMPORTANT

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

A tool (except part number 71203-00039) must always be fitted with the correct nose assembly and nose tip for your fastener but if you wish to
order a nose assembly or a nose tip separately, refer to the ‘NOSE TIPS’ table below and on pages 10 and 12.

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

Dimensions ‘A’ and ‘B’ below will help you assess the suitability of a particular nose tip.

You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted Type ‘2’ Nose Tips
are available for some fasteners. Refer to the table on page 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 71203-00039
complete tool, it is important that you check that the nose tip already fitted to the nose assembly is the correct one to place your fastener by sliding
the fastener stem into the nose tip. No force should be required and play should be minimal.

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

1

In inches then in millimetres.

2

Head forming nose tips for use with countersunk heads

ONLY.

TYPE 1

NOSE TIPS

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

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

1

/

8

1

/

8

1

/

8

–

5

/

32

5

/

32

5

/

32

1

/

8

1

/

8

1

/

8

5

/

32

1

/

8

1

/

8

1

/

8

3

/

32

4.8

3.3

2.9

4.8

3.3

3.3

3.3

3.3

3.3

4.8

3.3

3.3

3.3

4.8

3.3

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

12.7

71210-05002
71210-16070

07340-06401

2

71210-05002
71210-16070

07340-06501

2

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

3.2

3.2

3.2

3.0

4.0

4.0

4.0

3.2

3.2

3.2

4.0

3.2

3.2

3.2

2.4

AVEX

®

BULBEX

®

AVINOX® II
AVIBULB

®

AVDEL® SR

STAVEX

®

Q RIVET
N RIVET

…039*
…039*

…003
…039*
…039*

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

…033

A

B

*

Complete tool part number 71203-00039 does
not only include the 71203-15000 nose assembly
below but also the followin g two nose tips:
71210-0500 2 and 71210-1607 0 making up a
nose assembly kit part number 71203-15100.

Use

the nose tip listed in the table.

Note:

Alternative spring 07498-04301 should be fitted if
stem jammin g occure s when installin g smal l
diameter fasteners.

*

Items 3-11 availabl e as cartridg e assembl y
71203-20320

COMPLETE TOOL

PART NUMBER :

precede with 71203-00.

* See top left

NOSE ASSEMBLY

part nº 71203-15000

(+ 2nose tips above = 71203-15100)

ITEM DESCRIPTION PART Nº

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

1

2

3

4

5

6

7

10

11

9

8

Nose Tips

Nose Assemblies

10

1

In inches then in millimetres.

2

Head forming nose tips for use with countersunk heads

ONLY.

TYPE 1A

NOSE TIPS

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

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

5

/

32

3

/

16

3

/

16

3

/

16

3

/

16

-

5

/

32

5

/

32

5

/

32

5

/

32

2.8

2.8

3.3

4.1

2.8

3.3

2.8

2.8

2.8

3.3

12.7

12.7

19.0

12.7

12.7

12.7

12.7

12.7

12.7

12.7

07381-04701
07381-04701
07340-04800

07340-06601

2

07381-04701
07340-06201
07381-04701
07381-04701
07381-04701
07340-06201

4.0

4.8

4.8

4.8

4.8

4.3

4.0

4.0

4.0

4.0

AVEX

®

Large flange

BULBEX

®

T-LOK®
AVIBULB

®

STAVEX

®

Q RIVET

…020
…020
…016
…015
…020
…120
…020
…020
…020
…120

A

B

*

Items 3-11 availabl e as cartridg e assembl y

71213-20320

COMPLETE TOOL

PART NUMBER :

precede with 71203-00.

NOSE ASSEMBLY

part nº 71213-15000

ITEM DESCRIPTION PART Nº

1 TAPERED NOSE CASING 71213-00350
2 'O' RING 07003-00067
3 JAW HOUSING TAPERED 71210-15902*
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 'T' 71210-20321*
10 DETENT SLEEVE 71210-20322*
11 'O' RING 07003-00277*

1

2

3

4

5

6

7

10

11

98

Nose Assemblies

11

Nose Tips

40

11

35

41

39

• 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 Nose Assembly)

• The Jaw Spreader Housing 9* must be tightened onto Head Piston 35 trapping Vacuum Sleeve 41 finally tighten

Locknut 39 against Jaw Spreader Housing 9*.

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

To fit Nose Tip Type 2 or Nose Extension, the Male ‘T’ Adaptor 40 must be replaced with Jaw Spreader Housing 9*.

