I n s t r u c t i o n M a n u a l

G e n e s i s

®

G 2 L B

H y d ro - P n e u m a t i c P o w e r To o l

2

C o n t e n t s

Safety Rules

Specifications

Tool Specification

Tool Dimensions

Intent of Use

Part Numbering

Putting into Service

Air Supply

Operating Procedure

Nose Assemblies

Avdelok ® and Maxlok ® Nose Assemblies

Fitting Instructions Avdelok ®

Servicing Instructions

Fitting Instructions Maxlok ®

Servicing Instructions

Accessories

Stem Deflector

Extension

Servicing the Tool

Daily / Weekly

Moly Lithium Grease EP 3753 Safety Data

MolyKote ® 55m and MolyKote ® 111 Safety Data

Annually

Service Kit

Head Assembly

Pneumatic Piston Assembly

Valve Spool Assembly

Trigger

General Assembly of Base Tool

General Assembly and Parts List

Priming

Oil Details

Hyspin ® VG 32 Safety Data

Priming Kit

Priming Procedure

Fault Diagnosis

Symptom, Possible Cause and Remedy

4

5

5

6

7

7

8

9

9

10

10

11

11

12

12

13

14

14

14-15

15

15

15

16-17

18

18

18

19

20

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

4

S a f e t y R u l e s

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 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 unless specifically instructed otherwise.

13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.

14 If the tool is fitted with a stem collector, it must be emptied when half full.

15 If the tool is fitted with a stem deflector, it should be rotated until the aperture is facing way from the operator and other person(s) working in the vicinity.

16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against fastener ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the application.

17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be kept dry and clean for best possible grip.

18 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.

19 Excessive contact with hydraulic fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash thoroughly.

20 C.O.S.H.H. data for all hydraulic oils and lubricants is available on request from your tool supplier.

S p e c i f i c a t i o n s

To o l S p e c i f i c a t i o n

Air Pressure

Free Air Volume Required

Stroke

Pull Force

Cycle time

Noise Level

Weight

Vibration

Minimum - Maximum

@ 5.5 bar

5-7 bar (72.5 - 101.5 psi)

2.1 litres

Minimum 13mm

@ 5.5 bar 12.47 KN

Without nose equipment

Less than

75 dB(A)

1.35 kg

2.5 m/s 2 (8.2 ft/s 2 )

To o l D i m e n s i o n s

70

116

145

2

2 120

110

305

12

°30'

23

121

150

Dimensions in millimetres.

5

6

I n t e n t o f U s e

G2LB is a hydro-pneumatic tool designed to place Avdel Avdelok ® /Maxlok ® fasteners at high speed making it ideal for batch or flow-line assembly in a wide variety of applications throughout all industries.

A complete tool is made up of two separate elements. See diagram below.

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGES 8-9-10.

P a r t N u m b e r i n g

1

The part number of the base tool remains the same whichever nose assembly is fitted. See the General Assembly and

Parts List pages 16-17.

2 The nose assembly will allow placing of fasteners by simply selecting the appropriate nose assembly. See page 8.

2 MAXLOK®

NOSE ASSEMBLY

07610-02000( 3 / 16 )

07610-02100( 1 / 4 )

2 AVDELOK®

NOSE ASSEMBLY

71230-05010( 3 / 16 )

71230-05020( 1 / 4 )

1

BASE TOOL

71255-02000

1 + 2 =

COMPLETE TOOL

MAXLOK®

71255-00371( 3 / 16 )

71255-00372( 1 / 4 )

AVDELOK®

71255-00391( 3 / 16 )

71255-00392( 1 / 4 )

P u t t i n g i n t o S e r v i c e

A i r S u p p l y

All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and automatic filtering systems on the main air supply. These should be fitted within 3 metres of the tool (see diagram below) to ensure maximum tool life and minimum tool maintenance.

Air supply hoses should have a minimum working effective pressure rating of 150% of the maximum pressure produced in the system or

10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or 1 / 4 inch.

Read daily servicing details page 12.

