07900-00843 GB
Instruction Manual
Original Instruction
G1
Genesis ®
1
H y d ro - P n e u m a t i c P o w e r To o l
Contents
Safety Instructions
Specifications
Tool Specification
Tool Dimensions
4
5
5
Intent of Use
Range of Fasteners
Part Numbering
6
6
Putting into Service
Air Supply
Operating Procedure
7
7
Nose Assemblies
Fitting Instructions
Servicing Instructions
Nose Tips
Type 1
Type 1A
Jaw Spreader Housing
Type 2
8
8
9 to 12
9
10
11
12
Accessories
Stem Deflector
Preparing the Base Tool for use with Stem Deflector
Extension
Swivel Heads
Straight Swivel Head capability
Preparing the Base Tool for Right-Angle and Straight
Swivel Head Attachment
Right-Angle Swivel Head capability
Swivel Head Fitting Instructions
Swivel Head Servicing Instructions
Constant Components
15
16
17
17
Servicing the Tool
Daily / Weekly
MolyLithium Grease EP 3753 Safety Data
Molykote® 55m Grease Safety Data
Molykote® 111 Grease Safety Data
Service Kit
Maintenance
Nose Equipment
Dismantling the Tool
Head Assembly
Pneumatic Piston Assembly
Air Valve
Rotary Valve
Trigger
Stop Plate Assembly (71213-03900)
18
18
19
19
20
20
20
21
21
22
22
23
23
24
General Assembly of Base Tool
General Assembly
Parts List
26
27
Priming
Oil Details
Hyspin® VG32 Oil Safety Data
Priming Kit
Priming Procedure
28
28
28
29
Fault Diagnosis
Symptom, Possible Cause and Remedy
30
13
13
13
14
14
15
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.
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.
3
Safety Instructions
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
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 air line from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8
Do not operate a tool/machine that is directed towards any person(s) or the operator.
9
Always adopt a firm footing or a stable position before operating the tool/machine.
10 Ensure that vent holes do not become blocked or covered.
11 The operating pressure shall not exceed 7 bar.
12 Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise.
13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.
14 Vacuum Air MUST be turned off using the Trigger before removing the Stem Collector Bottle which MUST be emptied when half full.
15 The Tool MUST NOT be operated with the Stem Collector Bottle removed.
16 If the tool is fitted with a stem deflector, it should be rotated until the aperture is facing away from the operator and other person(s)
working in the vicinity.
17 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against fastener
ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the application.
18 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be kept
dry and clean for best possible grip.
19 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
20 Excessive contact with hydraulic fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
21 C.O.S.H.H. data for all hydraulic fluid oils and lubricants is available on request from your tool supplier.
4
Specifications
To o l S p e c i f i c a t i o n
Air Pressure
Minimum - Maximum
5-7 bar
Free Air Volume Required
@ 5.5 bar
1.2 litres
Stroke
Minimum
14 mm
Pull Force
@ 5.5 bar
6.0 kN
Cycle Time
Approximately
0.9 seconds
Weight
Including nose equipment
1.7 kg
Vibration
Less than
2.5 m/s2
Noise Level
75 dB(A)
To o l D i m e n s i o n s
82.30
22.80
DIA
123.3
0
120.6
1
282.00
54.00
DIA
30.00 DIA
15
104.00
0.
00
93.00 DIA
104.00
90.61
SCRAP VIEW SHOWING BOTTLE
STEM COLLECTOR (SHORT VERSION)
NOTE: Stem Collector Short
Version Bottle is an accessory
part number 71213-03810
Dimensions in millimetres
5
Intent of Use
Range of Fasteners
nG1 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.
If you wish to place most of the fasteners in the table
opposite, you can order the 71203-00039 complete tool
comprising of:
•
•
•
71203-02000 base tool
71203-15000 nose assembly
Nose tips 71210-05002 and 71210-16070. Fit nose tip
as indicated on page 8 or 9.
FASTENER SIZE (
FASTENER
NAME
2.4
3/32
MM
IN
)
3
3.2 4.0 4.3 4.8
5
5.2
6
6.5
7
–
1/8 5/32
–
–
–
–
–
–
3/16
AVEX ®
STAVEX ®
AVINOX ®II
AVIBULB ®
BULBEX®
T-LOK ®
AVDEL ® SR
ETR
N RIVET
Q RIVET
*AVSEAL®II
* For Avseal® equipment refer to separate Data Sheet 07900-00840.
You can order the above two nose tips and nose
assembly as a nose assembly kit part number 7120315100.
•
For some fasteners the base tool, nose assembly
and nose tip must be ordered separately.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON
PAGE 8.
To assist with nose equipment maintenance spanner
07900-00849 is supplied with the base tool.
Part Numbering
1
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 26-27. If a swivel head is fitted, the same base tool must be adapted. See details page 14.
These nose assemblies will allow placing of fasteners by simply selecting the appropriate nose tip from the
range of Type 1 or 1A Nose Tips. Other nose assemblies are available for applications with restricted
access and special fasteners. See table page 12. A nose assembly can be substituted by a swivel head
(see pages 14-15). In this case the nose tip is part of the swivel head.
2
3
3
2
1
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.
NOSE TIP
1
see note 3
+
2
+
3
=
COMPLETE TOOL
71203-00 . . .
NOSE ASSEMBLY
71203-15000
or 71213-15000
BASE TOOL
71203-02000
*
n
6
1
ADD 3 DIGITS FROM THE
LAST COLUMN OF A NOSE
TIP TABLE ON PAGE 10 OR
12.
FOR TOOLS WITH SWIVEL
HEADS USE TABLE PAGES 1415.
n
1
*
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 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.
STOP COCK
(USED DURING MAINTENANCE
OF FILTER/REGULATOR OR LUBRICATION UNITS)
TAKE OFF POINT
FROM
MAIN SUPPLY
3 METRES MAXIMUM
0 2 4
141
12 6
6 8 10
MAIN SUPPLY
DRAIN POINT
G1
AIR LUBRICATION
PERMISSABLE
PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)
O p e r a t i n g P ro c e d u r e
•
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.
Do not use tool when Stem
Collector Bottle is removed
•
A partial rotation and pull movement removes the collector bottle.
The Trigger should be lifted to cut-off the vacuum air supply prior
to removing the collector bottle.
•
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.
7
Nose Assemblies
Fitting Instructions
I M P O R TA N T
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 (pages 9, 10 and 12).
•
Lightly coat Jaws 4 with MolyLithium 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.
•
Insert Detent Sleeve 10 into Jaw Spreader Housing ‘T’ 9. Not applicable to Type ‘2’ Nose Assemblies.