• Loosen Locknut 39 using 16mm AF Spanner.

• Unscrew and remove Male ‘T’ Adaptor 40 together with ‘O’ Ring 11.

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

9*

10* or 11*

35

41

Jaw Spreader Housing

Nose Assemblies

12

Nose Tips

1

In inches then in millimetres.

COMPLETE TOOL

PART NUMBER :

precede with

71203-00

NOSE ASSEMBLY

part nº 71210-15200

A

B

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

TYPE 2

NOSE TIPS

8 7 6 5 4239&10

1

58.3

22.9

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

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

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

5

/

32

3

/

16

-

1

/

8

5

/

32

1

/

8

5

/

32

1

/

8

5

/

32

5

/

32

12.95

11.4

11.4

10.0

10.0

11.4

10.0

10.0

11.4

10.0

11.4

10.0

11.4

10.0

10.0

9.5

9.5

9.5

12.7

12.7

9.5

12.7

12.7

9.5

12.7

9.5

12.7

9.5

12.7

12.7

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

3.2

3.2

4.0

4.0

4.8

4.0

4.8

4.3

3.2

4.0

3.2

4.0

3.2

4.0

4.0

AVEX

®

BULBEX

®

T-LOK

®

STAVEX

®

AVIBULB

®

ETR

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

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

To fit Nose Tip Type 2 remove Male ‘T’ Adaptor 40 and replace with Jaw Spreader Housing 9* and ‘O’ Ring 10*.

Remove Male ‘T’ Adaptor 40 from the Tool (see page 11) and replace with
Jaw Spreader Housing 9* (71210-02101) and ‘O’ Ring 10*.

10 9

9* and 10* refer to the illustrations on this page. Item 40 refer to pages 26 and 27.

13

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

• Push the assembled Stem Deflector and Adaptor over Bottle

Adaptor Assembly 31 and align with the cut-out feature.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
9* refers to illustrations on pages 11 and 12.

INNER

OUTER

ADAPTOR
71213-20101

STEM DEFLECTOR

07340-00342

SEALED NUT

71213-02200

STEM DEFLECTOR: 71213-20100

EXTENSION - ‘T’ ADAPTOR 71213-12000

EXTENSION - NON QUICK RELEASE 71210-20300

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 extension onto Head Assembly 50.

• Fit the nose assembly onto the extension.

• Loosen Locknut 39 using

16mm AF Spanner.

• Unscrew and remove both

Male ‘T’ Adaptor 40 and
Locknut 39.

• Replace Locknut 39 with

‘Sealed Nut’ 71213-02200,
screw ‘Sealed Nut’ onto Head
Piston 35 to disable Vacuum
System.

• Male ‘T’ Adaptor 40 must be

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

• Remove the Stop Plate

Assembly (page 24) by
unscrewing Screws 63 (2off).

Stem Deflector

Accessories

Extension

Preparing the Base Tool for use with Stem Deflector

40

39

35

07340-00342

STEM DEFLECTOR

71213-20101

ADAPTOR

The air line must be disconnected before any servicing or dismantling.
‘Sealed Nut’ 71213-02200 replaces Locknut 39 (to cut-off air supply to Vacuum System) as follows:

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:

14

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.

1

In inches then in millimetres.

2

Long nose tip for deep placing.

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)SWIVEL HEAD

PART Nº

JAWS

see

below

'A' 'B'NAME

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

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

5

/

32

3

/

16

1

/

8

5

/

32

1

/

8

5

/

32

1

/

8

5

/

32

–
–
–

–

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

1.95

4.11

2.00

4.11

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

6.35

6.35

7.62

7.62

07345-03000
07345-03100
07345-03100
07345-03200
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07494-06000
07494-06600
07494-06100
07494-06700

PART Nº

07340-00213
07340-00213
07340-00213
07490-04602
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07340-00213
07340-00213
07340-00213

PART Nº

07345-03600
07345-03700
07345-03700
07345-03800
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
07494-06001

07494-06601

2

07494-06101

07494-06701

2

3.2

3.2

4.0

4.0

4.8

4.0

4.8

3.2

4.0

3.2

3.2

4.0

4.0

4
4
5
5

AVEX

®

BULBEX

®

AVINOX®II

STAVEX

®

AVSEAL®II

…001
…004
…004
…010
…010
…004
…010
…004
…010
…004
…010
…004
…010
…160
…180
…161
…181

COMPLETE TOOL PART NUMBER :

precede with 71203-30

(the stop nut and safety cap are included)

IMPORTANT: by opposition to complete tools

with nose assemblies, those fitted with swivel heads

include the nose tip as a part of the head.