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR)

3 METRES MAXIMUM

4

6

8 10

12

TAKE OFF POINT

FROM

MAIN SUPPLY

PRESSURE REGULATOR

AND FILTER (DRAIN DAILY)

MAIN SUPPLY

DRAIN POINT

O p e r a t i n g P ro c e d u r e

• Ensure that the correct nose assembly is fitted.

• Connect the tool to the air supply.

• Disable the vacuum extraction system by turning Rotary Valve

65 until you feel or hear no air flow out of the front of the nose assembly.

• Push the fastener stem through the application hole.

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

• 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.

• 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 AVDELOK

®

/MAXLOK

®

Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.

7

8

N o s e A s s e m b l i e s

A v d e l o k ® a n d M a x l o k ® N o s e A s s e m b l i e s

N O S E A S S E M B LY

NOSE ASSEMBLY part nº

71230-05010 for 4.8 ( 3 /

16

") Avdelok ®

NAME

AVDELOK ®

F A S T E N E R

Ø

1

MATERIAL

3/16

1/4

4.8

6.4

All

All

1

In inches then in millimetres

N O S E A S S E M B LY

PART Nº

7 1 2 3 0 - 0 5 0 1 0

7 1 2 3 0 - 0 5 0 2 0 s e e b e l o w

… 3 9 1

… 3 9 2

COMPLETE TOOL PART NUMBER : precede with 71255-00

NOSE ASSEMBLY part nº

71230-05020 for 6.4 ( 1 /

4

") Avdelok ®

ITEM DESCRIPTION PART

2 BUFFER

3 ANVIL

4 SHROUD

71230-05014

71230-05011

71230-05013

8 SPRING

10 nG4 CHUCK COLLET ADAPTOR

9 8 6

1

5

07220-02103

07610-00501

7 7

10 nG4 CHUCK COLLET ADAPTOR

4 3

11

(nG4)

10

(nG4)

M A X L O K ® -

N O S E A S S E M B LY

NAME

MAXLOK ®

F A S T E N E R

Ø 1 MATERIAL

3/16

1/4

4.8

6.4

All

Al Alloy

1

In inches then in millimetres

2 1

N O S E A S S E M B LY

PART Nº

0 7 6 1 0 - 0 2 0 0 0

0 7 6 1 0 - 0 2 1 0 0 s e e b e l o w

… 3 7 1

… 3 7 2

COMPLETE TOOL PART NUMBER : precede with 71255-00

ITEM

4

7

8

9

10

NOSE ASSEMBLY part nº 07610-02000 for 3 /

16

" ø

DESCRIPTION

JAWS

SPRING

LOCKING RING

CHUCK COLLET

SPRING GUIDE

12

13

ANVIL nG4 STOP NUT ASSY

14 nG4 CHUCK COLLET ADAPTOR

15

16

ANVIL ADAPTOR

ANVIL NUT

PART Nº

07610-02003

07610-02107

07610-02004

07610-02002

07220-02104

07610-02001

71233-20200

07610-00501

71230-02063

07610-00307

ITEM

4

7

8

9

10 part nº 07610-02100 for 1 /

4

" ø

DESCRIPTION

JAWS

SPRING

LOCKING RING

CHUCK COLLET

SPRING GUIDE

PART Nº

07610-02103

07610-02107

07610-02004

07610-02102

07220-02104

12

13

ANVIL

nG4 STOP NUT ASSY

07610-02101

71233-20200

14 nG4 CHUCK COLLET ADAPTOR 07610-00501

15

16

ANVIL ADAPTOR

ANVIL NUT

71230-02063

07610-00307

16 13

(nG4)

14

(nG4)

15 8 10 7 10 4

READ MAXLOK ® 'FITTING INSTRUCTIONS' PAGE 10.

9 12

52

N o s e A s s e m b l i e s

F i t t i n g I n s t r u c t i o n s A v d e l o k ®

I M P O R T A N T

Air supply must be disconnected when fitting or removing nose assemblies

• Assemble Chuck Jaws 6, Spring Guides 7 and Spring 8 into Chuck Collet 5. (Lightly coat Chuck Jaws and Chuck Collet internal bores with Molylithium grease).

