Textron Genesis G2 Instruction Manual
Instruction Manual
Genesis G2 model
Hydro-Pneumatic Power Tool
2
3
Contents
Safety Rules 4
Tool Specifications
Tool Dimensions 5
Intent of Use
Range of Fasteners 6
Part Numbering 6
Putting into Service
Air Supply 7
Operating Procedure 7
Adjusting the Vacuum Extraction 7
Nose Assemblies
Selection of Nose Tips 8&10
Fitting and Servicing Instructions 9
Accessories
Stem Deflector 11
Extension 11
Side Ejector 11
Stem Collector 11
Swivel Heads 12
Preparing the Base Tool 13
Swivel Head Fitting Instructions 14
Swivel Head Servicing Instructions 15
Servicing the Tool
Daily / Weekly 16
Moly Lithium Grease EP 3753 Safety Data 16
Service Kit 17
Annually 18
Head Assembly 18
Pneumatic Piston Assembly 19
Valve Spool Assembly 19
Trigger 19
General Assembly of Base Tool
General Assembly and Parts List 20-21
Priming
Oil Details 22
Hyspin VG 32 Oil Safety Data 22
Priming Kit 22
Priming Procedure 23
Fault Diagnosis
Symptom, Possible Cause & Remedy 24
Textron Fastening Systemspolicy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
Warranty
Textron Fastening Systems installation tools carry a 12 month warranty against defects
caused by faulty materials or workmanship, the warranty period commencing from the
date of delivery confirmed by invoice or delivery note.
The warranty applies to the user/purchaser when sold through an authorised outlet,
and only when used for the intended purpose. The warranty is invalidated if the
installation tool is not serviced, maintained and operated according to the instructions
contained in the Instruction and Service Manuals.
In the event of a defect or failure, and at its sole discretion, Textron Fastening Systems
undertakes only to repair or replace faulty components.
CONTENTS
4
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.
3 Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Textron
Fastening Systems or their representatives, shall be the customer’s entire responsibility. Textron Fastening Systems 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
procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Textron Fastening
Systems 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 If the tool is fitted with a stem collector,it must be emptied when half full.
15 If the G2 tool is fitted with a stem deflector, it should be rotated until the aperture is facing way from the operator and other person(s)
working in the vicinity.
16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against fastener
ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the application.
17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be kept
dry and clean for best possible grip.
18 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
19 Excessive contact with hydraulic fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
Safety Rules
5
Specifications
TOOL SPECIFICATION
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 Without nose equipment 1.35 kg
Vibration Less than 2.5 m/s
2
30
121
150
104
120
284
2
12°30'
126
116
70
TOOL DIMENSIONS
Dimensions in millimetres
6
Intent of Use
G2 is a hydro-pneumatic tool designed to place Avdel®breakstem
fasteners at high speed making it ideal for batch or flow-line
assembly in a wide variety of applications throughout all industries.
It can place all fasteners listed opposite.
The tool features an adjustable vacuum system for fastener
retention and trouble free collection of the spent stems regardless
of tool orientation. See the ‘Operating Procedure’ on page 7 for
adjustment instructions.
A complete tool, except the 71210-00039, 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 71210-00039 complete tool comprising of:
• 71210-02000 base tool
• 71210-15000 nose assembly
• Nose tips 71210-05002, 71210-16070 and 07381-04701,
two screwed into the base cover. Fit nose tip as indicated page
9 or 11.
You can order the above three nose tips and nose assembly
as a nose assembly kit part number 71210-15100.
• For some fasteners the base tool and nose assembly and
nose tip must be ordered separately.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON
PAGE 9.
FASTENER
NAME
MM
IN
FASTENER SIZE ( )
AVEX
®
STAVEX
®
AVINOX
®
AVIBULB
®
ETR
BULBEX
®
T-LOK
®
AVDEL® SR
MONOBOLT
®
INTERLOCK
®
TLR
®
AVDEL
®
MBC
MBC/LC
AVSEAL
®
3 3.2 4.0 4.3 4.8 5 5.2 6 6.5 7
–1/85/32 –3/16 –––––
●●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●●●●
COMPLETE TOOL
71210-00 . . .