STRAIGHT SWIVEL HEAD capability

A

B

360• rotation

56

92

6

20

Remove Male ‘T’ Adaptor 40 from the Tool (see pages 11 and 15) and replace with
Jaw Spreader Housing (71210-02101).

15

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)SWIVEL HEAD

PART Nº

JAWS

see

below

'A' 'B'NAME

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

1

/

8

1

/

8

5

/

32

5

/

32

3

/

16

5

/

32

3

/

16

1

/

8

5

/

32

–
–
–
–

1

/

8

5

/

32

1

/

8

5

/

32

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

3.81

1.95

4.11

2.00

4.11

3.81

3.81

3.81

3.81

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

7.87

6.35

6.35

7.62

7.62

7.87

7.87

7.87

7.87

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

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

PART Nº

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

71213-16402

2

71213-16403

71213-16404

2

07345-03700
07345-03800
07345-03700
07345-03800

3.2

3.2

4.0

4.0

4.8

4.0

4.8

3.2

4.0

4
4
5
5

3.2

4.0

3.2

4.0

AVEX

®

BULBEX

®

AVINOX

®

II

AVSEAL

®

II

STAVEX

®

…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010

RIGHT-ANGLE SWIVEL HEAD capability

1

In inches then in millimetres.

2

Long nose tip for deep placing.

COMPLETE TOOL PART NUMBER :

precede with 71203-40

(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.

7.6

32

20

52

56

74

97

A

B

360• rotation

07346-03100
07346-03200
07346-03100
07346-03200

40 11 39 48

18

14

35

View with 24 removed
and stop nut
replacing removed
items 14, 18, 39, 48 and 40

71213-20200

STOP NUT

71213-20201

SAFETY CAP

• Disconnect the air supply.

• Remove any nose assembly items.

• Remove Stem Collector Bottle Assembly

24 (71213-03800).

• Replace assembly 24 with Safety Cap

(71213-20201)

• Unscrew Male ‘T’ Adaptor 40 and remove

with ‘O’ Ring 11, Locknut 39, ‘O’ Rings 18
and 14, and Seal Housing 48. Do not refit
these items.

• Screw Stop Nut (71213-20200) onto the

front of Head Piston 35 as far as it will go
by hand.

• Fit Jaw Spreader Housing (71210-02101)

and ‘O’ Ring 11, tighten onto Head Piston
35, finally tighten Stop Nut against Jaw

Spreader Housing.

The tool is now ready to be fitted with a swivel
head. Instructions page 16.

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

27.

Base tool to receive a nose assembly

Base tool to receive a swivel head

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

Accessories

Remove Male ‘T’ 40 Adaptor from the Tool and replace with Jaw Spreader Housing
(71210-02101) See ‘Preparing the Base Tool’ above and page 11.

16

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 page 15.

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

16

1

3

12

14

13

16

6

5

21

22

11

7

9

8

8

8

10

17

18

19

20

STRAIGHT SWIVEL HEAD

2

1

15

9

8

8

10

7

11

17

23

18

19

20

3

16

16

4

12

14

13

6

6

5

RIGHT-ANGLE HEAD

A Fit Locking Ring 10 over Jaw Spreader Housing 9*

(71210-02101). *See pages 11 and 12.

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 MolyLithium 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 11 and 12.

Swivel Head Servicing Instructions

Accessories

5

7

17

18

19

20

Swivel heads should be serviced at weekly intervals.

• Remove the complete head using the reverse procedure to

the ‘Fitting instructions’ omitting step ‘L’.

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

one.

• Any worn or damaged parts should be replaced.

• Pay particular attention to jaw carrier items in the upper

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 the tables on pages 14 and 15.

17

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
07346-03102
07494-03028
07346-03101
07165-00305
07494-03027

-

-

07210-00804

CONSTANT COMPONENTS

18

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 a swivel head is fitted.

• Check that Base Cover 30 is fully tightened onto Body 29.

• Stem Collector Bottle: ‘O’ Rings 19 and 27 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 MolyLithium 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

2

, 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 oxidizing agent.

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

MolyLithium Grease EP 3753 Safety Data

19

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

FLASH POINT: Above 101.1°C. (closed cup)

Explosive Properties: No

Suitable Extinguishing Media: Carbon Dioxide, Foam, Dry Powder or fine water spray.

Water can be used to cool fire exposed containers.

