Textron Genesis G4 Instruction Manual

G4

Hydro-Pneumatic Power Tool

Genesis

¨

Instruction Manual

Inc.

4

model

Textron Fastening Systems Inc. is a wholly owned subsidary of Textron Inc.

Inc.

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 - All fasteners except
Avtainer® and Maxlok

®

7

Operating Procedure - Avtainer® and Maxlok

®

8

Nose Assemblies

Nose Tip Selection 9
Fitting Instructions - All Nose Assemblies except
Avtainer® and Maxlok

®

9
Nose Tips 10 - 13
Type 1 Standard 10
Avseal® II Nose Tip 11
Type 2 Limited Access 12
Type 3 Aerospace 12
Type 6 Hemlok®/Interlock

®

12
Type 5 Avtainer

®

13
Maxlok

®

13
Fitting Instructions for Avtainer® and Maxlok

®

Nose Assemblies 14
Servicing Instructions for all Nose Assemblies 14

Accessories

Stem Deflector 15
Preparing the Base Tool for use with Stem Deflector 15
Extension 15

Servicing the Tool

Daily / Weekly 16
Moly Lithium Grease EP 3753 Safety Data 16
Molykote®55m Grease Safety Data 17
Molykote®111 Grease Safety Data 17
Service Kit 18
Maintenance 18
Nose Equipment 18
Dismantling the Tool 19
Head Assembly 19
Pneumatic Piston Assembly 20
Air Valve 20
Rotary Valve 21
Trigger 21

Stop Plate Assembly (71213-03900) 22

General Assembly of Base Tool

General Assembly 24
Parts List 25

Priming

Oil Details 26
Hyspin®VG 32 Oil Safety Data 26
Priming Kit 26
Priming Procedure 27

Fault Diagnosis

Symptom, Possible Cause and Remedy 28

Textron Fastening Systems Incpolicy 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 Inc.

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 nG4 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.

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.

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

Specifications

Inc.

5

Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cu ft)
Stroke Minimum 17 mm
Pull Force @ 5.5 bar 18.68 kN (4200 lbf)
Cycle Time Approximately 1.2 seconds
Noise Level 75 dB(A)
Weight Including nose equipment 2.3 kg
Vibration Less than 2.5 m/s

2

Dimensions in millimetres

Tool Dimensions

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

Inc.

6

Intent of Use

nG4 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 9.

FASTENER

NAME

MM

IN

FASTENER SIZE ( )

AVEX

®

STAVEX

®

AVINOX

®

AVIBULB

®

BULBEX

®

T-LOK

®

AVDEL® SR

INTERLOCK

®

HEMLOK

®

TLR

®

MAXLOK

®

AVTAINER

®

AVDEL

®

MBC

®

MBC/LC

®

AVSEAL® II

Q

TM

RIVET

T

TM

RIVET

CHERRYMATE

TM

4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10 11 12
–

3

/16 –––1/4 ––––3/8 – – –

●●

●●

●

●●

●

●●

●●

●●

●

●●

●●

●

●

●

●

●●● ●● ●

●●

●●

●●

COMPLETE TOOL

71233-00 . . .

*

BASE TOOL

1

1

2

3

1

NOSE ASSEMBLY

NOSE TIP

2

71233-02000

71210-15000

see note 3

2

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 24 and 25.

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

This single nose assembly will allow placing of non-aerospace fasteners by simply selecting the appropriate
nose tip from the range of Type 1 Nose Tips. Other nose assemblies are available for applications with
restricted access, for aerospace and special fasteners see table page 12.

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE
TIP TABLE ON PAGE 10, 11 or

12.

Range of Fasteners

Part Numbering

Inc.

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.

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

• 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 -All fasteners except Avtainer®and Maxlok

®

• 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.

Inc.

8

Putting into Service

Operating Procedure

AVTAINER®AND MAXLOK

®

• Ensure that the correct nose assembly is fitted see page 13.

• Connect the tool to the air supply.

• Push the Maxlok

®

or Avtainer®stem through the application hole.

• Place the collar on the stem (orientation as shown below).