•
Fit Locking Ring 8 onto the Jaw Spreader Housing “T’ 9.
•
For tools converted to nose assembly Type ‘2’, fit Locking Ring 8 onto the Jaw Spreader Housing ‘T’ 9 attached to the tool.
•
Tighten Jaw Housing 3 and assembled components onto Jaw Spreader Housing ‘T’ 9.
•
Utilising the ‘T’ section profiles assemble Nose Assembly onto the tool piston via the Male ‘T’ Adaptor 40 - pages 26-27.
Not applicable to Type ‘2’ Nose Assemblies.
•
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
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 equipment.
•
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 Service Kit. For complete list see page 20.
8
Nose Assemblies
Nose Tips
I M P O R TA N T
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A tool (except part number 71203-00039) 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’ table below and on pages 10 and 12.
If your application presents no access restriction use a Type ‘1’ 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 12.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a 71203-00039
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.
Swivel heads are available as an alternative to nose assemblies when further reach is required. See pages 14-16 in the ‘Accessories’ section.
TYPE 1
NOSE TIPS
1 In inches then in millimetres.
2 Head forming nose tips for use with countersunk heads
ONLY.
* Complete tool part number 71203-00039 does
not only include the 71203-15000 nose assembly
below but also the followin g two nose tips:
71210-0500 2 and 71210-1607 0 making up a
nose assembly kit part number 71203-15100. Use
the nose tip listed in the table.
FA S T E N E R
MATERIAL
Ø1
1/8
3.2 Al Alloy
1/8
3.2 Steel
1/8
3.2 Al Alloy
–
3.0 Al Alloy
5 / 32 4.0
Al Alloy
5 / 32 4.0
Al Alloy
5 / 32
4.0 Al Alloy
BULBEX ®
AVINOX ® II 1/8 3.2 Stainless Steel
1/8
3.2 Steel
AVIBULB ®
AVDEL ® SR 1/8 3.2 Any
5 / 32
4.0 Any
1/8
3.2 Steel
STAVEX ®
1/8
3.2 Stainless Steel
1/8
3.2 Any
Q RIVET
3
Any
/ 32 2.4
N RIVET
NAME
AVEX ®
NOSE TIP (mm)
PART Nº
'A'
'B'
71210-05002 12.7 4.8
71210-16070 12.7 3.3
07340-064012 12.7 2.9
71210-05002 12.7 4.8
71210-16070 12.7 3.3
07340-065012 12.7 3.3
71210-16070 12.7 3.3
71210-16070 12.7 3.3
71210-16070 12.7 3.3
71210-05002 12.7 4.8
71210-16070 12.7 3.3
71210-16070 12.7 3.3
71210-16070 12.7 3.3
71210-05002 12.7 4.8
71200-16051 12.7 3.3
N O S E A S S E M B LY
part nº 71203-15000
* Items 3-11 availabl e as cartridg e assembl y
71203-20320
Note:
Alternative spring 07498-04301 should be fitted if
stem jamming occure s when installin g small
diameter fasteners.
(+ 2nose tips above = 71203-15100)
ITEM
DESCRIPTION
1
TAPERED NOSE CASING
2
'O' RING
3
JAW HOUSING TAPERED
4
JAWS
5
JAW SPREADER
6
BUFFER
7
(See Note:) SPRING
8
LOCKING RING
9 JAW SPREADER HOUSING 'T'
10
DETENT SLEEVE
11
'O' RING
PART Nº
71213-00350
07003-00067
71210-15902*
71200-15001*
07498-04502*
71210-05001*
07500-00418*
07340-00327*
71210-20321*
71210-20322*
07003-00277*
A
1
see
below
… 0 3 9*
… 0 3 9*
…003
… 0 3 9*
… 0 3 9*
…009
… 0 3 9*
… 0 3 9*
… 0 3 9*
… 0 3 9*
… 0 3 9*
… 0 3 9*
… 0 3 9*
… 0 3 9*
…033
2
3
4 5 6
7
10 8 11 9
B
COMPLETE TOOL
PART NUMBER :
precede with 71203-00.
* See top left
9
Nose Assemblies
Nose Tips
TYPE 1A
NOSE TIPS
1 In inches then in millimetres.
2 Head forming nose tips for use with countersunk heads
ONLY.
* Items 3-11 availabl e as cartridg e assembl y
71213-20320
FA S T E N E R
MATERIAL
Ø1
5 / 32 4.0
Steel
3 / 16 4.8
Al Alloy
3 / 16
4.8 Al Alloy
Large flange
3 / 16 4.8
Al Alloy
3 / 16 4.8
Al Alloy
BULBEX ®
®
4.3 Steel
T-LOK
®
5
/ 32
4.0 Steel
AVIBULB
5 / 32 4.0
Steel
STAVEX ®
5 / 32
4.0 Stainless Steel
5 / 32 4.0
Any
Q RIVET
NAME
AVEX ®
NOSE TIP (mm)
PART Nº
'A'
'B'
07381-04701 12.7 2.8
07381-04701 12.7 2.8
07340-04800 19.0 3.3
07340-066012 12.7 4.1
07381-04701 12.7 2.8
07340-06201 12.7 3.3
07381-04701 12.7 2.8
07381-04701 12.7 2.8
07381-04701 12.7 2.8
07340-06201 12.7 3.3
see
below
…020
…020
…016
…015
…020
…120
…020
…020
…020
…120
N O S E A S S E M B LY
part nº 71213-15000
ITEM
DESCRIPTION
1
TAPERED NOSE CASING
2
'O' RING
3
JAW HOUSING TAPERED
4
JAWS
5
JAW SPREADER
6
BUFFER
7
SPRING
8
LOCKING RING
9 JAW SPREADER HOUSING 'T'
10
DETENT SLEEVE
11
'O' RING
PART Nº
71213-00350
07003-00067
71210-15902*
71210-15001*
07498-04502*
71210-05001*
07500-00418*
07340-00327*
71210-20321*
71210-20322*
07003-00277*
A
1
10
2
3
4 5 6
7
10 8 11 9
B
COMPLETE TOOL
PART NUMBER :
precede with 71203-00.
Nose Assemblies
Nose Tips
Jaw Spreader Housing
To fit Nose Tip Type 2 or Nose Extension, the Male ‘T’ Adaptor 40 must be replaced with Jaw Spreader Housing 9*.
•
•
Loosen Locknut 39 using 16mm AF Spanner.
Unscrew and remove Male ‘T’ Adaptor 40 together with ‘O’ Ring 11.
