Avdel GENESIS NG4 Manuale del proprietario

4

Hydro-Pneumatic Power Tool

Druckluftgerät

Outil oléo-pneumatique

Attrezzo oleopneumatico

Genesis

®

G4

Instruction Manual

Manuel d’instructions

Betriebsanleitung

Manuale d’istruzione

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

Français 33

Deutsch 63

Italiano 93

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.

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.

Contents

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 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 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.

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.

Tool Specification

Specifications

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.

English

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 II

®

AVIBULB

®

BULBEX

®

T-LOK

®

AVDEL

®

SR

INTERLOCK

®

HEMLOK

®

MAXLOK

®

AVTAINER

®

AVDEL

®

MBC

®

MBC

®

/LC

AVSEAL

®

II

Q

TM

RIVET

T

TM

RIVET

CHERRYMATE

TM

KLAMPTITE

TM

KLAMPTITE

TM

KTR

LOCKBOLT

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

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

* For

3

/

16

and

1

/

4

Lockbolt equipment refer to separate Data Sheet 07900-00795.

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.

English

Do not use tool when Stem

Collector Bottle is removed

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

®

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.

English

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 assembly.

• 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.

Servicing Instructions

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

Steel

Aluminium

Steel

Stainless Steel

Steel

Aluminium

Stainless Steel

Steel

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

Al Alloy

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

3

/

16

3

/

16

3

/

16

3

/

16

3

/

16

–

3

/

16

3

/

16

–

3

/

16

1

/

4

3

/

16

3

/

16

3

/

16

1

/

4

3

/

16

1

/

4

3/16

1/4

3/16

1/4

3/16

1/4

2.8

3.3

4.1

3.3

2.8

4.8

3.3

4.8

3.3

5.7

3.3

5.7

2.8

3.3

9.5

8.0

9.5

9.0

11.2

8.0

10.2

8.3

4.8

2.8

12.7

19.0

12.7

19.0

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

07340-04800

71220-16080

07498-01401

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

71220-16060

71220-16061

07381-04701

07162-02001

4.8

6.4

4.8

4.3

4.8

6.0

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

4.8

6.4

AVEX

®

Large flange

STAVEX

®

Countersunk

Large flange

BULBEX

®

AVINOX

®

II

T-LOK

®

AVIBULB

®

AVDEL

®

SR

Countersunk

INTERLOCK

®

Q

™

RIVET

CHERRYMATE

®

T

™

RIVET

Large flange

KLAMPTITE

™KTR

KLAMPTITE

™

…010

…016

…017

…015

…021

…016

…010

…082

…120

…082

…021

…062

…063

…064

…010

…120

…021

…120

…021

…380

…381

…383

…384

…385

…386

…387

…388

…500

…501

…010

…021

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

Al Alloy

11

AVSEAL

®

II

NOSE TIPS

FASTENER

MATERIAL

Ø

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'

NAME

Standard Al. Alloy - Flush Nose Tip

Standard Al. Alloy - 2mm Extended Nose Tip

Standard Al. Alloy - 8mm Extended Nose Tip

Standard & Low Pressure - Flush Nose Tip

Standard & Low Pressure - 2mm Ext Nose Tip

Standard & Low Pressure - 8mm Ext Nose Tip

Standard Al. Alloy - Flush Nose Tip

Standard Al. Alloy - 2mm Extended Nose Tip

Standard Al. Alloy - 8mm Extended Nose Tip

Standard & Low Pressure - Flush Nose Tip

Standard & Low Pressure - 2mm Ext Nose Tip

Standard & Low Pressure - 8mm Ext Nose Tip

Low Pressure Al. Alloy - Flush Nose Tip

Low Pressure Al. Alloy - 2mm Ext Nose Tip

Low Pressure Al. Alloy - 8mm Ext Nose Tip

–

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

12.7

14.3

13.9

71210-16105

71210-16109

71210-16113

71230-16102

71220-16103

71230-16104

71230-16102

71230-16104

71230-16106

71230-16103

71230-16105

71230-16107

71220-16105

71220-16106

71220-16107

71210-16100

71220-16100

71230-15800

71230-16100

71220-16100

7.0

8.0

9.0

10.0

9.0

AVSEAL

®

II

… 410

… 411

… 412

… 413

… 414

… 415

… 416

… 417

… 418

… 419

… 420

… 421

… 430

… 431

… 432

A

B

COMPLETE TOOL

PART NUMBER :

precede with 71233-00.

