Textron Genesis G3 Instruction Manual
3
Hydro-Pneumatic Power Tool
Genesis®G3 model
Instruction Manual
3
Safety Rules 4
Specifications
Tool Specifications 5
Tool Dimensions 5
Intent of Use
Range of Fasteners 6
Part Numbering 6
Putting into Service
Air Supply 7
Operating Procedure 7
Nose Assemblies
Fitting Instructions 8
Servicing Instructions 8
Nose Tips 9-11
Accessories
Stem Deflector 12
Extension 12
Side Ejector 12
Swivel Heads 13
Preparing the Base Tool 14
Swivel Head Fitting Instructions 15
Swivel Head Servicing Instructions 16
Servicing the Tool
Daily / Weekly / Monthly 17
Moly Lithium Grease EP 3753 Safety Data 17
MolyKote 55m & MolyKote 111 Safety Data 18
Annually 19
Service Kit 19
Head Assembly 19-20
Pneumatic Piston Assembly 20
Valve Spool Assembly 20
Trigger 20
General Assembly of Base Tools
General Assembly and Parts List 22-23
Priming
Oil Details 24
Hyspin VG 32 Safety Data 24
Priming Kit 24
Priming Procedure 25
Fault Diagnosis
Symptom, Possible Cause & Remedy 26
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
Safety Rules
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. The plastic body and End Cap must be changed whenever there is evidence of impact damage, chipping
or cracks. 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 G3 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. Any
such sharp features must not be allowed to indent or otherwise damage the plastic body or End Cap of the tool - see Safety Rule 4. Do
not operate the tool if it is not fitted with a Rubber Base Cover.
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.
20 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.
Tool Specification
5
Specifications
Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 4.3 litres
Stroke Minimum 26 mm
Pull Force @ 5.5 bar 12.9 kN
Cycle time Approximately 1.2 second
Noise Level 75 dB(A)
Weight Without nose equipment 1.64 kg
Vibration Less than 2.5 m/s
2
30
12°30'
134
128
152
150
316
126
116
70
3
Dimensions in millimetres.
Tool Dimensions
Intent of Use
6
G3 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
light / medium industries where
the plastic components will not
be subject to impact damage. It
can place all fasteners listed
below.
The tool features an adjustable
vacuum system for fastener
retention and trouble free
collection of the spent stems
regardless of tool orientation.
See the ‘Operating Procedure’ on
page 7, for adjustment
instructions.
A complete tool is made up of
three separate elements which
will be supplied individually. See
diagram below.
NOSE EQUIPMENT MUST BE
FITTED AS DESCRIBED ON
PAGE 8.
FASTENER
NAME
MM
IN
FASTENER SIZE ( )
AVEX
®
STAVEX
®
AVINOX
®
AVIBULB
®
ETR
BULBEX
®
T-LOK
®
AVDEL® SR
MONOBOLT
®
INTERLOCK
®
TLR
®
AVTAINER
®
AVDEL
®
MBC
MBC/LC
AVSEAL
®
Q
™ RIVET
T
™ RIVET
CHERRYMATE™
KLAMPTITE™
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 –
●
●
●
●
●●●●●●●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
COMPLETE TOOL
71220-00 . . .
*
BASE TOOL
1
1
2
3
1
NOSE ASSEMBLY
NOSE TIP
2
71220-02000
71210-15000
see note 3
2
3
++=
3
3
3
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 22-23. 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 page 9 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 10-11. A nose assembly can be substituted by a
swivel head (see pages 13-15). 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, 10 0R 11.
FOR TOOLS WITH SWIVEL HEADS
USE TABLE PAGES 13-14.
Range of Fasteners
Part Numbering
Air Supply
7
Putting into Service
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 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 17.
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)
3 METRES MAXIMUM
3
• Ensure that either the correct nose assembly or swivel head
suitable for the fastener is fitted (see pages 8-11 and 13-15).
• 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 22-23.
Operating Procedure
Nose Assemblies
8
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A complete tool will 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 on pages 9-11.
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’ 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 10.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool.
The type 4 is an alternative to place
1
/4 in Monobolt®. See respective table.
Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required. See page 1216 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*.
* Item included in the G3 service kit. For complete list see page 19.
Fitting Instructions
Servicing Instructions
9
Nose Assemblies
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
3
Long nose tip for deep placing
4
Dome head.
5
Countersunk.
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
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
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel
Steel
Steel
Steel
Any
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
/
4
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
6.35
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
4.9
6.9
4.7
6.9
5.3
7.2
5.4
7.3
5.4
7.3
5.5
7.3
5.6
7.3
5.6
7.3
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
3.6
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
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
14.3
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
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
71220-16006
71220-16011
3
71220-16007
71220-16012
3
71220-16008
71220-16013
3
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
4
71210-16050
5
71220-60001
07381-04701
07612-02001
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
4.0
4.0
4.0
4.8
4.8
4.8
4.8
6.4
4.8
4.0
4.8
4
4
5
5
6
6
6.5
6.5
7
7
8
8
9
9
10
10
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
6.4
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
®
AVSEAL
®
TLR
®
AVINOX® II
T-LOK
®
AVIBULB
®
AVDEL® SR
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
…160
…180
…161
…181
…162
…182
…163
…183
…164
…184
…165
…185
…166
…186
…167
…187
…140
…141
…004
…010
…082
…120
…120
…004
…010
…082
…021
…001
…004
…062
…064
…063
…010
…021
…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
71220-00
8 7 6 5 4 23 1
61
22.9
Nose Tips
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
Any
Any
Any
1
/
8
1
/
8
5
/
32
5
/
32
3
/
16
3
/
16
5
/
32
3
/
16
–
3
/
16
1
/
8
5
/
32
5
/
32
1
/
8
5
/
32
3
/
16
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
12.95
11.4
11.4
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
9.5
9.5
9.5
07340-02805
07340-02806
07340-02806
07340-02807
07340-02807
07340-07301
07340-02806
07340-02807
07241-07101
07241-07101
07340-02806
07340-02807
07340-02807
07340-02805
07340-02806
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
3.2
4.0
4.8
AVEX
®
BULBEX
®
T-LOK
®
AVIBULB
®
ETR
T™ RIVET
…002
…008
…008
…014
…014
…018
…008
…014
…121
…121
…008
…014
…014
…002
…008
…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
COMPLETE TOOL
PART NUMBER :
precede with
71220-00
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
71220-00
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 07500-00418
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
Stainless Steel
Any
Any
Any
Any
Any
Any
1
/
8
1
/
8
1
/
8
5
/
32
5
/
32
5
/
32
3
/
16
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
2.4
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
12.7
71210-16030
71210-16031
71210-16032
71210-16033
71210-16034
71210-16035
71210-16036
71210-16037
71220-16038
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
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
…295
…300
…305
…310
…320
…320
…320
A
B
8 7 6 5 423
Nose Tips
Loading...