40
11
39
41
35
•
Fit Jaw Spreader Housing 9* (71210-02101) together with ‘O’ Ring 10* or 11* (Jaw Spreader Housing 9* and ‘O’ Ring 10* or
11* are supplied with Type 2 Nose Assembly)
•
The Jaw Spreader Housing 9* must be tightened onto Head Piston 35 trapping Vacuum Sleeve 41 finally tighten
Locknut 39 against Jaw Spreader Housing 9*.
9*
10* or 11*
41
35
Items 9* and 10* or 11* refer to illustrations on pages 9, 10 and 12.
For other items refer to the general assembly drawing and parts list on pages 26 and 27.
11
Nose Assemblies
Nose Tips
To fit Nose Tip Type 2 remove Male ‘T’ Adaptor 40 and replace with Jaw Spreader Housing 9* and ‘O’ Ring 10*.
TYPE 2
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15200
ITEM
DESCRIPTION
1
NOSE CASING
2
'O' RING
3
JAW HOUSING
4
JAWS
5
JAW SPREADER
6
BUFFER
7
SPRING
8
LOCKING RING
9 JAW SPREADER HOUSING
10
'O' RING
PART Nº
07340-02804
07003-00067
07340-00304
71210-15001
07498-04502
71210-05001
07500-00418
07340-00327
71210-02101
07003-00277
FASTENER
MATERIAL
Ø1
1/8
3.2 Aluminium Alloy
1/8
3.2 Steel
5 / 32 4.0
Aluminium Alloy
5 / 32 4.0
Steel
3 / 16 4.8
Aluminium Alloy
BULBEX ® 5/32 4.0 Aluminium Alloy
3 / 16 4.8
Aluminium Alloy
T-LOK ®
4.3 Steel
1/8
STAVEX ®
3.2 Steel
5 / 32 4.0
Steel
1/8
3.2 Stainless Steel
5 / 32 4.0
Stainless Steel
AVIBULB ® 1/8 3.2 Steel
5 / 32 4.0
Steel
5 / 32 4.0
ETR
Steel
NAME
AVEX ®
1
NOSE TIP (mm)
PART Nº
'A'
'B'
07340-02805 9.5 12.95
07340-02806 9.5 11.4
07340-02806 9.5 11.4
07340-02807 12.7 10.0
07340-02807 12.7 10.0
07340-02806 9.5 11.4
07340-02807 12.7 10.0
07241-07101 12.7 10.0
07340-02806 9.5 11.4
07340-02807 12.7 10.0
07340-02806 9.5 11.4
07340-02807 12.7 10.0
07340-02806 9.5 11.4
07340-02807 12.7 10.0
07340-02807 12.7 10.0
see
below
…002
…008
…008
…014
…014
…008
…014
…121
…008
…014
…008
…014
…008
…014
…014
In inches then in millimetres.
TYPE 2 NOSE TIPS ARE EXTENDED
TO ALLOW ACCESS INTO
APPLICATIONS WHERE TYPE 1
NOSE TIPS WILL NOT REACH.
COMPLETE TOOL
PART NUMBER :
precede with
71203-00
A
B
22.9
9&10
10
9
8
7
6 5 4
2
1
58.3
Remove Male ‘T’ Adaptor 40 from the Tool (see page 11) and replace with
Jaw Spreader Housing 9* (71210-02101) and ‘O’ Ring 10*.
9* and 10* refer to the illustrations on this page. Item 40 refer to pages 26 and 27.
12
3
Accessories
Stem Deflector
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:
Preparing the Base Tool for use with Stem Deflector
The air line must be disconnected before any servicing or dismantling.
‘Sealed Nut’ 71213-02200 replaces Locknut 39 (to cut-off air supply to Vacuum System) as follows:
•
•
•
•
•
Loosen Locknut 39 using
16mm AF Spanner.
Unscrew and remove both
Male ‘T’ Adaptor 40 and
Locknut 39.
Replace Locknut 39 with
‘Sealed Nut’ 71213-02200,
screw ‘Sealed Nut’ onto Head
Piston 35 to disable Vacuum
System.
Male ‘T’ Adaptor 40 must be
tightened onto Head Piston
35, finally tightening ‘Sealed
Nut’ against it.
Remove the Stop Plate
Assembly (page 24) by
unscrewing Screws 63 (2off).
40
39
71213-20101
ADAPTOR
35
07340-00342
STEM DEFLECTOR
STEM DEFLECTOR
07340-00342
•
•
Fit Stem Deflector (07340-00342) into Adaptor (71213-20101).
Push the assembled Stem Deflector and Adaptor over Bottle
Adaptor Assembly 31 and align with the cut-out feature.
SEALED NUT
71213-02200
ADAPTOR
71213-20101
STEM DEFLECTOR: 71213-20100
Extension
Fitted between the tool and the nose assembly the extension allows
access into deep channels.
•
•
•
•
•
The Tool must be fitted with Jaw Spreader Housing 9* (7121002101) and ‘O’ Ring before extension (71210-20300). See
page 11.
To fit the extension, remove any nose assembly components.
Screw the Inner extension to Jaw Spreader Housing 9*.
Screw the Outer extension onto Head Assembly 50.
Fit the nose assembly onto the extension.
INNER
OUTER
EXTENSION - ‘T’ ADAPTOR 71213-12000
EXTENSION - NON QUICK RELEASE 71210-20300
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
9* refers to illustrations on pages 11 and 12.
13
Accessories
Swivel Heads
Instead of a nose assembly, a swivel head can be fitted to a base tool. It allows 360° rotation of the tool about the nose tip and allows
access into many applications otherwise too restrictive. There are two types of swivel heads: the straight swivel head with the nose tip
slightly offset from the centre line of the tool head and the right-angle swivel head with the nose tip on a perpendicular axis to the head of
the tool. See drawings below for dimensions and pages 15-16 for detail.
I M P O R TA N T
PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the Base Tool opposite.
In contrast to nose assemblies part numbers of swivel heads do INCLUDE a nose tip as shown below.
Swivel heads are supplied separately for fitting to a base tool forming a complete tool. See table below for part numbers. Jaws and nose
tips vary depending on the fastener to be placed but all other components remain the same within each type of swivel head. See the
‘capability’ tables below and page 15. For the ‘Constant Components’ table see page 17.
'A’ and ‘B’ dimensions will help you assess the accessibility of your application.