NOSE ASSEMBLY

part nº 71210-16100

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-00306

2 'O' RING 07003-00067

3 JAW HOUSING 07430-00304

4 JAWS 71210-16101

5 JAW SPREADER 07498-04502

6 BUFFER 71210-05001

7 SPRING 07500-00418

8 LOCKING RING 07340-00327

NOSE ASSEMBLY

part nº 71230-16100

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-00306

2 'O' RING 07003-00067

3 JAW HOUSING 07612-02003

4 JAWS 71230-16101

5 JAW SPREADER 07498-04502

6 BUFFER 07948-03003

7 SPRING 07500-00418

8 LOCKING RING 07340-00327

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

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

Low Pressure Al. Alloy - Flush Nose Tip

Low Pressure Al. Alloy - 2mm Ext Nose Tip

Low Pressure Al. Alloy - 8mm Ext Nose Tip

Low Pressure Al. Alloy - Flush Nose Tip

Low Pressure Al. Alloy - 2mm Ext Nose Tip

Low Pressure Al. Alloy - 8mm Ext Nose Tip

Low Pressure Al. Alloy - Flush Nose Tip

Low Pressure Al. Alloy - 2mm Ext Nose Tip

Low Pressure Al. Alloy - 8mm Ext Nose Tip

–

3.3

5.4

11.4

3.3

5.4

11.4

3.3

5.4

11.4

13.9

17.3

71230-16109

71230-16112

71230-16115

71230-16110

71230-16113

71230-16116

71230-16111

71230-16114

71230-16117

71230-15800

71230-16100

10.0

11.0

12.0

… 433

… 434

… 435

… 436

… 437

… 438

… 439

… 440

… 441

8 7 6 5 4 23 1

61

22.9

NOSE

ASSEMBLY

Nose Tips

Nose Assemblies English

12

Nose Assemblies

Nose Tips

1

In inches then in millimetres.

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

below

PART Nº 'A' 'B'NAME

Aluminium

Steel

Aluminium

Steel

3

/

16

3

/

16

3

/

16

–

3

/

16

10.0

11.8

10.0

12.7

07340-02807

07340-07301

07340-02807

07241-07101

4.8

4.3

4.8

AVEX

®

BULBEX

®

T-LOK

®

…014

…018

…014

…121

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

COMPLETE TOOL

PART NUMBER :

precede with

71233-00

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

9 10

TYPE 3

NOSE TIPS

COMPLETE TOOL

PART NUMBER :

precede with

71233-00

1

In inches then in millimetres.

O

Oversize

NOSE ASSEMBLY

part nº 71210-15300

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm) see

below

PART Nº 'A' 'B'NAME

Aluminium

O

Stainless Steel

Any

3

/

16

3

/

16

3

/

16

3

/

16

3

/

16

2.5

2.4

5.1

4.6

12.7

71210-16036

71210-16037

71220-16038

07340-06901

07344-04701

4.8

AVDEL

®

MBC

®

MBC L/C

®

…293

…294

…295

…310

…320

A

B

TYPE 3 NOSE TIPS ARE SPECIFICALLY

FOR THE AEROSPACE FASTENERS

LISTED ABOVE.

8 7 6 5 423

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

9 JAW SPREADER HOUSING 71210-02101

10 'O' RING 07003-00277

9 10

1

56.3

22.9

1

In inches then in millimetres.

TYPE 6

NOSE TIPS

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm)

see

above

PART Nº 'A' 'B'NAME

A

B

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

COMPLETE TOOL

PART NUMBER :

precede with

71233-00

NOSE ASSEMBLY

part nº 71230-15800

8 7 6 5 423

1

61

22.9

HEMLOK

®

INTERLOCK

®

STAVEX

®

Any

1

/

4

1

/

4

1

/

4

3.6

14.3

07612-02001

6.4

…261

NOTE: Items 9 & 10 are not required when assembling Type 2 or 3 Nose Tips to base tool nG4 (71233-02000).