• Screw chuck collet (assembled as above) onto Chuck Collet Adaptor of tool assembly (item 1 page 16). Lock in position with

Friction Ring 9.

• Screw Anvil 3 into front of placing tool.

• Assemble Buffer 2 over Anvil 3 followed by Anvil Casing 1.

• Fit rubber Shroud 4 over Anvil Casing 1 and Buffer 2 and locate over flange of Anvil 3 to hold components in position.

9 7 8 7 6

1

5

4 3 2

S e r v i c i n g I n s t r u c t i o n s

• Remove nose assembly from tool using the reverse procedure to the fitting instructions above.

• Clean parts. Worn or damaged parts should be replaced.

• Check Anvil 3 for wear and/or damage to the swaging bore.

• Lightly coat Chuck Jaws 6 and Chuck Collet 5 internal bores with Molylithium grease.

• Assemble as above instructions.

• For ease of fitting the rubber shroud, liquid soap can be smeared on its internal surface prior to assembly.

1

Item numbers in bold refer to the Avdelok ® Nose Assembly on page 8.

9

N o s e A s s e m b l i e s

F i t t i n g I n s t r u c t i o n s M a x l o k ®

I M P O R T A N T

Air supply must be disconnected when fitting or removing nose assemblies

• 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 10 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 15 into the Head Assembly.

• Place Anvil 12 over Chuck Collet 9 and lock into place with Anvil Nut 16.

15 8 10 7 10 4 9 12

S e r v i c i n g I n s t r u c t i o n s

• Remove nose assembly from tool using the reverse procedure to the fitting instructions above.

• Clean parts. Worn or damaged parts should be replaced.

• Check the Anvil 12 for wear and/or damage to the swaging bore.

• Lightly coat Chuck Jaws 4 and Chuck Collet 9 internal bores with Molylithium grease.

• Assemble as above instructions.

16

10

Item numbers in bold refer to the Maxlok ® Nose Assembly on page 8.

A c c e s s o r i e s

S t e m D e f l e c t o r

The stem deflector is a very simple alternative to the standard stem collector and allows access in restricted areas. It is easy to fit to the tool as follows:

• Unscrew Retaining Nut 26 by inserting a 3 millimetre diameter rod into one of the holes.

• Remove Retaining Nut 26 and the stem collector assembly, items 18, 20, 21, 22, 23, 24, and 25.

• Push the boss end of the stem deflector into the internal groove of the adaptor nut.

• Rotate the stem deflector until the aperture faces away from the operator and other person(s) in the vicinity.

STEM DEFLECTOR

07340-00342

ADAPTOR NUT

71210-20101

KIT PART NUMBER: 71210-20100

E x t e n s i o n

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 Chuck Collet Adaptor 1.

• Screw the outer onto Head Assembly 4.

• Fit the nose assembly onto the extension.

INNER OUTER

EXTENSION PART NUMBER: 71210-20300

Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16 and 17.

11

S e r v i c i n g t h e To o l

I M P O R T A 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.

D a i l y

• 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 is correct for the fastener to be placed.

• Check that the stroke of the tool meets the minimum specification (page 5). The last step of the Priming Procedure on page 19 explains how to measure the stroke.

• Either a stem collector or a stem deflector must be fitted to the tool.

• Ensure that Rotary Valve 65 is turned OFF.

We e k l y

• Dismantle and clean nose assembly, with special attention to the jaws. Lubricate with Moly Lithium grease EP 3753 before assembling.

• Check for air leaks.

M o l y L i t h i u m G r e a s e E P 3 7 5 3 S a f e t y D a t a

Grease can be ordered as a single item, the part number is shown in the Service Kit page 13.

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 16-17.

12

S e r v i c i n g t h e To o l

M o l y k o t e ® 5 5 m G r e a s e S a f e t y D a t a

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.

M o l y k o t e ® 1 1 1 G r e a s e S a f e t y D a t a

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.

13

14

S e r v i c i n g t h e To o l

A n n u a l l y

(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 ®

Molykote

®

111 for hydraulic sealing.