STRAIGHT SWIVEL HEAD capability
SWIVEL HEAD
PART Nº
07345-03000
07345-03100
07345-03100
07345-03200
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
07494-06000
07494-06600
07494-06100
07494-06700
FA S T E N E R
MATERIAL
Ø1
1 / 8 3.2 Al Alloy
1 / 8 3.2 Steel
5 / 32 4.0 Al Alloy
5 / 32 4.0 Steel
3 / 16 4.8 Al Alloy
BULBEX ® 5/32 4.0 Al Alloy
3 / 16 4.8 Al Alloy
AVINOX ®II 1/8 3.2 Stainless Steel
5 / 32 4.0 Stainless Steel
1 / 8 3.2 Steel
STAVEX ®
5 / 32 3.2 Steel
1 / 8 4.0 Stainless Steel
5 / 32 4.0 Stainless Steel
–
AVSEAL ®II
4 Al Alloy
–
4 Al Alloy
–
5 Al Alloy
–
5 Al Alloy
NAME
AVEX ®
56
92
NOSE TIP (mm)
'A'
PART Nº
07345-03600
7.87
07345-03700
7.87
07345-03700
7.87
07345-03800
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
07494-06001
6.35
6.35
07494-066012
7.62
07494-06101
7.62
07494-067012
A
20
'B'
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
1.95
4.11
2.00
4.11
JAWS
PART Nº
07340-00213
07340-00213
07340-00213
07490-04602
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07340-00213
07340-00213
07340-00213
see
below
…001
…004
…004
…010
…010
…004
…010
…004
…010
…004
…010
…004
…010
…160
…180
…161
…181
COMPLETE TOOL PART NUMBER :
precede with 71203-30
(the stop nut and safety cap are included)
6
360• rotation
1 In inches then in millimetres.
B
IMPORTANT: by opposition to complete tools
with nose assemblies, those fitted with swivel heads
include the nose tip as a part of the head.
2 Long nose tip for deep placing.
Remove Male ‘T’ Adaptor 40 from the Tool (see pages 11 and 15) and replace with
Jaw Spreader Housing (71210-02101).
14
Accessories
Preparing the Base Tool for Right-Angle and Straight Swivel Head A t t a c h m e n t
•
•
•
Disconnect the air supply.
Remove any nose assembly items.
Remove Stem Collector Bottle Assembly
24 (71213-03800).
Replace assembly 24 with Safety Cap
(71213-20201)
Unscrew Male ‘T’ Adaptor 40 and remove
with ‘O’ Ring 11, Locknut 39, ‘O’ Rings 18
and 14, and Seal Housing 48. Do not refit
these items.
Screw Stop Nut (71213-20200) onto the
front of Head Piston 35 as far as it will go
by hand.
Fit Jaw Spreader Housing (71210-02101)
and ‘O’ Ring 11, tighten onto Head Piston
35, finally tighten Stop Nut against Jaw
Spreader Housing.
•
•
•
•
The tool is now ready to be fitted with a swivel
head. Instructions page 16.
Base tool to receive a nose assembly
40
11 39
48
18
14
35
Base tool to receive a swivel head
71213-20201
SAFETY CAP
71213-20200
STOP NUT
View with 24 removed
and stop nut
replacing removed
items 14, 18, 39, 48 and 40
Item numbers in bold refer to the general
assembly drawing and parts list on pages 2627.
R I G H T- A N G L E S W I V E L H E A D c a p a b i l i t y
FASTENER
MATERIAL
Ø1
1 / 8 3.2 Aluminium Alloy
1 / 8 3.2 Steel
5 / 32 4.0 Aluminium Alloy
5 / 32 4.0 Steel
3 / 16 4.8 Aluminium Alloy
5 / 32 4.0 Aluminium Alloy
BULBEX®
3 / 16 4.8 Aluminium Alloy
1 / 8 3.2 Stainless Steel
AVINOX ® II
5 / 32 4.0 Stainless Steel
–
4 Aluminium Alloy
AVSEAL ® II
–
4 Aluminium Alloy
–
5 Aluminium Alloy
–
5 Aluminium Alloy
1 / 8 3.2 Steel
STAVEX ®
5 / 32 4.0 Steel
1 / 8 3.2 Stainless Steel
5 / 32 4.0 Stainless Steel
NAME
AVEX ®
SWIVEL HEAD
PART Nº
07346-03000
07346-03100
07346-03100
07346-03200
07346-03200
07346-03100
07346-03200
07346-03100
07346-03200
71213-04000
71213-04700
71213-04100
71213-04800
07346-03100
07346-03200
07346-03100
07346-03200
NOSE TIP (mm)
'A'
PART Nº
07345-03600
7.87
07345-03700
7.87
07345-03700
7.87
07345-03800
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
7.87
71213-16401
6.35
2
71213-16402
6.35
71213-16403
7.62
71213-16404 2
7.62
7.87
07345-03700
7.87
07345-03800
7.87
07345-03700
7.87
07345-03800
97
74
7.6
56
52
32
A
20
B
360• rotation
1
In inches then in millimetres.
2
'B'
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
1.95
4.11
2.00
4.11
3.81
3.81
3.81
3.81
JAWS
PART Nº
07340-00213
07340-00213
07340-00213
07490-04602
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07340-00213
07340-00213
07340-00213
07340-00213
07490-04602
07340-00213
07490-04602
see
below
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010
COMPLETE TOOL PART NUMBER :
precede with 71203-40
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete tools
with nose assemblies, those fitted with swivel
heads include the nose tip as a part of the head.
Long nose tip for deep placing.
Remove Male ‘T’ 40 Adaptor from the Tool and replace with Jaw Spreader Housing
(71210-02101) See ‘Preparing the Base Tool’ above and page 11.
15
Accessories
The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.
I M P O R TA N T
PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the Base Tool page 15.
The air supply must be disconnected when fitting or removing swivel heads.
Swivel Head Fitting Instructions
The following procedure will allow you to assemble and fit either of the swivel heads to the tool. If you order a complete swivel head
rather than individual components, you will only need to start at stage ‘L’.
All moving parts should be lubricated. Unless stated otherwise use MolyLithium grease (details page 18).
When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.
1
18
17
16
3
20
19
16
5
14
13
6
12
21
10
8
7
22
11
A
Fit Locking Ring 10 over Jaw Spreader Housing 9*
(71210-02101). *See pages 11 and 12.
B
Coat Screw 13 with thread locking adhesive and use to
secure Nose Tip 14 onto Body 5.
C
Lightly lubricate items 17, 18, 19, 20 and insert into
Jaw Carrier 3 as shown. Secure with Screws 16.
D
Position Lever 4 into Body 5 and hold in place with pin
15 through the hole of Body 5 (not a slot).
E
Lubricate the sides of the Jaw Carrier Assembly and
insert into Body 5.
F
Lubricate Rollers 8 and ENSURE that they will freely
rotate in the holes of Adaptor 9. If necessary ream the
holes.