• Keeping the head of the stem against the application, push the tool onto the protruding stem.

• Fully depress the trigger. One cycle will ensure that the collar is swaged into the lock grooves of the stem and that the

stem breaks at the breaker groove.

• Release the trigger. The tool completes its cycle by pushing itself off the collar and the spent stem will be pushed to

the rear of the tool on insertion of the next fastener.

Placing AVTAINER

®

Placing MAXLOK

®

Inc.

9

Nose Tip Selection

Nose Assemblies

IMPORTANT

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

A 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 10 to 13.

If your application presents no access restriction use a Type 1 nose tip unless you are placing aerospace fasteners which require a
Type 3 nose tip, Avtainer

®

a Type 5, Hemlok®and 1/4” Interlock®a Type 6. Maxlok®requires a special nose assembly which does
not make use of any nose tip, see pages 10 to 13.
Dimensions ‘A’ and ‘B’ 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 with extra reach, are available for some fasteners. Refer to the table on page 12.
It is essential that a fastener-compatible nose assembly and nose tip are fitted prior to operating the tool (no nose tip with Maxlok

®

).

Fitting Instructions - All Nose Assemblies except Avtainer® and Maxlok

®

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 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 nG4 Service Kit. For complete list see page 18.

Inc.

10

Nose Tips

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

Material of the body then of the stem. 'Al' is the

abbreviation for Aluminium.

5

Domehead.

6

Countersunk.

TYPE 1

NOSE TIPS

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

Aluminium
Aluminium
Steel
Aluminium
Aluminium
Steel
Steel
Stainless Steel
Steel
Steel
Aluminium
Aluminium
Aluminium
Stainless Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
Any
Any
Any
Any
Al/Al

4

Al/Al

4

Al/Steel

4

Al/Steel

4

Al/Al

4

Al/Al

4

Al/Steel

4

Al/Steel

4

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

3

/

16

1

/

4

3

/

16

–

3

/

16

3

/

16

–

3

/

16

1

/

4

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

1

/

4
3/16
3/16
3/16
3/16

1/4
1/4
1/4
1/4

2.8

3.3

3.3

4.1

3.3

3.3

2.8

2.8

2.8

2.8

2.8

4.1

4.4

4.8

3.3

3.3

4.8

3.3

5.7

3.3

5.7

2.8

3.3

3.3

3.3

3.3

9.5

8.0

9.5

9.0

11.2

8.0

10.2

8.3

12.7

19.0

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

15.9

12.7

15.9

12.7

17.5

12.7

16.7

12.7

07381-04701
07340-04800
07490-04401

07340-06601

2

07612-02001
07381-04701
07381-04701
07381-04701
07340-04800
07612-02001
07381-04701
07605-00220
71220-16080
07498-01401
07340-06201
07340-06201
07498-01401
07612-02001

07348-07001

5

71220-60001

71210-16050

6

07381-04701
07340-06201
07612-02001
07340-06201
07612-02001
703-A-25-6TA

703-B-21

703-A-25-6T

703-B-26

743-A-25-8TA

743-B-21

743-A-25-8T

743-B-26

4.8

4.8

4.8

4.8

6.4

4.8

4.8

4.8

4.8

6.4

4.8

4.8

6.4

4.8

4.3

4.8

4.8

6.0

4.8

6.4

4.8

4.8

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

STAVEX

®

Countersunk

Large flange

BULBEX

®

TLR

®

AVINOX

®

II

T-LOK

®

AVIBULB

®

AVDEL

®

SR

Countersunk

INTERLOCK

®

Q™ RIVET

CHERRYMATE

®

T™ RIVET

Large flange

Large flange

Large flange

Large flange

…010
…016
…017
…015
…021
…016
…010
…010
…010
…021
…010
…140
…141
…082
…120
…120
…082
…021
…062
…063
…064
…010
…120
…021
…120
…021
…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

COMPLETE TOOL

PART NUMBER :

precede with

71233-00

8 7 6 5 4 23 1

61

22.9

NOSE ASSEMBLY

part nº 71210-15000