55m grease for pneumatic sealing or

For an easy complete service, Avdel

® is offering a complete service kit.

SERVICE KIT : 71210-99990

PART Nº DESCRIPTION

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 2 MM PIN PUNCH

07900-00224 4 MM A/F ALLEN KEY

07900-00734 STOP NUT - MAXLOK ®

Spanners are specified in inches and across flats unless otherwise stated

PART Nº DESCRIPTION ®

07900-00164 CIRCLIP PLIERS

07900-00008

07900-00012

07900-00015

7 /

16

x 1 /

2

SPANNER

9

/

16

x

5

/

8

SPANNER

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 - MOLY LITHIUM E.P.3753

I M P O R T A 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 should be examined regularly for damage and malfunction.

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 19.

Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the Nose Assemblies section, pages 8,

9 and 10.

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.

H e a d A s s e m b l y

• Unscrew Retaining Nut 26 and pull off stem collector assembly, items 18, 20, 21, 22, 23, 24 and 25.

• Using the ‘T’ spanner*, remove End Cap Assembly 73 together with Seal 17, ‘O’ Ring 16, Lip Seal 28 and Spring 70.

• Loosen Locknut 3 with a spanner* then unscrew Chuck Collet Adaptor 1.

• Remove Locknut 3 together with ‘O’ rings 49 and 50.

• Remove screw 9 and Bonded Seal 10.

• Push Head Piston 7 to the rear and out of Head Assembly 4 taking care not to damage the cylinder bore.

• Remove Seal Retainer 30. Push Lip Seal 8 to the rear and out of Head Assembly 4 taking care again not to damage the cylinder bore.

• Remove Seal Housing 5 and Lip Seal 67.

* Item included in the Service Kit.

Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.

S e r v i c i n g t h e To o l

H e a d A s s e m b l y

Assemble in reverse order to dismantling noting the following points:

• Place Lip Seal 8 onto the insertion rod* ensuring correct orientation. Push the guide tube* into the head of the tool and push the insertion rod* with the seal into place through the guide tube*. Pull the insertion rod* out then the guide tube.

• Drop Seal Retainer 30 against Lip Seal 8 large flange first.

• Fit Lip Seal 11 and ‘O’ Ring 13 (2 off) onto the head piston 7.

• Lubricate the cylinder bore and place the piston sleeve* into the back of Head Assembly 4. Slide the bullet* onto the threaded part of

Head Piston 7 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 the piston sleeve.

• Fit Seal Housing 5 and Lip Seal 67.

• Tighten Chuck Collet Adaptor 1 fully tightened onto Head Piston 7 BEFORE tightening Locknut 3 against it.

• Use Loctite ® 932 when reassembling Retaining Nut 26.

P n e u m a t i c P i s t o n A s s e m b l y

• Remove ‘ON/OFF’ Valve Assembly 60.

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

• Pull off Rubber Boot 80.

• Using the peg spanner* unscrew Base Cover 40.

• Unscrew Locknuts 76 (2 off) and remove Base Plate 77.

• Remove Cylinder Liner 45 together with Sealing Washers 75 (2 off) and 'O' Rings 78 (2 off).

• Remove Pneumatic Piston Assembly 42 together with ‘O’ Ring 39, Lip Seals 41 (3 off) and Guide Ring 35.

• Engage the Seal Extractor* into Seal Assembly 34 and withdraw Seal Assembly from intensifier tube of the Head Assembly 4.

Assemble in reverse order.

Va l v e S p o o l A s s e m b l y

• Remove Pneumatic Piston Assembly 42 and Intensifier Seal Assembly 34 as described above.

• Using the ‘T’ spanner* and ‘T’ spanner spigot* undo Clamp Nut 36 and remove it together with Top Plate 63, Transfer Tube Assembly

44, ‘O’ ring 6 and Silencers 62.

• Release the tool from the vice and separate Body 38 with ‘O’ Ring 31 from Handle Assembly 32.

• Remove ‘O’ Ring 33 from the intensifier tube and pull off Head Assembly 4 from Handle Assembly 32.