13

Nose Tips

Nose Assemblies

TYPE 5

AVTAINER

®

-

NOSE TIP

COMPLETE TOOL

PART NUMBER :

precede with

71233-00

1

In inches then in millimetres

NOSE ASSEMBLY part nº 71230-15600

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07498-00501

2 'O' RING 07003-00067

9 CHUCK COLLET 07498-00801

4 JAWS 07220-02302

ITEM DESCRIPTION PART Nº

10 FRONT SPRING GUIDE 07498-00803

7 SPRING 07500-02005

11 REAR SPRING GUIDE 07498-00503

8 LOCKING RING 07340-00327

13 VAC SHUT-OFF STOP NUT ASSY 71233-20200

FASTENER

MATERIAL

Ø

1

NOSE TIP (mm) see

below

PART Nº 'A' 'B'NAME

Steel

3

/

8

4.119.107498-00802

9.6

…243

98.5

20.6

11 7 10 4298

A

B

AVTAINER

®

13

MAXLOK

®

-

NO NOSE TIP

12

1

In inches then in millimetres

NOSE ASSEMBLY NOSE ASSEMBLY

part nº 07610-02000 for

3

/

16

" ø part nº 07610-02100 for

1

/

4

" ø

ITEM DESCRIPTION PART Nº

9

CHUCK COLLET 07610-02002

4 JAWS 07610-02003

10 SPRING GUIDE 07220-02104

7 SPRING 07610-02107

8 LOCKING RING 07610-02004

12 ANVIL

07610-02001

13

VAC SHUT-OFF STOP NUT ASSY

71233-20200

ITEM DESCRIPTION PART Nº

9

CHUCK COLLET 07610-02102

4 JAWS 07610-02103

10 SPRING GUIDE 07220-02104

7 SPRING 07610-02107

8 LOCKING RING 07610-02004

12 ANVIL

07610-02101

13

VAC SHUT-OFF STOP NUT ASSY

71233-20200

FASTENER

MATERIAL

Ø

1

NOSE ASSEMBLY see

below

PART NºNAME

All

3

/

16

1

/

4

07610-02000

07610-02100

4.8

6.4

MAXLOK

®

…371

…372

8 7 10 9410

COMPLETE TOOL PART NUMBER :

precede with 71233-00

The three adapting components

illustrated below left are

not included in the nose

assembly part number.

Each item must be ordered

separately, using individual

part numbers.

MAXLOK

®

NOSE ASSEMBLIES

will place both the ordinary flange

collar and the large flange collars.

07610-00501

CHUCK COLLET ADAPTOR

71230-02063

ANVIL ADAPTOR

07610-00307

ANVIL NUT

13

THE THREE COMPONENTS ILLUSTRATED LEFT ARE ESSENTIAL WHEN FITTING

A MAXLOK

®

NOSE ASSEMBLY TO THE G4 TOOL.

READ MAXLOK

®

'FITTING INSTRUCTIONS' PAGE 14.

64.5

19

CHUCK COLLET ADAPTOR

ANVIL ADAPTOR

ANVIL NUT

English

* Item included in the nG4 service kit. For complete list see page 18

Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.

Nose Assemblies

IMPORTANT

The air supply must be disconnected when ﬁtting or removing any nose assembly unless speciﬁcally instructed

otherwise.

The air vacuum extraction system MUST be disabled by ﬁtting Vacuum ‘Shut-Off’ Stop Nut 71233-20200 before

operating a nG4 tool with a Maxlok

®

or Avtainer

®

nose assembly.

Refer to the ‘Operating Procedure’ for Avtainer

®

and Maxlok

®

, page 8.

AVTAINER

®

Item numbers in bold refer to the general assembly and parts

list pages 24 and 25. Other items numbers refer to the ‘Type 5

Nose Tip’ table page 13.

• Remove Jaw Spreader Housing 41, ‘O’ ring 12, Locknut

40, Vacuum Sleeve 42 and Seal Housing 52.

• Screw Vacuum ‘Shut-off’ Stop Nut Assy 13 onto Head Piston

36. (Items 40, 42 and 52 are not reﬁtted).

• Replace Jaw Spreader Housing 41 and ‘O’ Ring 12.

• Lightly coat jaws 4 with Moly Lithium grease*.

• Drop jaws 4 into Chuck Collet 9.

• Insert Front Spring Guide 10 into Chuck Collet 9.

• Locate Spring 7 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.

• Screw the assembled 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 with ‘O’ Ring 2 over Chuck Collet 9

and screw onto the tool, tightening with spanner*

MAXLOK

®

When ﬁtting a Maxlok

®

nose assembly, the base tool must be

adapted using three auxiliary components illustrated page 13

and Vacuum ‘Shut-off’ Stop Nut Assembly 13, must be ﬁtted.

Item numbers in bold refer to the general assembly and parts

list pages 26-27. Other items numbers refer to the ‘Maxlok

®

No

Nose Tip’ table page 12.

• Remove Jaw Spreader Housing 41, ‘O’ Ring 12, and

Vacuum Sleeve 42. Seal housing 52 and Locknut 40.