Environment

No adverse effects are predicted.

Handling

General ventilation is recommended. Avoid eye contact.

Storage

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

Molykote®111 Grease Safety Data

Servicing the Tool

20

Service Kit

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

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 LOCATION SPIGOT
07900-00684 GUIDE TUBE
07900-00685 INSERTION ROD
07900-00351 3 mm ALLEN KEY
07900-00469 2.5 mm ALLEN KEY
07900-00158 2 mm PIN PUNCH
07900-00164 CIRCLIP PLIERS
07900-00008

7

/

16

î

x 1/

2

”

SPANNER

07900-00012

9

/

16

”

x 5/

8

”

SPANNER

07900-00015

5

/

8

”

x 11/

16

”

SPANNER
07900-00686 PEG SPANNER
07900-00677 SEAL EXTRACTOR
07900-00698 STOP NUT
07900-00700 PRIMING PUMP
07992-00020 GREASE - MOLYLITHIUM E.P.3753
07992-00075 GREASE - MOLYKOTE

®

55m

07900-00755 GREASE - MOLYKOTE

®

111
07900-00850 PIN SPANNER
07900-00898 VALVE HOOK
07900-00224 4 mm ALLEN KEY
07900-00734 STOP NUT - MAXLOK

®

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 five 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 MolyLithium Grease 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.

21

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 53 remove Bleed Screw 1 and Bonded Seal 5.

• 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 24. See illustration on page 7.

• Remove Stop Plate Assembly 69 by unscrewing Screws 63 2 off.

• Unscrew Retaining Nut 47.

• Pull off Bottle Adaptor Assembly 31 together with ‘O’ Rings 19 and 27.

• Remove End Cap Assembly 34 together with ‘O’ Rings 65 and Lip Seal 8.

• Remove Spring 64.

• Loosen Locknut 39 with a spanner* and unscrew Male ‘T’ Adaptor 40 together with ‘O ’ Ring 11.

• Withdraw Vacuum Sleeve 41.

• Remove Locknut 39 together with ‘O’ Rings 18 and 14.

• Push Head Piston 35 to the rear and out of Head Assembly 50 taking care not to damage the cylinder bore.

• Using circlip pliers* remove Seal Retainer 42. Push Lip Seal 7 and Bearing Tape 25 to the rear and out of Head Assembly 50 taking

care not to damage the cylinder bore.

• Remove Seal Housing 48 and Lip Seal 2.

Assemble in reverse order noting the following points:

• Place Lip Seal 7 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 42 must face forward with the gap at the bottom.

• After fitting Lip Seals 10, 9, ‘O’ Ring 17 and Bearing Tape 26 onto the Head Piston 35 ensuring correct orientation, lubricate the

cylinder bore and place the piston sleeve* into the back of Head Assembly 50. Slide the bullet* onto the threaded part of Head Piston
35 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 40 must be fully tightened onto Head Piston 35 before tightening Locknut 39 against it.

• Reprime in accordance with the instructions on page 29.

* Item included in the 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

22

• Remove ‘ON/OFF’ Valve Assembly 53.

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

• Pull off Rubber Boot 28.

• Using the peg spanner* unscrew Base Cover 30.

• Remove Cylinder Liner 36.

• Remove Pneumatic Piston Assembly 49 together with ‘O’ Ring 57, Lip Seal 56 and Guide Ring 58.

• Engage the Seal Extractor* into Intensifier Seal Assembly 54 and withdraw Seal Assembly from intensifier tube of the Head Assembly 50.

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 49 as described above in Pneumatic Piston Assembly.

• Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706). Unscrew Clamp Nut 38 and remove together with Clamp

Plate 43 together with Transfer Tube Assembly 52, Valve Rod Assembly 55 and ‘O’ Rings 13.

• Remove tool from vice and separate Body 29 from Handle Assembly 70. Remove ‘O’ Ring 16.

• Push out the Valve Seat 33, from the Body 29, together with ‘O’ Rings 13.

• Pull out Valve Spool Assembly 51 from Handle Assembly 70. Remove ‘O’ Ring 6 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 38 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 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

23

Servicing the Tool

Dismantling

• Using a 2mm pin punch (07900-00158) drive Trigger Pin 45 out and remove Trigger Assembly 32.

• Remove Pneumatic Piston Assembly 49 as described in Pneumatic Piston Assembly page 22.

• Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706), unscrew Clamp Nut 38 and remove together

with Clamp Plate 43 together with Transfer Tube Assembly 52 and seperate Body 29 from Handle Assembly 70. Remove ‘O’
Rings 15 and 16.