G
Position Spring Clip 7 over Adaptor 9 past the holes for
the rollers and rotate until the locating peg is aligned
with the corresponding hole in Adaptor 9 (smallest
hole).
H
Fit Adaptor 9 over the end of Body 5 and drop Rollers 8
into place. Push Spring Clip 7 over Rollers 8.
I
Insert Spindle 11 through Adaptor 9 into Jaw Carrier 3
until the hole lines up with slot in Body 5. Temporarily
hold in place with Pin 6.
J
Insert Pin 12 through the front slot of Body 5 into Jaw
Carrier 3.
K
Hold the assembly vertical to prevent all pins dropping
out and slide the jaw carrier assembly back and forth a
few times to ensure free movement. Go to M.
L
Remove Screws 23 (4 off) and Guard 1. On a straight
swivel head also remove Screw 21 and Platform 22.
8
9
8
STRAIGHT SWIVEL HEAD
18
23 17
19
20
15
1
16
2
11
16
4
3
14
N
Screw the assembly over Spindle 11 onto the tool
handle. Replace Pin(s) 6.
O
On straight swivel heads attach Platform 22 onto the
top of the Spindle 11 with Screw 21. Deburr the back
end of Platform 22 so that it cannot catch on Guard 1.
P
Snap Guard 1 over the assembly, align screw holes in
guard with tapped holes in body assembly.
Q
Insert Pivot Pin 15 through slots in guard and hole in
body. Fit Circlip 2 onto pivot pin so that the circlip seats
in groove provided.
R
Coat the thread of Screws 23 (4 off) with thread locking
adhesive and screw into body assembly securing guard
to body assembly.
7
6
8
6
13
M Push Pin(s) 6 out and let Spindle 11 drop out. Screw
Spindle 11 onto the Jaw Spreader Housing of the tool,
leaving the small screw fixing hole uppermost for
straight swivel. Tighten gently with a tommy bar.
12
5
9
8
10
RIGHT-ANGLE HEAD
9* refers to illustrations on pages 11 and 12.
16
Accessories
Swivel Head Servicing Instructions
Swivel heads should be serviced at weekly intervals.
•
Remove the complete head using the reverse procedure to
the ‘Fitting instructions’ omitting step ‘L’.
18
17
•
If Guard 1 is at all damaged it must be replaced by a new
one.
20
19
•
Any worn or damaged parts should be replaced.
•
Pay particular attention to jaw carrier items in the upper
illustration opposite as follows:
Check wear on Jaws 17.
Check that Jaw Spreader Tube 18 is not distorted.
Check that Spring 19 is neither broken or distorted.
Check that Spring Guide 20 is not damaged.
•
Check that Spring clip 7 is not distorted. When removing
Spring Clip 7, use two screwdrivers as shown in the lower
illustration opposite.
•
Check for excessive wear on slots of Body 5.
•
Assemble according to fitting instructions.
7
5
Item numbers in bold refer to Swivel Head illustrations on
this page. Guard 1 refers to illustration on page 16.
While nose tips and jaws will vary for each swivel head, other components remain constant within each type of head. See table below.
For nose tips and jaws part numbers see the tables on pages 14 and 15.
CONSTANT COMPONENTS
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
18
19
20
21
22
23
DESCRIPTION
STRAIGHT SWIVEL
RIGHT-ANGLE SWIVEL
GUARD
CIRCLIP
JAW CARRIER
LEVER
BODY
PIVOT PIN
SPRING CLIP
ROLLER
ADAPTOR
LOCKING RING
SPINDLE
DOWEL PIN
SCREW
PIVOT PIN
SCREW
JAW SPREADER
SPRING
SPRING GUIDE
SCREW
PLATFORM
SCREW
07494-05000
07494-03026
07494-03015
07343-02207
07495-03900
07007-00039
07345-03001
07345-03003
07345-03002
07007-00038
07342-02207
07494-03028
07346-03101
07165-00305
07494-03027
07001-00368
07345-00401
-
07495-03003
07004-00105
07494-03026
07495-03004
07495-03002
07343-02207
07495-03900
07007-00039
07345-03001
07345-03003
07345-03002
07007-00038
07342-02207
07346-03102
07494-03028
07346-03101
07165-00305
07494-03027
07210-00804
17
S e r v i c i n g t h e To o l
I M P O R TA N T
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
•
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 29 explains
how to measure the stroke.
•
Either a stem collector or a stem deflector must be fitted to the tool unless a swivel head is fitted.
•
Check that Base Cover 30 is fully tightened onto Body 29.
•
Stem Collector Bottle: ‘O’ Rings 19 and 27 to be checked for wear, cleaned and lubricated with Molykote® 55m.
We e k l y
•
Dismantle and clean the nose assembly with special attention to the jaws. Lubricate with MolyLithium grease before assembling.
•
Check for oil leaks and air leaks in the air supply hose and fittings.
MolyLithium Grease EP 3753 Safety Data
Grease can be ordered as a single item, the part number is shown in the Service Kit page 20.
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: CO2, Halon or water spray if applied by an experienced operator.
Environment
Scrape up for incineration or disposal on approved site.
Handling
Use barrier cream or oil resistant gloves
Storage
Away from heat and oxidizing agent.
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
18
S e r v i c i n g t h e To o l
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.
Molykote® 111 Grease Safety Data
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.
19
S e r v i c i n g t h e To o l
Service Kit
For an easy complete service, Avdel offers the complete service kit below.
SERVICE KIT : 71210-99990
PART Nº
07900-00667
07900-00692
07900-00670
07900-00672
07900-00706
07900-00684
07900-00685
07900-00351
07900-00469
07900-00158
07900-00164
07900-00008
Spanners are specified in inches and across flats unless otherwise stated
DESCRIPTION
PISTON SLEEVE
TRIGGER VALVE EXTRACTOR
BULLET
'T' SPANNER
LOCATION SPIGOT
GUIDE TUBE
INSERTION ROD
3 mm ALLEN KEY
2.5 mm ALLEN KEY
2 mm PIN PUNCH
CIRCLIP PLIERS
7
/16î x 1/2” SPANNER
PART Nº
DESCRIPTION
07900-00012 9/16” x 5/8” SPANNER
07900-00015 5/8” x 11/16” 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 GREASE - MOLYKOTE® 111
07900-00850 PIN SPANNER
07900-00898 VALVE HOOK
07900-00224 4 mm ALLEN KEY
07900-00734 STOP NUT - MAXLOK ®
Maintenance
(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.
I M P O R TA N T
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.
The air line 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 five steps of the ‘Priming Procedure’ on page 29.
Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 8 to
12 or if a swivel head was fitted pages 14 to 16.
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 and to fit an appropriate nose assembly or swivel head.
Nose Equipment
•
Unscrew Nose Casing 1 and Nose Tip.
•
Remove the Nose Equipment Cartridge by sliding in the same plane to the Piston.
•
Unscrew Jaw Housing 3 from the Jaw Spreader Housing ‘T’ 9 and remove Jaws 4, Jaw Spreader 5, Spring 7, Buffer 6 and Detent
Sleeve 10.
•
Inspect all components. Renew all damaged or worn parts.
•
Clean all parts and apply MolyLithium Grease EP 3753 (07992-00020) to taper bore of Jaw Housing.
•
Reassemble in reverse order to above.
Item numbers in bold refer to Nose Tip Tables on pages 9 and 10.
20
S e r v i c i n g t h e To o l
D i s m a n t l i n g t h e To o l
Before dismantling the tool the oil must be emptied from it.
•
With the air supply switched OFF at ON/OFF Valve Assembly 53 remove Bleed Screw 1 and Bonded Seal 5.
•
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.
Ensure the bleed screw orifice is facing away from the person performing this operation.
Head Assembly
•
Twist and pull off Stem Collector Bottle Assembly 24. See illustration on page 7.
•
Remove Stop Plate Assembly 69 by unscrewing Screws 63 2 off.
•
Unscrew Retaining Nut 47.
•
Pull off Bottle Adaptor Assembly 31 together with ‘O’ Rings 19 and 27.
•
Remove End Cap Assembly 34 together with ‘O’ Rings 65 and Lip Seal 8.
•
Remove Spring 64.
•
Loosen Locknut 39 with a spanner* and unscrew Male ‘T’ Adaptor 40 together with ‘O’ Ring 11.
•
Withdraw Vacuum Sleeve 41.
•
Remove Locknut 39 together with ‘O’ Rings 18 and 14.
•
Push Head Piston 35 to the rear and out of Head Assembly 50 taking care not to damage the cylinder bore.
•
Using circlip pliers* remove Seal Retainer 42. Push Lip Seal 7 and Bearing Tape 25 to the rear and out of Head Assembly 50 taking
care not to damage the cylinder bore.
•
Remove Seal Housing 48 and Lip Seal 2.
Assemble in reverse order noting the following points:
•
Place Lip Seal 7 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*.
•
The chamfered edge of Seal Retainer 42 must face forward with the gap at the bottom.
•
After fitting Lip Seals 10, 9, ‘O’ Ring 17 and Bearing Tape 26 onto the Head Piston 35 ensuring correct orientation, lubricate the
cylinder bore and place the piston sleeve* into the back of Head Assembly 50. Slide the bullet* onto the threaded part of Head Piston
35 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*.
•
Male ‘T’ Adaptor 40 must be fully tightened onto Head Piston 35 before tightening Locknut 39 against it.
•
Reprime in accordance with the instructions on page 29.
* Item included in the Service Kit. For complete list see page 20.
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
21
S e r v i c i n g t h e To o l
Pneumatic Piston Assembly
•
Remove ‘ON/OFF’ Valve Assembly 53.
•
Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice fitted with soft jaws.
•
Pull off Rubber Boot 28.
•
Using the peg spanner* unscrew Base Cover 30.
•
Remove Cylinder Liner 36.
•
Remove Pneumatic Piston Assembly 49 together with ‘O’ Ring 57, Lip Seal 56 and Guide Ring 58.
•
Engage the Seal Extractor* into Intensifier Seal Assembly 54 and withdraw Seal Assembly from intensifier tube of the Head Assembly 50.
Assemble in reverse order to dismantling.
•
Seals should be checked for damage and replaced as necessary. Lubricate pneumatic seals with Molykote® 55m and hydraulic seals with
Molykote® 111.
A i r Va l v e
Dismantling
•
Remove Pneumatic Piston Assembly 49 as described above in Pneumatic Piston Assembly.
•
Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706). Unscrew Clamp Nut 38 and remove together with Clamp
Plate 43 together with Transfer Tube Assembly 52, Valve Rod Assembly 55 and ‘O’ Rings 13.
•
Remove tool from vice and separate Body 29 from Handle Assembly 70. Remove ‘O’ Ring 16.
•
Push out the Valve Seat 33, from the Body 29, together with ‘O’ Rings 13.
•
Pull out Valve Spool Assembly 51 from Handle Assembly 70. Remove ‘O’ Ring 6 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 38 and tighten to torque 11ftlb (14.91 Nm)
I M P O R TA N T
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 Service Kit. For complete list see page 20.
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
22
S e r v i c i n g t h e To o l
R o t a r y Va l v e
Dismantling
•
Using a 2mm pin punch (07900-00158) drive Trigger Pin 45 out and remove Trigger Assembly 32.
•
Remove Pneumatic Piston Assembly 49 as described in Pneumatic Piston Assembly page 22.
•
Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706), unscrew Clamp Nut 38 and remove together
with Clamp Plate 43 together with Transfer Tube Assembly 52 and seperate Body 29 from Handle Assembly 70. Remove ‘O’
Rings 15 and 16.
•
Seperate Head Assembly 50 from Handle Assembly 70. NOTE ORIENTATION OF ROTARY VALVE 37.
•
Push out Rotary Valve 37 together with ‘O’ Rings 4.
Assemble in reverse order to Dismantling Instructions noting the following:
•
Seals should be checked for damage and replaced if necessary, lubricated with Molykote® 55m grease.
•
Ensure Rotary Valve 37 is assembled in correct orientation to align valve pins with forks on the Trigger Assembly 32.
See illustration below.
Tr i g g e r
Dismantling
•
Using a 2mm pin punch (07900-00158) drive Trigger Pin 45 out and remove Trigger Assembly 32.
•
Unscrew Trigger Valve 20 using trigger valve extractor (07900-00692).
Assemble in reverse order to Dismantling Instructions noting the following:
•
When assembling Trigger Assembly 32 the trigger forks locate on the pins each side of the Rotary Valve 37.
•
Ensure Rotary Valve 37 is orientated correctly. See illustration below.
37
32
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
23
S e r v i c i n g t h e To o l
Stop Plate Assembly (71213-03900)
Assembly (see illustration below)
•
Place ‘O’ Ring 2 into the recess in Housing 5 retain in position using grease Molykote® 55m.
•
Assemble ‘O’ Ring 4 onto Piston 1 and push assembly into Housing 5 making sure it is in as far as it will go.
•
Position the slot in Piston 1 parallel to the step face in Housing 5.
