Greenlee G3 User Manual
Hydro-Pneumatic Power Tool
Genesis
®
Instruction Manual
Inc.
model
Textron Fastening Systems Inc. is a wholly owned subsidary of Textron Inc.
G3
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 - 12
Type 1 Standard 9
Avseal®II Nose Tips 10
Type 2 Limited Access 11
Type 3 Aerospace 11
Type 4 Monobolt
® -
Extended 12
Type 5 Avtainer
®
12
Type 6 Monobolt
® -
Interlock
®
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
Textron Fastening Systems Inc 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
TFS makes the limited warranty that it’s 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 TFS of such defect, upon inspection and
testing. TFS makes the foregoing limited warranty for a period of twelve (12) months following
TFS’ delivery of the product to the direct purchaser from TFS. 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 TFS’ 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 TFS.
Contents
Inc.
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 Textron Fastening Systems Inc.
3 Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Textron
Fastening Systems Inc. or their representatives, shall be the customer’s entire responsibility. Textron Fastening Systems Inc. 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 Textron Fastening Systems
Inc. procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Textron
Fastening Systems Inc. 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 Textron Fastening Systems.
6 The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
7 Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8 Do not operate a tool/machine that is directed towards any person(s) or the operator.
9 Always adopt a firm footing or a stable position before operating the tool/machine.
10 Ensure that vent holes do not become blocked or covered.
11 The operating pressure shall not exceed 7 bar.
12 Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise.
13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.
14 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 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.
Inc.
Tool Specification
Specifications
5
Air Pressure Minimum - Maximum 5-7 bar (72.5 - 101.5 psi)
Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cuft)
Stroke Minimum 26 mm (1.02 in)
Pull Force @ 5.5 bar 12.9 kN (2900 lbf)
Cycle Time Approximately 1.2 seconds
Noise Level 75 dB(A)
Weight Including nose equipment 2.25 Kg
Vibration Less than 2.5 m/s
2
(8.2 ft/s2 )
Dimensions in millimetres
Tool Dimensions
Note: Stem Collector Short
Version Bottle is an accessory
part number 71213-03810.
Inc.
6
Intent of Use
nG3 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.
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 and 27. If a swivel head is fitted, the same base tool must be adapted. See details pages 14-15.
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 pages 11 and 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 11. A nose assembly can be
substituted by a swivel head (see pages 14 and 15). In this case the nose tip is part of the swivel head.
* ADD 3 DIGITS FROM THE
LAST COLUMN OF A NOSE
TIP TABLE ON PAGE 9 - 12.
FOR TOOLS WITH SWIVEL
HEADS USE TABLE PAGES 14-
15.
Range of Fasteners
Part Numbering
FASTENER
NAME
®
AVEX
®
STAVEX
®
AVINOX
ETR
T-LOK
®
TLR
AVDEL
®
MBC
™ RIVET
™ RIVET
®
®
®
®
®
®
®
®
AVIBULB
BULBEX
AVDEL® SR
MONOBOLT
INTERLOCK
AVTAINER
MBC/LC
AVSEAL®II
Q
T
CHERRYMATE™
KLAMPTITE™
FASTENER SIZE ( )
3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10
–1/85/32 –3/16 –– –1/4 –– ––3/8 –
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
MM
IN
●
●
●
●
●
●
●
● ●●●●
●
●
●
●
●
1
BASE TOOL
1
71223-02000
2
NOSE ASSEMBLY
2
71210-15000
3
see note 3
Inc.
NOSE TIP
1
2
++=
3
COMPLETE TOOL
71223-00 . . .
3
*
7
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.
• 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.
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.
Do not use tool when Stem
Collector Bottle is removed
OF FILTER/REGULATOR OR LUBRICATION UNITS)
3 METRES MAXIMUM
STOP COCK
(USED DURING MAINTENANCE
10
8
6
12
4
14
2
16
0
TAKE OFF POINT
FROM
MAIN SUPPLY
MAIN SUPPLY
DRAIN POINT
AIR LUBRICATION
PERMISSABLE
PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)
Lift Trigger to
cut-off the
vacuum air
supply.
Inc.
8
Nose Assemblies
* Item included in the nG3 Service Kit. For complete list see page 20.
Fitting Instructions
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A complete tool must always be fitted with the correct nose assembly and nose tip for your fastener and must be ordered separately,
refer to the ‘NOSE TIPS’ tables on pages 9 to 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 or Avtainer
®
fasteners a Type 5 Nose Tip.