• Seperate Head Assembly 50 from Handle Assembly 70. NOTE ORIENTATION OF ROTARY VALVE 37.

• Push out Rotary Valve 37 together with ‘O’ Rings 4.

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 37 is assembled in correct orientation to align valve pins with forks on the Trigger Assembly 32.

See illustration below.

Rotary Valve

Dismantling

• Using a 2mm pin punch (07900-00158) drive Trigger Pin 45 out and remove Trigger Assembly 32.

• Unscrew Trigger Valve 20 using trigger valve extractor (07900-00692).

Assemble in reverse order to Dismantling Instructions noting the following:

• When assembling Trigger Assembly 32 the trigger forks locate on the pins each side of the Rotary Valve 37.

• Ensure Rotary Valve 37 is orientated correctly. See illustration below.

Trigger

37

32

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

24

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 31*.

• Position the above assembled parts onto Bottle Adaptor Assembly 31*.

• Secure in position using two Screws 63*.

*see pages 26 and 27.

2

1

3

4

4

5

6

7

31*

63*

1 PISTON

2 ‘O’ RING

3 PLATE SHUT OFF

4 ‘O’ RING

5 HOUSING

6 COVER PLATE

7 SPRING

ITEM DESCRIPTION

CLOSED

OPEN

25

Notes

26

General Assembly of Base Tool 71203-02000

B - B

374

B

B

40 11 39 1,5 42

48

Assy

50

2 7

16

70 Assy

20

45

Assy 32

41

18

14

34 Assy

35

8

64

12

27 10

9

'X'

25

6319

69 Assy

24 Assy

47

13

33

13

6

61

59

Assy 51

62

60

3

21

13

22

43

53 Assy

23

65 31

66

3

Suspension

Ring

A - A

44

Detail 'X'

26

17

16

15

54 Assy

58

38

46

29

57

30

28

49

52 Assy

55 Assy

36

43

56

A

A

27

Parts List for 71203-02000

28

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 (part number 07992-

00006) containers. Please see safety data below.

First Aid

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

Fire

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

2

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

Environment

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

Handling

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

Storage

No special precautions.

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

PART Nº DESCRIPTION

PRIMING KIT : 07900-00688

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

®

Oil Details

Hyspin®VG32 Oil Safety Data

Priming Kit

29

Priming Procedure

Priming

IMPORTANT

DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE SPOOL 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 53.

• Remove all nose equipment. (see page 8)

• Remove Bleed Screw 1 and Bonded Seal 5.

• Invert tool over suitable container, switch ON air supply at ON/OFF Valve Assembly 53 and actuate tool.

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

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 53.

• Screw priming pump (07900-00700) into bleed screw port, utilising Bonded Seal 5.

• 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 PRIMING PUMP.

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

• Replace the Bleed Screw 1 together with Bonded Seal 5.

• Switch ON air supply at ON/OFF Valve Assembly 53.

• 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).

• Check that the stroke of the tool meets the minimum specification of 14 millimetres. To chech the stroke, measure the distance

between the front face of the jaw spreader housing and the front 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 26 and 27.

30

* 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 20 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 UK Limited.

Low oil level or air present in oil Prime tool 28-29

31

Declaration of Conformity

We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY

declare under our sole responsibility that the product:

Model nG1

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

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

EN ISO 12100 - parts 1 & 2

BS EN ISO 8662 - part 6 BS EN ISO 11202

BS EN ISO 3744 BS EN 982

ISO EN 792 part 13 - 2000 BS EN 983

following the provisions of the Machine Directive 2006/42/EC

This box contains a power tool which is in
conformity with Machines Directive
2006/42/EC. The ‘Declaration of Conformity’
is contained within.

A. Seewraj - Product Engineering Manager - Automation Tools

Date of issue

Since 1 936 2010 Since 1922

www.avdel-global.com
www.infastech.com

02.2011 • © 2010 Infastech

Autosert® (equipment), Avbolt®, Avdel®, Avdelmate®, Avdel TX2000®, Avdelok®, Avex®, Avibulb®, Avinox®, Avinut™, Avlug®, Avmatic®, Avplas®,

Avseal

®

, Avsert®, Avtainer®, Avtronic®, Briv®, Bulbex®, Chobert®, Eurosert®, Fastriv®, Finsert®, Genesis®, Grovit®, Hemlok®, Hexsert®, Holding

your world together

®

, Hydra®, Interlock®, Klamp-Tite®, Klamptite KTR®, Kvex®, Maxlok®, Monobolt®, Monobulb®, Neobolt®, Nutsert®, Nutsert