•
Slide Plate Shut Off 3 into the assembled parts 1, 2, 4, and 5. Retain parts in place using grease Molykote® 55m.
•
Place ‘O’ Ring 4 into the recess of Cover Plate 6 retain in position using grease Molykote® 55m.
•
Place Spring 7 into position, locate using the recesses in both Plate Shut Off 3 and Bottle Adaptor Assembly 31*.
•
Position the above assembled parts onto Bottle Adaptor Assembly 31*.
•
Secure in position using two Screws 63*.
*see pages 26 and 27.
ITEM DESCRIPTION
4
1
PISTON
2
‘O’ RING
3
PLATE SHUT OFF
4
‘O’ RING
5
HOUSING
6
COVER PLATE
1
7
SPRING
3
31*
2
4
5
63*
6
7
CLOSED
24
OPEN
Notes
25
26
18
14
41
B
B
A
56
49
55 Assy
52 Assy
36
A
43
20
66
48
Assy 32
45
39
40 11
35
'X'
15
16
28
30
57
29
46
38
58
Detail 'X'
17
26
24 Assy
34 Assy
69 Assy
12 27
19 47 63
64
65 31
8
9
54 Assy
70 Assy
16
Assy
50 2 25 7 1,5 42 10
3
44
21
33
60
A-A
13
43
13
23
61
62
6
13
59
Assy 51
Suspension
Ring
4
3
22
53 Assy
B-B
37
G e n e r a l A s s e m b l y o f B a s e To o l 7 1 2 0 3 - 0 2 0 0 0
Parts List for 71203-02000
27
Priming
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full stroke
after considerable use, when the stroke may have been reduced and fasteners are not now being fully placed by one operation of the trigger.
Oil Details
The recommended oil for priming is Hyspin® VG32 available in 0.5 litre (part number 07992-00002) or one gallon (part number 0799200006) containers. Please see safety data below.
Hyspin® VG32 Oil Safety Data
First Aid
SKIN:
Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact requires no
immediate attention.
INGESTION:
Seek medical attention immediately. DO NOT induce vomiting.
EYES:
Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact.
Fire
Flash point 232°C. Not classified as flammable.
Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets.
Environment
WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation.
SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material.
Handling
Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.
Storage
No special precautions.
Priming Kit
To enable you to follow the priming procedure opposite, you will need to obtain a priming kit:
PRIMING KIT : 07900-00688
PART Nº
07900-00351
07900-00700
07900-00224
07900-00698
07900-00734
28
DESCRIPTION
3mm ALLEN KEY
PRIMING PUMP
4mm ALLEN KEY
STOP NUT
STOP NUT - MAXLOK®
Priming
P r i m i n g P ro c e d u r e
I M P O R TA N T
DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE SPOOL 62.
REMOVE NOSE ASSEMBLY OR SWIVEL HEAD COMPONENTS.
All operations should be carried out on a clean bench, with clean hands in a clean area.
Ensure that the new oil is perfectly clean and free from air bubbles.
Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result.
•
Switch OFF air supply at ON/OFF Valve Assembly 53.
•
Remove all nose equipment. (see page 8)
•
Remove Bleed Screw 1 and Bonded Seal 5.
•
Invert tool over suitable container, switch ON air supply at ON/OFF Valve Assembly 53 and actuate tool.
•
Residual oil in the tools hydraulic system will empty through bleed screw port.
CARE SHALL BE TAKEN TO ENSURE THAT THE BLEED HOLE IS NOT DIRECTED TOWARDS THE OPERATOR OR OTHER
PERSONNEL.
•
Switch air supply OFF at ON/OFF Valve Assembly 53.
•
Screw priming pump (07900-00700) into bleed screw port, utilising Bonded Seal 5.
•
Actuate Priming Pump by pressing down and releasing several times until resistance is evident and the Head Piston starts to move
rearward.
ENSURE PUMP IS KEPT ‘SQUARE’ TO BLEED SCREW PORT DURING PRIMING OPERATION TO PREVENT BREAKAGE OF
BLEED NIPPLE ON PRIMING PUMP.
•
Remove the priming pump, surplus oil will expel from bleed screw port.
•
Replace the Bleed Screw 1 together with Bonded Seal 5.
•
Switch ON air supply at ON/OFF Valve Assembly 53.
•
Check that the stroke of the head piston reaches specification. If not repeat above procedure.
•
Switch OFF air supply and refit nose equipment. (see page 8).
•
Check that the stroke of the tool meets the minimum specification of 14 millimetres. To chech the stroke, measure the distance
between the front face of the jaw spreader housing and the front of the head, BEFORE pressing the trigger and when the trigger is
fully actuated. The stroke is the difference between the two measurements. If it does not meet the minimum specification, repeat the
Priming Procedure.
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
29
Fault Diagnosis
M PpTtO
SSyYm
oM
m
P oP sO sS iSbI Bl eL ECCaAuUsSeE
M EeDdYy
RReEm
P aPA
g GeE RReEfF
More than one
Air leak
Tighten joints or replace components
operation of the
Insufficient air pressure
Adjust air pressure to within specification
5
trigger needed to
Worn or broken jaws
Fit new jaws
8
place fastener
Low oil level or air in oil
Prime tool
28, 29
Build up of dirt inside the nose assembly
Service nose assembly
8†
Tool will not grip
Worn or broken jaws
Fit new jaws
8, 9, 10, 12
stem of fastener
Build up of dirt inside the nose assembly
Service nose assembly
8
Loose jaw housing
Tighten against locking ring
8
Weak or broken spring in nose assembly
Fit new spring
8, 9, 10, 12
Incorrect component in nose assembly
Identify and replace
9, 10, 12
Jaws will not release
Build up of dirt inside the nose assembly
Service nose assembly
8†
broken stem of
Jaw housing, nose tip or nose casing
fastener
not properly seated
Tighten nose assembly
9, 10, 12
Weak or broken spring in nose assembly
Fit new spring
9, 10, 12
Air or oil leak
Tighten joints or replace components
Low oil level or air present in oil
Prime tool
28-29
Broken stems jammed inside tool
Empty stem collector
7
Cannot feed next
fastener
Slow cycle
Tool fails to operate
Check jaw spreader is correct
9, 10, 12
Adjust air pressure to within specification
5
Low air pressure
Adjust air pressure to within specification
5
Build up of dirt inside the nose assembly
Service nose assembly
8†
No air pressure
Connect and adjust to within specification
5
Damaged Trigger Valve 20
Replace
23
Adjust air pressure to within specification
5
Fastener fails to break Insufficient air pressure
Fastener outside tool capability
Use more powerful Genesis tool.