Dimensions ‘A’ and ‘B’ in the following Nose Tip tables will help you assess the suitability of a particular nose tip.
You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted Type
‘2’ Nose Tips are available for some fasteners. Refer to the table on page 11.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool.
The Type 4 Nose Tip is an alternative to place
1
/4 in Monobolt®. Refer to the table on page 12.
Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required.
See pages 14 to 17 in the ‘Accessories’ section.
Nose assemblies should be serviced at weekly intervals. You should hold some stock of all internal components of the nose assembly and
nose tips as they will need regular replacement.
• Remove the nose equipment using the reverse procedure to the ‘Fitting instructions’.
• Any worn or damaged part should be replaced.
• Clean and check wear on Jaws.
• Ensure that neither the Jaw Spreader nor the Front Spring Guide is distorted.
• Check Spring 7 is not distorted.
• Assemble according to fitting instructions above.
IMPORTANT
The air supply must be disconnected when fitting or removing nose assemblies.
Item numbers in bold refer to nose assembly components in all 5 nose tip tables.
• Lightly coat Jaws 4 with Moly Lithium grease*.
• Drop Jaws 4 into Jaw Housing 3 or Chuck Collet 9 depending on which nose assembly you are using.
• Insert Jaw Spreader 5 into Jaw Housing 3 or insert Front Spring Guide 10 into Chuck Collet 9.
• Locate Buffer 6 on Jaw Spreader 5.
• Locate Spring 7 onto Jaw Spreader 5 or onto Front Spring Guide 10.
• Screw Rear Spring Guide 11 into Chuck Collet 9.
• Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool.
• Holding tool pointing down, screw the assembled Jaw Housing or Chuck Collet onto the Jaw Spreader Housing and tighten with spanner*.
• Screw the nose tip into Nose Casing 1 and tighten with spanner*.
• Place Nose Casing 1 over Jaw Housing 3 or Chuck Collet 9 and screw onto the tool, tightening with spanner*.
Servicing Instructions
Inc.
Nose Tips
Nose Assemblies
9
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
TYPE 1
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15000
FASTENER
MATERIAL
Ø
1
NOSE TIP (mm)
see
below
PART Nº 'A' 'B'NAME
Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Steel
Al Alloy
Al Alloy
Any
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
Any
Any
Steel
Steel
Steel
Steel
Steel
Stainless Steel
Stainless Steel
Stainless Steel
Any
Any
Any
Any
Any
Any
Any
Any
Al Alloy
Al Alloy
Al Alloy/Steel
Al Alloy/Steel
Al Alloy
Al Alloy
Al Alloy/Steel
Al Alloy/Steel
1
/
8
1
/
8
1
/
8
–
5
/
32
5
/
32
5
/
32
3
/
16
3
/
16
3
/
16
3
/
16
1
/
4
3
/
16
5
/
32
3
/
16
3
/
16
1
/
4
1
/
8
5
/
32
3
/
16
–
3
/
16
1
/
8
5
/
32
3
/
16
–
1
/
8
5
/
32
3
/
16
3
/
16
1
/
4
3
/
16
1
/
8
5
/
32
3
/
16
3
/
16
3
/
16
1
/
8
5
/
32
3
/
16
1
/
8
5
/
32
3
/
16
1
/
4
3
/
16
1
/
4
3
/
16
1
/
4
3
/
16
3
/
16
3
/
16
3
/
16
1
/
4
1
/
4
1
/
4
1
/
4
4.8
3.3
2.9
6.35
3.3
2.8
3.3
2.8
3.3
3.3
4.1
3.3
4.1
3.3
2.8
4.1
4.4
3.3
2.8
4.8
3.3
3.3
3.3
2.8
4.8
3.3
6.35
3.3
5.7
5.7
3.3
2.8
3.3
2.8
2.8
3.3
2.8
3.3
2.8
2.8
6.35
3.3
3.3
3.3
3.3
3.3
4.8
4.8
6.35
6.35
6.35
6.35
6.65
6.65
6.65
6.65
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
19.0
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
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
19.0
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
12.7
12.7
12.7
12.7
12.7
71210-05002
71210-16070
07340-06401
2
71210-05002
71210-16070
07381-04701
07340-06501
2
07381-04701
07340-04800
07490-04401
07340-06601
2
07612-02001
71210-16020
71210-16070
07381-04701