SQ

®

, Portariv®, Rivmatic®, Rivscrew®, Speed Fastening®, Squaresert®, Stavex®, Supersert®, Thin Sheet Nutsert®, Titan®, T-Lok®, TLR®, TSN®,

TX2000

®

, Versa-Nut®, Viking® and Viking 360® are trademarks of Avdel UK Limited. Infastech™ and Our Technology, Your Success™ are
trademarks of Infastech Intellectual Properties P te Ltd. The names and logos of other companies mentioned herein may be trademarks
of their respective owners. This document is for informational purposes only. Infastech makes no warranties, expressed or implied, in this
document. Data shown is subject to change without prior notice as a result of continuous product development and improvement policy.
Your local Avdel representative is at your disposal should you need to confirm latest information.

AUSTRALIA
Infastech (Australia) Pty Ltd.

891 Wellington Road
Rowville
Victoria 3178
Tel: [phone]
Fax: [phone]
[e-mail]

CANADA
Avdel Canada Limited

1030 Lorimar Drive
Mississauga
Ontario L5S 1R8
Tel: [phone]
Fax: [phone]
[e-mail]

CHINA
Infastech (China) Ltd.

RM 1708, 17/F., Nanyang Plaza,
57 Hung To Rd., Kwun Tong
Hong Kong
Tel: [phone]
Fax: [phone]
[e-mail]

FRANCE
Avdel France S.A.S.

33 bis, rue des Ardennes
BP4
75921 Paris Cedex 19
Tel: [phone]
Fax: [phone]
[e-mail]

GERMANY
Avdel Deutschland GmbH

Klusriede 24
30851 Langenhagen
Tel: [phone]
Fax: [phone]
[e-mail]

INDIA
Infastech Fastening Technologies
India Private Limited

Plot No OZ-14, Hi Tech SEZ,
SIPCOT Industrial Growth Center,
Oragadam, Sriperumbudur Taluk,
Kanchipuram District,
602105 Tamilnadu
Tel: [phone]
Fax: [phone]
[e-mail]

ITALY
Avdel Italia S.r.l.

Viale Lombardia 51/53
20047 Brugherio (MI)
Tel: [phone]
Fax: [phone]
[e-mail]

JAPAN
Infastech Kabushiki Kaisha

Center Minami SKY,
3-1 Chigasaki-Chuo, Tsuzuki-ku,
Yokohama-city,
Kanagawa Prefecture
Japan 224-0032
Tel: [phone]
Fax: [phone]
[e-mail]

MALAYSIA
Infastech (Malaysia) Sdn Bhd

Lot 63, Persiaran Bunga Tanjung 1,
Senawang

Industrial Park
70400 Seremban
Negeri Sembilan
Tel:

[phone]
Fax: [phone]
[e-mail]

SINGAPORE
Infastech (Singapore) Pte Ltd.

31 Kaki Bukit Road 3
#05-03/06 Techlink
Singapore, 417818
Tel: [phone]
Fax: [phone]
[e-mail]

SOUTH KOREA
Infastech (Korea) Ltd.

212-4, Suyang-Ri,
Silchon-Eup, Kwangju-City,
Kyunggi-Do, Korea, 464-874
Tel: [phone]
Fax: [phone]
[e-mail]

SPAIN
Avdel Spain S.A.

C/ Puerto de la Morcuera, 14
Poligono Industrial Prado Overa
Ctra. de Toledo, km 7,8
28919 Leganés (Madrid)
Tel: [phone]
Fax: [phone]
[e-mail]

TAIWAN
Infastech/Tri-Star Limited

No 269-7, Baodong Rd,
Guanmiao Township,
71841 Tainan County,
Taiwan, R.O.C
Tel:

[phone] (ext 201)
Fax: [phone]
[e-mail]

UNITED KINGDOM
Avdel UK Limited

Pacific House
2 Swiftfields
Watchmead Industrial Estate
Welwyn Garden City
Hertfordshire AL7 1LY
Tel: [phone]
Fax: [phone]
[e-mail]

USA
Avdel USA LLC

614 NC Highway 200 South
Stanfield, North Carolina 28163
Tel: [phone]
Fax: [phone]
[e-mail]

Manual No. Issue Change Note No.

B 07/044

B2 07/103

B3 07/174

C 11/017

07900-00843