*
BASE TOOL
1
1
2
3
1
NOSE ASSEMBLY
NOSE TIP
2
71210-02000
71210-15000
see note 3
2
3
++=
3
2
2
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 20-21. If a swivel head is fitted, the same base tool must be adapted. See details page 13.
The nose tip part number relates to a specific fastener. If access to the application is
restricted, some extended nose tips are available. See page 10 for selection table.
This single nose assembly will allow placing of non-aerospace fasteners by simply selecting the appropriate nose
tip from the range of type 1 nose tips. Other nose assemblies are available for applications with restricted
access, for aerospace and special fasteners. See tables pages 8 & 10. A nose assembly can be substituted by
a swivel head (see pages 12-15). 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 8 OR 10.
FOR TOOLS WITH SWIVEL
HEADS USE TABLE PAGES 12-
13.
7
Putting into Service
AIR SUPPLY
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and automatic
oiling/filtering systems on the main air supply. These should be fitted within 3 metres of the tool (see diagram below) to ensure maximum tool
life and minimum tool maintenance.
Air supply hoses should have a minimum working effective pressure rating of 150% of the maximum pressure produced in the system or
10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where operating
conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or
1
/4 inch.
Read servicing daily details page 16.
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
PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)
LUBRICATOR
3 METRES MAXIMUM
2
OPERATING PROCEDURE
• Ensure that either the correct nose assembly or swivel head
suitable for the fastener is fitted (see pages 8-10 and 12-15).
• Connect the tool to the air supply.
• Insert the fastener stem into the nose of the tool. If using a nose
assembly, the fastener should remain held in by the vacuum
system. If not, adjust the vacuum extraction rotary valve 60.
• If using a swivel head, the vacuum extraction is disabled but the
jaws themselves will grip the fastener.
• Bring the tool with the fastener to the application so that the
protruding fastener enters squarely the hole of the application.
• Fully actuate the trigger. The tool cycle will broach the fastener
and with standard nose assemblies the broken stem will be
projected to the rear of the tool .
ADJUSTING THE VACUUM EXTRACTION
• Using a screwdriver, turn rotary valve 60 until the air flow at the
rear of the tool ceases.
• With the nose of the tool pointing downwards, insert a fastener
into the nose and hold it into position.
• Turn the rotary valve either way until there is sufficient suction to
retain the fastener.
Item numbers in bold refer to the general assembly drawing and parts list on pages 20-21.
8
Nose Assemblies
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A tool (except part number 71210-00039) 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.
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 10.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a 71210-00039
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. The two alternative nose tips are screwed
into the base of the tool.
Swivel heads are available as an alternative to nose assemblies when further reach is required. See page 12-15 in the ‘Accessories’ section.
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
3
Long nose tip for deep placing.
TYPE 1
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15000
(+ 3 nose tips above = 71210-15100)
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
Any
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
1
/
8
1
/
8
1
/
8
–
5
/
32
5
/
32
5
/
32
3
/
16
3
/
16
3
/
16
3
/
16
3
/
16
5
/
32
3
/
16
–
–
–
–
–
–
–
–
–
–
3
/
16
1
/
8
5
/
32
3
/
16
–
3
/
16
1
/
8
5
/
32
3
/
16
1
/
8
5
/
32
3
/
16
3
/
16
6.35
3.3
2.9
6.35
3.3
2.8
3.3
2.8
3.3
3.3
4.1
4.1
3.3
2.8
4.9
6.9
4.7
6.9
5.3
7.2
5.4
7.3
5.4
7.3
4.1
3.3
2.8
4.8
3.3
3.3
3.3
2.8
4.8
6.35
3.3
5.7
2.8
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
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
71210-16020
71210-16070
07381-04701
71210-16001
71210-16006
3
71210-16002
71210-16007
3
71210-16003
71210-16008
3
71210-16004
71210-16009
3
71210-16005
71210-16010
3
07605-00220
71210-16070
07381-04701
07498-01401
07340-06201
07340-06201
71210-16070
07381-04701
07498-01401
71210-05002
71210-16070
07348-07001
07381-04701
3.2
3.2
3.2
3
4.0
4.0
4.0
4.8
4.8
4.8
4.8
4.8
4.0
4.8
4
4
5
5
6
6
6.5
6.5
7
7
4.8
3.2
4.0
4.8
4.3
4.8
3.2
4.0
4.8
3.2
4.0
4.8
4.8
AVEX
®
Large flange
MONOBOLT
®
BULBEX
®
AVSEAL
®
TLR
®
AVINOX® II
T-LOK
®
AVIBULB
®
AVDEL® SR
INTERLOCK
®
…039*
…039*
…003
…039
…039*
…039*
…009
…039
…016
…017
…015
…200
…039*
…039*
…160
…180
…161
…181
…162
…182
…163
…183
…164
…184
…140
…039*
…039*
…082
…120
…120
…039*
…039*
…082
…039*
…039*
…062
…039
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 07498-04301
8 LOCKING RING 07340-00327
*
Complete tool part number 71210-00039 does
not only include the 71210-15000 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 71210-
15100.