07605-00220
71220-16080
71210-16070
07381-04701
07498-01401
07340-06201
07340-06201
71210-16070
07381-04701
07498-01401
07612-02001
71210-05002
71210-16070
07348-07001
71210-16050
71220-60001
07381-04701
71210-16070
07381-04701
07381-04701
07340-04800
07381-04701
71210-16070
07381-04701
07381-04701
71210-05002
07340-06201
07340-06201
07612-02001
07340-06201
07612-02001
71220-16060
71220-16061
703-A-25-6TA
703-B-21
703-A-25-6T
703-B-26
743-A-25-8TA
703-B-21
743-A-25-8T
743-B-26
3.2
3.2
3.2
3.0
4.0
4.0
4.0
4.8
4.8
4.8
4.8
6.4
4.8
4.0
4.8
4.8
6.4
3.2
4.0
4.8
4.3
4.8
3.2
4.0
4.8
6
3.2
4.0
4.8
4.8
6.4
4.8
3.2
4.0
4.8
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.8
6.4
4.8
6.4
4.8
6.4
4.8
4.8
4.8
4.8
6.4
6.4
6.4
6.4
AVEX
®
Large flange
MONOBOLT
®
BULBEX
®
TLR
®
AVINOX®II
T-LOK
®
AVIBULB
®
AVDEL® SR
Countersunk
INTERLOCK
®
STAVEX
®
Large flange
Countersunk
Q™ RIVET
CHERRYMATE™
KLAMPTITE™
T™ RIVET
Large flange
Large flange
Large flange
Large flange
…001
…004
…003
…001
…004
…010
…009
…010
…016
…017
…015
…021
…200
…004
…010
…140
…141
…004
…010
…082
…120
…120
…004
…010
…082
…021
…001
…004
…062
…064
…063
…010
…004
…010
…010
…016
…010
…004
…010
…010
…001
…120
…120
…021
…120
…021
…430
…435
…380
…381
…383
…384
…385
…386
…387
…388
A
B
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07340-00304
4 JAWS 71210-15001
5 JAW SPREADER 07498-04502
6 BUFFER 71210-05001
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
* In ADDITION to the nose assembly shown below,
an extra long nose assembly is available to place
1
/4" Monobolt® in applications with restricted
access. See type 4 NOSE TIP table.
COMPLETE TOOL
PART NUMBER :
precede with
71223-00
8 7 6 5 4 23 1
61
22.9
Inc.
10
Nose Assemblies
Nose Tips
NAME
AVSEAL®II
NOSE ASSEMBLY
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07340-00304
4 JAWS 71210-16001
5 JAW SPREADER 07498-04502
6 BUFFER 71210-05001
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
AVSEAL®II
NOSE TIPS
FASTENER
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
part nº 71210-16100
MATERIAL
Ø
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
Standard & Low Pressure - Flush Nose Tip
8.0
Standard & Low Pressure - 2mm Ext Nose Tip
8.0
Standard & Low Pressure - 8mm Ext Nose Tip
8.0
Low Pressure Al. Alloy - Flush Nose Tip
9.0
Low Pressure Al. Alloy - 2mm Ext Nose Tip
9.0
Low pressure Al. Alloy - 8mm Ext Nose Tip
9.0
NOSE
ASSEMBLY
71210-16100
71210-16100
71210-16100
71210-16100
71210-16100
71210-16100
71210-16100
71210-16100
71210-16100
71220-16100
71220-16100
71220-16100
71230-15800
71230-15800
71230-15800
NOSE ASSEMBLY
part nº 71220-16100
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07612-02003
4 JAWS 71220-16120
5 JAW SPREADER 07498-04502
6 BUFFER 07498-03003
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
NOSE TIP (mm)
PART Nº 'A' 'B'
71210-16104
71210-16108
71210-16112
71210-16114
71210-16115
71210-16116
71210-16105
71210-16109
71210-16113
71220-16102
71220-16103
71220-16104
71220-16105
71220-16106
71220-16107
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
14.3
14.3
14.3
12AF
12AF
12AF
A
COMPLETE TOOL
PART NUMBER :
precede with 71223-00.
2.5
5.4
11.4
2.5
5.4
11.4
2.5
5.4
11.4
2.5
5.4
11.4
3.3
5.4
11.4
… 407
… 408
… 409
… 413
… 414
… 415
… 410
… 411
… 412
… 413
… 414
… 415
… 430
… 431
… 432
B
NOSE ASSEMBLY
part nº 71230-15800
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07612-02003
4 JAWS 07612-02002
5 JAW SPREADER 07498-04502
6 BUFFER 07498-03003
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
see
below
8 7 6 5 4 23 1
Inc.
22.9
61
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