• Push out Valve Seat 64 with ‘O’ Ring 6.

• Pull out all the components of Valve Spool Assembly 54.

• Finally remove ‘O’ Ring 59 out of the handle counterbore.

Assemble in reverse order noting the following points -

• Ensure that the central port in Valve Seat 64 faces upwards.

• Use Loctite ® 243 when reassembling Clamp Nut 36, torque to 11ft lb (14.91 Nm).

Tr i g g e r

• Using the 2 millimetre diameter pin punch*, drive Trigger Pin 48 out and lift off Trigger 47.

• Unscrew Trigger Valve 46 using the trigger valve extractor*.

Assemble in reverse order to dismantling.

I M P O R T A N T

Check the tool against daily and weekly servicing

Priming is ALWAYS necessary after the too has been dismantled and prior to operating.

* Item included in the Service Kit. For complete list see page 14.

Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.

15

16

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 5 5 - 0 2 0 0 0

P a r t s L i s t f o r 7 1 2 5 5 - 0 2 0 0 0

17

18

P r i m i n g

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 be reduced and fasteners are not fully placed by one operation of the trigger.

O i l D e t a i l s

The recommended oil for priming is Hyspin ®

07992-00006). Please see safety data below.

VG32 available in 0.5l (part number 07992-00002) or one gallon containers (part number

H y s p i n

®

V G 3 2 O i l S a f e t y D a t a

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: CO

2

, 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.

P r i m i n g K i t

To enable you to follow the priming procedure opposite, you will need to obtain a priming kit:

PART Nº

PRIMING KIT : 07900-00688

DESCRIPTION

07900-00351

07900-00698

07900-00700

07900-00224

07900-00734

3mm ALLEN KEY

STOP NUT

PRIMING PUMP

4mm ALLEN KEY

MAXLOK ® STOP NUT

P r i m i n g

P r i m i n g P ro c e d u r e

I M P O R T A N T

DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 55.

REMOVE NOSE ASSEMBLY.

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.

• Remove bleed Screw 9 and Bonded Seal 10.

• Connect air supply to tool and switch ON/OFF Valve Assembly 60 to "ON” position.

• Invert tool over suitable container and actuate trigger. Waste oil will be ejected through the bleed screw hole.

CARE SHALL BE TAKEN TO ENSURE THAT THE BLEED HOLE IS NOT DIRECTED TOWARDS THE OPERATOR OR OTHER

PERSONNEL.

• Screw stop nut 07900-00734 onto Chuck Collet Adaptor 1.

• Disconnect air supply to tool or switch ON/OFF Valve Assembly 60 to ‘OFF” position.

• Fill the priming pump with oil.

• Screw priming pump 07900-00700 into the bleed screw hole with Bonded Seal 10 in place.

• Actuate the priming pump by pressing down and releasing several times until resistance is felt.

• Remove the priming pump and the stop nut.

• Replace bleed Screw 9 and Bonded Seal 10.

• Connect air supply to tool and switch ON/OFF Valve Assembly 60 to ‘ON” position.

• Check that the stroke of the tool meets the minimum specification of 13 millimetres. To check the stroke, measure the distance between the front face of Chuck Collet Adaptor 1 and the front face 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 16-17.

19

F a u l t D i a g n o s i s

S y m p t o m P o s s i b l e C a u s e R e m e d y P a g e R e f

More than one operation of the trigger needed to place fastener

Tool will not grip stem of fastener

Air leak

Insufficient air pressure

Worn or broken jaws

Low oil level or air in oil

Tighten joints or replace components

Adjust air pressure to within specification

Fit new jaws

Prime tool

Build up of dirt inside the nose assembly Service

Worn or broken jaws Fit new jaws

Build up of dirt inside the nose assembly Service

Loose jaw housing or chuck collet Tighten against locking ring

Weak or broken spring in nose assembly Fit new spring

Incorrect component in nose assembly Identify and replace

Jaws will not release Build up of dirt inside the nose assembly Service broken stem of chuck collet.