Use the nose tip listed in the table.
COMPLETE TOOL
PART NUMBER :
precede with 71210-00.
* See top left
8 7 6 5 4 23 1
61
22.9
9
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.
• 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 G2 service kit. For complete list see page 17.
FITTING INSTRUCTIONS
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.
• Lightly coat jaws 4 with Moly lithium grease*.
• Drop jaws 4 into jaw housing 3.
• Insert jaw spreader 5 into jaw housing 3.
• Locate buffer 6 on jaw spreader 5.
• Locate spring 7 onto jaw spreader 5.
• Fit locking ring 8 onto the jaw spreader housing of the tool.
• Holding tool pointing down, screw the assembled jaw housing onto the jaw spreader housing and tighten with spanner.
• Screw the nose tip into nose casing 1 and tighten with spanner*.
• Place nose casing 1 over jaw housing 3 and screw onto the tool, tightening with spanner*.
SERVICING INSTRUCTIONS
10
Nose Assemblies
1
In inches then in millimetres.
FASTENER
MATERIAL
Ø
1
NOSE TIP (mm)
see
below
PART Nº 'A' 'B'NAME
Al Alloy
Steel
Al Alloy
Steel
Al Alloy
Steel
Al Alloy
Al Alloy
Steel
Steel
Steel
Steel
Steel/Brass
1
/
8
1
/
8
5
/
32
5
/
32
3
/
16
3
/
16
5
/
32
3
/
16
–
3
/
16
1
/
8
5
/
32
5
/
32
12.95
11.4
11.4
10.0
10.0
11.8
11.4
10.0
10.0
10.0
11.4
10.0
10.0
9.5
9.5
9.5
12.7
12.7
12.7
9.5
12.7
12.7
12.7
9.5
12.7
12.7
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
3.2
3.2
4.0
4.0
4.8
4.8
4.0
4.8
4.3
4.8
3.2
4.8
5.2
AVEX
®
BULBEX
®
T-LOK
®
AVIBULB
®
E.T.R
…002
…008
…008
…014
…014
…018
…008
…014
…121
…121
…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 07498-04301
8 LOCKING RING 07340-00327
COMPLETE TOOL
PART NUMBER :
precede with
71210-00
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 5 423
1
58.3
22.9
TYPE 3
NOSE TIPS
COMPLETE TOOL
PART NUMBER :
precede with
71210-00
1
56.3
22.9
1
In inches then in millimetres.
O
Oversize
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 07498-04301
8 LOCKING RING 07340-00327
TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE
FASTENERS LISTED BELOW.
FASTENER
MATERIAL
Ø
1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Al Alloy
Al Alloy
O
Stainless Steel
Al Alloy
Al Alloy
O
Stainless Steel
Al Alloy
Al Alloy
O
Any
Any
Al Alloy
Any
Any
Al Alloy
1
/
8
1
/
8
1
/
8
5
/
32
5
/
32
5
/
32
3
/
16
3
/
16
1
/
8
5
/
32
3
/
16
1
/
8
5
/
32
3
/
16
2.5
2.5
3.3
2.5
2.5
3.3
2.5
2.5
4.8
5.0
5.1
4.6
4.6
4.6
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
71210-16030
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
3.2
3.2
3.2
4.0
4.0
4.0
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.8
AVDEL
®
MBC
MBC L/C
…283
…284
…285
…288
…289
…290
…293
…294
…300
…305
…310
…320
…320
…320
A
B
8 7 6 5 423
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