Contact Avdel UK Limited.
Low oil level or air present in oil
Prime tool
* Pages 14 to 16 if a swivel head is used instead of a nose assembly.
† Page 16 if a swivel head is used instead of a nose assembly.
Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.
30
28-29
Declaration of Conformity
We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY
declare under our sole responsibility that the product:
Model nG1
Serial No.
................................................
to which this declaration relates is in conformity with the following standards:
EN ISO 12100 - parts 1 & 2
BS EN ISO 8662 - part 6
BS EN ISO 11202
BS EN ISO 3744
BS EN 982
ISO EN 792 part 13 - 2000
BS EN 983
following the provisions of the Machine Directive 2006/42/EC
A. Seewraj - Product Engineering Manager - Automation Tools
Date of issue
This box contains a power tool which is in
conformity with Machines Directive
2006/42/EC. The ‘Declaration of Conformity’
is contained within.
31
Since 1 936
2010
AUSTRALIA
Infastech (Australia) Pty Ltd.
891 Wellington Road
Rowville
Victoria 3178
Tel:
+61 3 9765 6400
Fax: +61 3 9765 6445
info@infastech.com.au
GERMANY
Avdel Deutschland GmbH
Klusriede 24
30851 Langenhagen
Tel:
+49 (0) 511 7288 0
Fax: +49 (0) 511 7288 133
AvdelDeutschland@infastech.com
INDIA
Infastech Fastening Technologies
India Private Limited
Plot No OZ-14, Hi Tech SEZ,
SIPCOT Industrial Growth Center,
Oragadam, Sriperumbudur Taluk,
Kanchipuram District,
602105 Tamilnadu
Tel:
+91 44 4711 8001
Fax: +91 44 4711 8009
info-in@infastech.com
CANADA
Avdel Canada Limited
1030 Lorimar Drive
Mississauga
Ontario L5S 1R8
Tel:
+1 905 364 0664
Fax: +1 905 364 0678
infoAvdel-Canada@infastech.com
CHINA
Infastech (China) Ltd.
RM 1708, 17/F., Nanyang Plaza,
57 Hung To Rd., Kwun Tong
Hong Kong
Tel:
+852 2950 0631
Fax: +852 2950 0022
infochina@infastech.com
ITALY
Avdel Italia S.r.l.
Viale Lombardia 51/53
20047 Brugherio (MI)
Tel:
+39 039 289911
Fax: +39 039 2873079
vendite@infastech.com
FRANCE
Avdel France S.A.S.
33 bis, rue des Ardennes
BP4
75921 Paris Cedex 19
Tel:
+33 (0) 1 4040 8000
Fax: +33 (0) 1 4208 2450
AvdelFrance@infastech.com
Manual No.
07900-00843
JAPAN
Infastech Kabushiki Kaisha
Center Minami SKY,
3-1 Chigasaki-Chuo, Tsuzuki-ku,
Yokohama-city,
Kanagawa Prefecture
Japan 224-0032
Tel:
+81 45 947 1200
Fax: +81 45 947 1205
info@infastech.co.jp
Issue
MALAYSIA
Infastech (Malaysia) Sdn Bhd
Lot 63, Persiaran Bunga Tanjung 1,
Senawang Industrial Park
70400 Seremban
Negeri Sembilan
+606 676 7168
Tel:
Fax: +606 676 7101
info-my@infastech.com
TAIWAN
Infastech/Tri-Star Limited
No 269-7, Baodong Rd,
Guanmiao Township,
71841 Tainan County,
Taiwan, R.O.C
+886 6 596 5798 (ext 201)
Tel:
Fax: +886 6 596 5758
info-tw@infastech.com
SINGAPORE
Infastech (Singapore) Pte Ltd.
31 Kaki Bukit Road 3
#05-03/06 Techlink
Singapore, 417818
Tel:
+65 6372 5653
Fax: +65 6744 5643
info-sg@infastech.com
UNITED KINGDOM
Avdel UK Limited
Pacific House
2 Swiftfields
Watchmead Industrial Estate
Welwyn Garden City
Hertfordshire AL7 1LY
Tel:
+44 (0) 1707 292000
Fax: +44 (0) 1707 292199
enquiries@infastech.com
SOUTH KOREA
Infastech (Korea) Ltd.
212-4, Suyang-Ri,
Silchon-Eup, Kwangju-City,
Kyunggi-Do, Korea, 464-874
Tel:
+82 31 798 6340
Fax: +82 31 798 6342
info@infastech.co.kr
USA
Avdel USA LLC
614 NC Highway 200 South
Stanfield, North Carolina 28163
Tel:
+1 704 888 7100
Fax: +1 704 888 0258
infoAvdel-USA@infastech.com
SPAIN
Avdel Spain S.A.
C/ Puerto de la Morcuera, 14
Poligono Industrial Prado Overa
Ctra. de Toledo, km 7,8
28919 Leganés (Madrid)
Tel:
+34 91 3416767
Fax: +34 91 3416740
ventas@infastech.com
Change Note No.
B
07/044
B2
07/103
B3
07/174
C
11/017
www.avdel-global.com
www.infastech.com
Autosert® (equipment), Avbolt ®, Avdel®, Avdelmate ®, Avdel TX2000®, Avdelok®, Avex®, Avibulb ®, Avinox®, Avinut™, Avlug®, Avmatic®, Avplas®,
Avseal®, Avsert®, Avtainer ®, Avtronic®, Briv®, Bulbex®, Chobert®, Eurosert®, Fastriv®, Finsert®, Genesis®, Grovit®, Hemlok ®, Hexsert®, Holding
your world together®, Hydra®, Interlock ®, Klamp-Tite ®, Klamptite KTR ®, Kvex®, Maxlok ®, Monobolt ®, Monobulb ®, Neobolt®, Nutsert®, Nutsert
SQ®, Portariv®, Rivmatic ®, Rivscrew®, Speed Fastening ®, Squaresert®, Stavex®, Supersert®, Thin Sheet Nutsert ®, Titan®, T-Lok®, TLR®, TSN®,
TX2000®, Versa-Nut ®, Viking® and Viking 360 ® are trademarks of Avdel UK Limited. Infastech™ and Our Technology, Your Success™ are
trademarks of Infastech Intellectual Properties Pte Ltd. The names and logos of other companies mentioned herein may be trademarks
of their respective owners. This document is for informational purposes only. Infastech makes no warranties, expressed or implied, in this
document. Data shown is subject to change without prior notice as a result of continuous product development and improvement policy.
Your local Avdel representative is at your disposal should you need to confirm latest information.
02.2011 • © 2010 Infastech
Since 1922
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