(None of the above parts are reﬁtted).

• Screw Vacuum Shut-off ‘Stop Nut’ 13 onto Head Piston 36.

• Substitute Jaw Spreader Housing 1 with Chuck Collet

Adaptor 07610-00501. Tighten fully onto piston before

tightening the Stop Nut 13 against it.

• Fit Locking Ring 8 onto the Chuck Collet Adaptor.

• Lightly coat Jaws 4 with Moly Lithium grease.

• Drop Jaws 4 into Chuck Collet 9.

• Insert one Spring Guide 10 into Chuck Collet 9.

• Locate Spring 7 onto the Spring Guide already in place.

• Drop the other Spring Guide 10 into Spring 7.

• Holding tool pointing down, screw the assembled Chuck

Collet onto the Chuck Collet Adaptor and tighten with

spanner.

• Screw Anvil Adaptor 71230-02063 into the Head Assembly.

• Place Anvil 12 over Chuck Collet 9 and lock into place with

Anvil Nut 07610-00307.

Fitting instruction for Avtainer

®

and Maxlok

®

Nose Assemblies

Servicing Instructions for all 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 assembly 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 that the spring is not distorted.

• On nose assemblies for Maxlok

®

and Avtainer

®

check that the spring guides are not distorted.

• On nose assemblies for Maxlok

®

check that the anvil is neither cracked nor has any scoring or corrosion marks on the inside face

of the concave shape at the front end.

• Assemble according to ﬁtting instructions.

14

15

Stem Deflector

Accessories

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:

Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.

Fitted between the tool and the nose assembly the extension

allows access into deep channels.

• To ﬁt the extension, remove any nose assembly

components.

• Screw the inner extension to Jaw Spreader Housing 41.

• Screw the outer onto Head Assembly 58.

• Fit the nose assembly onto the extension.

• Loosen Locknut 40 using

16mm A Spanner.

• Unscrew and remove both Jaw

Spreader Housing 41 and

Locknut 40.

• Replace Locknut 40 with

‘Sealed’ Nut 71213-02200,

screw ‘Sealed” Nut onto Piston

36.

• Jaw Spreader Housing 41

must be tightened onto Piston

36, ﬁnally tightening ‘Sealed’

Nut against it.

• Remove the Stop Plate

Assembly (page 22) by

unscrewing Screws 89 (2 off).

Extension

Preparing the Base Tool for use with Stem Deflector

07340-00342

STEM DEFLECTOR

71213-20101

ADAPTOR

41

40

36

The airline must be disconnected before any servicing or dismantling.

‘Sealed’ Nut 71213-02200 replaces Locknut 40 (to cut-off air supply to Vacuum System) as follows:

Note: If Pintail Deﬂector is used with Maxlok

®

equipment then Seal Housing 52 will need to be removed and Stop Nut 71233-20200

ﬁtted instead of ‘Sealed’ Nut 71213-02200.

English

• Fit Stem Deﬂector (07340-00342) into Adaptor

(71213-20101).

• Push the assembled Stem Deﬂector and Adaptor over

Bottle Adaptor 32 and align with the cut-out feature.

ADAPTOR

71213-20101

STEM DEFLECTOR

07340-00342

SEALED NUT

71213-02200

STEM DEFLECTOR: 71213-20100

INNER

OUTER

MAXLOK

®

/EXTENSION 71230-20300

EXTENSION PART NUMBER 71210-20300

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 25 explains

how to measure the stroke.

• Either a stem collector or a stem deﬂector must be ﬁtted to the tool unless using a swivel head.

• Check that Base Cover 31 is fully tightened onto Body 30.

• Stem Collector Bottle: ‘O’ Rings 20 and 28 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 Moly Lithium 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 18.

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 burning or disposal on approved site.

Handling

Use barrier cream or oil resistant gloves

Storage

Away from heat and oxidising agent.

Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.

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

Moly Lithium Grease EP 3753 Safety Data

16

17

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

English

Service Kit

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

PART N DESCRIPTIONPART N 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 'T' SPANNER SPIGOT

07900-00684 GUIDE TUBE

07900-00685 INSERTION ROD

07900-00351 3 MM ALLEN KEY

07900-00469 2.5 MM ALLEN KEY

07900-00158

07900-00164

2 MM PIN PUNCH

CIRCLIP PLIERS

07900-00008

716 1/ x /2 SPANNER

07900-00012

916 5/ x /8 SPANNER

07900-00015

58 11/ x /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

07900-00850

07900-00898

GREASE - MOLYKOTE 111

®

PIN SPANNER

VALVE HOOK

Servicing the Tool

Maintenance

The airline 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 three steps of the ‘Priming Procedure’ on page 26.

Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 9 to

14.

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 see page 26 and to ﬁt an appropriate nose assembly see pages 9 to 14.

(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.

• Unscrew Jaw Housing 3 and remove Jaws 4, Jaw Spreader 5, Spring 7 and Buffer 6.

• Inspect all components. Renew all damaged or worn parts.

• Clean all parts and apply Moly Lithium Grease EP 3753 (07992-00020) to taper bore of Jaw Housing 3.

• Insert Jaws 4, Jaw Spreader 5, Spring 7 and Buffer 6 into Jaw Housing 3 and assemble onto Jaw Spreader Housing 41*.

• Screw Nose Tip into Nose Casing and tighten.

Item numbers in bold refer to Nose Tip Tables on pages 10 to 13.

41* refers to illustration on page 24.

18

19

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 62 remove Bleed Screw 1 and Bonded Seal 6.

• 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.

This operation must have the Bleed Screw oriﬁce facing away from the person performing this operation.

• Twist and pull off Stem Collector Bottle Assembly 25. See illustration on page 7.

• Remove Stop Plate Assembly 104 by unscrewing Screws 89 2 off.

• Unscrew Retaining Nut 50.

• Pull off Bottle Adaptor Assembly 32 together with ‘O’ Rings 20 and 28.

• Remove End Cap Assembly 35 together with ‘O’ Ring 97 and Lip Seal 9.

• Remove Spring 91.

• Loosen Locknut 40 with a spanner* and unscrew Jaw Spreader Housing 41 together with ‘O’ Ring 12.

• Remove Locknut 40 together with ‘O’ Rings 19 and 15, withdraw Vacuum Sleeve 42..

• Push Head Piston 36 to the rear and out of Head Assembly 58 taking care not to damage the cylinder bore

• Remove Seal Retainer 43. Push Lip Seal 8 and Bearing Tape 26 to the rear and out of Head Assembly 58 taking care not to damage

the cylinder bore.

• Remove Seal Housing 52 and Lip Seal 2.

Assemble in reverse order noting the following points:

• Place Lip Seal 8 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*.

• After ﬁtting Lip Seals 11, ‘O’ Rings 18 and Bearing Tape 27 onto the Head Piston 36 ensuring correct orientation, lubricate the cylinder

bore and place the piston sleeve* into the back of Head Assembly 58. Slide the bullet* onto the threaded part of Head Piston 36 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*.

• Jaw Spreader Housing 41 must be fully tightened onto Head Piston 36 before tightening Locknut 40 against it.

• Reprime in accordance with the instructions on page 26.

* Item included in the nG4 Service Kit. For complete list see page 18.

Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.

Head Assembly

English

• Remove ‘ON/OFF’ valve assembly 62.

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

• Pull off Rubber Boot 48.

• Using the peg spanner* unscrew Base Cover 31.

• Unscrew Nyloc Nuts 67 (2 off) and remove Base Plate Assembly 65.

• Remove Cylinder Liner 37 together with Sealing Washers 29 (2 off) and ‘O’ Rings 66 (2 off).

• Remove Pneumatic Piston Assembly 57 together with ‘O’ Ring 75, Lip Seal 90 (3 off) and Guide Ring 51.

• Engage the Seal Extractor* into Intensiﬁer Seal Assembly 63 and withdraw Seal Assembly from intensiﬁer tube of the Head Assembly 58.

Assemble in reverse order to dismantling.

* seals should be checked for damage and replaced as necessary. Lubricate Pneumatic seals with Molykote

®

55m Grease and Hydraulic

seals with Molykote

®

111 Grease.

Dismantling

•

Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Piston Assembly.

• Using Spanner (07900-00672), and Location Spigot (07900-00671). Unscrew Clamp Nut 39 and remove together with Top Plate

Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, ‘O’ Rings 14 and Silencer 53.

• Remove tool from vice and separate Body 30 from Handle Assembly 64. Remove ‘O’ ring 17.

• Push out the Valve Seat 34, from the Body 30, together with ‘O’ Rings 14.

• Pull out Valve Spool Assembly 59 from Handle Assembly 64. Remove ‘O’ Ring 7 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 39 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 nG4 Service Kit. For complete list see page 18.

Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.

Pneumatic Piston Assembly

Servicing the Tool

Air Valve

20

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Avdel GENESIS NG4 Manuale del proprietario

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