fastener Tighten nose assembly

Weak or broken spring in nose assembly Fit new spring

Air or oil leak

Low oil level or air present in oil

Tighten joints or replace components

Prime tool

Low oil level or air present in oil

Tool fails to swage Insufficient air pressure collar Worn or damaged anvil

Low oil level or air present in oil

9

8-9

18-19

Cannot feed next fastener

Slow cycle

Broken stems jammed inside tool Empty stem collector

Check correct equipment is fitted

Adjust air pressure to within specification

4 (point 14)

8-9

5

Low air pressure Adjust air pressure to within the specification 5

Build up of dirt inside the nose assembly Service 12

Tool fails to operate No air pressure

Damaged Trigger Valve 46

Loose stem collector

Connect and adjust to within the specification 5

Replace

Tighten Retaining Nut 26

15

15

Fastener fails to break Insufficient air pressure

Fastener outside tool capability

Adjust air pressure to within specification 5

Use more powerful Genesis tool.

Contact Avdel Uk Limited

Prime tool 18-19

Adjust air pressure to within specification

Replace

Prime tool

5

8-9

18-19

9

9

9

9

9

5

9

18-19

9

12

Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.

Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.

20

N o t e s

21

N o t e s

22

D e c l a r a t i o n o f C o n f o r m i t y

We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY declare under our sole responsibility that the product:

Model G2LB

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 3744

ISO EN 792 part 13 - 2000

BS EN ISO 11202

BS EN 982

BS EN 983 following the provisions of the Machine Directive 98/37/EC

A. Seewraj - Product Engineering Manager - Automation Tools

Date of issue

This box contains a power tool which is in conformity with Machines Directive

98/37/EC. The ‘Declaration of Conformity’ is contained within.

23

AUSTRALIA

Acument Australia Pty Ltd.

891 Wellington Road

Rowville, Victoria 3178

Tel: +61 3 9765 6400

Fax: +61 3 9765 6445

Email: [email protected]

CANADA

Avdel Canada, a Division of Acument

Canada Limited.

87 Disco Road

Rexdale

Ontario M9W 1M3

Tel: +1 416 679 0622

Fax: +1 416 679 0678

Email: [email protected]

CHINA

Acument China Ltd.

RM 1708, 17/F., Nanyang Plaza,

57 Hung To Rd., Kwun Tong

Hong Kong

Tel: +852 2950 0631

Fax: +852 2950 0022

Email: [email protected]

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

Email: [email protected]

GERMANY

Avdel Deutschland GmbH

Klusriede 24

30851 Langenhagen

Tel: +49 (0) 511 7288 0

Fax: +49 (0) 511 7288 133

Email: [email protected]

ITALY

Avdel Italia S.r.l.

Viale Lombardia 51/53

20047 Brugherio (MI)

Tel: +39 039 289911

Fax: +39 039 2873079

Email: [email protected]

JAPAN

Acument Japan 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

Email: [email protected]

SINGAPORE

Acument Asia Pacific (Pte) Ltd.

#05-03/06 Techlink

31 Kaki Bukit Road 3

Singapore, 417818

Tel: +65 6840 7431

Fax: +65 6840 7409

Email: [email protected]

SOUTH KOREA

Acument 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

Email: [email protected]

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 (0) 91 3416767

Fax: +34 (0) 91 3416740

Email: [email protected]

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

Email: [email protected]

USA

Avdel USA LLC

614 NC Highway 200 South

Stanfield,

North Carolina 28163

Tel: +1 704 888-7100

Fax: +1 704 888-0258

Email: [email protected]

Manual No.

07900-00834

Issue Change Note No.

A 04/065

B 07/044

B2

B3

07-103

08-096

Date

06/04

02/07

03/07

07/08

Avdel®, Avdel® SR, Avex®, Avibulb®, Avinox®, Avseal®, Avtainer®, Bulbex®, Cherrymate®, Hemlock®, Interlock®, MBC®, Maxlok®, Q-Rivet™,

Stavex®, T-Lok®, TLR®, T Rivet™, are trademarks of Avdel UK Limited.

www.avdel-global.com