GENESIS NG2 - Pneumatic tool AVDEL - Free user manual and instructions

USER MANUAL GENESIS NG2 AVDEL

Safety Instructions	4	Servicing the Tool
		Daily / Weekly	18
Specifications		Moly Lithium Grease EP 3753 Safety Data	18
Tool Specification	5	Molykote® 55m Grease Safety Data	19
Tool Dimensions	5	Molykote® 111 Grease Safety Data	19
		Service Kit	20
Intent of Use		Maintenance	20
Range of Fasteners	6	Nose Equipment	20
Part Numbering	6	Dismantling the Tool	21
		Head Assembly	21
Putting into Service		Pneumatic Piston Assembly	22
Air Supply	7	Air Valve	22
Operating Procedure	7	Rotary Valve	23
		Trigger	23
Nose Assemblies		Stop Plate Assembly (71213-03900)	24
Fitting Instructions	8	General Assembly of Base Tool
Servicing Instructions	8	General Assembly	26
Nose Tips	9, 11	Parts List	27
Type 1	9
Avseal® II	10	Priming
Type 2	12	Oil Details	28
Type 3	12	Hyspin® VG 32 Oil Safety Data	28
		Priming Kit	28
		Priming Procedure	29
Accessories
Stem Deflector	13	Fault Diagnosis
Preparing the Base Tool for use with Stem Deflector	13	Symptom, Possible Cause and Remedy	30
Extension	13
Swivel Heads	14
Straight Swivel Head capability	14	François	33
Preparing the Base Tool for Right-Angle and Straight	15	Deutsch	63
Swivel Head Attachment
Right-Angle Swivel Head capability	15	Italiano	93
Swivel Head Fitting Instructions	16
Swivel Head Servicing Instructions	17
Constant Components	17

LIMITED WARRANTY

Avdel make 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 forgoing 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 forgoing warranty, the sole remedy shall be to return the defective Goods for replacement or refund for the purchase price at Avdel's option. THE FORGOING EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTY AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDING BY AVDEL.

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 oils and lubricants is available on request from your tool supplier.

Tool Specification

Air Pressure	Minimum - Maximum	5-7 bar
Free Air Volume Required	@ 5.5 bar	2.1 litres
Stroke	Minimum	17 mm
Pull Force	@ 5.5 bar	9.34 kN
Cycle Time	Approximately	0.9 seconds
Noise Level		75 dB(A)
Weight	Including nose equipment	2.1 kg
Vibration	Less than	2.5 m/s2

Tool Dimensions

Dimensions in millimetres

Intent of Use

Range of Fasteners

nG2 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 71213-00039 complete tool comprising of:

71213-02000 base tool
71213-15000 nose assembly
- Nose tips 71210-05002, 71210-16070 and 07381-04701. Fit nose tip as indicated page 8 or 9.

You can order the above three nose tips and nose assembly as a nose assembly kit part number 71213-15100.

FASTENER NAME	FASTENER SIZE (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®		●	●		●
ETR							●
BULBEX®			●		●
AVDEL® SR		●	●		●
MONOBOLT®					●
INTERLOCK®					●
AVDEL®		●	●		●
MBC®		●	●		●
MBC®/LC		●	●		●
AVSEAL®II			●			●		●	●	●
KLAMPTITE™KTR					●
KLAMPTITE™					●

• 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.

Part Numbering

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.

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. 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.

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.

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.

Operating Procedure

• 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.
• 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.

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 4 Nose Tip tables (pages 9, 10 and 12).

Lightly coat Jaws 4 with Moly Lithium 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 and 3 nose assemblies.
- Fit locking ring 8 onto the Jaw Spreader Housing "T' 9.
For tools converted to nose assemblies Type 2 and 3, 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 41 - pages 26-27. Not applicable to Type 2 and 3 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 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.

Nose Tips

IMPORTANT

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

A tool (except part number 71213-00039) 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' tables below and page 10 and 12.

If your application presents no access restriction use a Type '1' Nose Tip unless you are placing aerospace fasteners which requires a Type '3' Nose Tip.

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 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 71213-00039 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	FASTENER Ø1	MATERIAL	NOSE TIP (mm) PART N°	'A'	'B'	see below
AVEX® Large flange	1/8:3.2	Al Alloy	71210-05002	12.7	4.8	...039*
	1/8:3.2	Steel	71210-16070	12.7	3.3	...039*
	1/8:3.2	Al Alloy	07340-064012	12.7	2.9	...003
	-:3.0	Al Alloy	71210-05002	12.7	4.8	...039*
	5/32:4.0	Al Alloy	71210-16070	12.7	3.3	...039*
	5/32:4.0	Steel	07381-04701	12.7	2.8	...039*
	5/32:4.0	Al Alloy	07340-065012	12.7	3.3	...009
	3/16:4.8	Al Alloy	07381-04701	12.7	2.8	...039*
	3/16:4.8	Al Alloy	07340-04800	19.0	3.3	...016
	3/16:4.8	Steel	07490-04401	12.7	3.3	...017
	3/16:4.8	Al Alloy	07340-066012	12.7	4.1	...015
* Complete tool part number 71213-00039 does not only include the 71213-15000 nose assembly below but also the following three nose tips: 71210-05002, 71210-16070 and 07381-04701 making up a nose assembly kit part number 71213-15100. Use the nose tip listed in the table.	BULBEX® 3/16:4.8	Any	71210-16070	12.7	3.3	...039*
	3/16:4.8	Al Alloy	07381-04701	12.7	2.8	...039*
T-LOK® AVIBULB®	1/8:3.2	Stainless Steel	71210-16070	12.7	3.3	...039*
	5/32:4.0	Stainless Steel	07381-04701	12.7	2.8	...039*
	3/16:4.8	Stainless Steel	07498-01401	12.7	4.8	...082
* Items 3-11 available as cartridge assembly 71213-20320	AVDEL® SR	1/8:3.2	Any	71210-05002	12.7	4.8	...039*
	5/32:4.0	Any	71210-16070	12.7	3.3	...039*
	3/16:4.8	Any	07348-070014	12.7	5.7	...062
	3/16:4.8	Any	71210-160505	12.7	5.7	...064
INTERLOCK® STAVEX® Large flange Countersunk	1/8:3.2	Steel	71210-16070	12.7	3.3	...039*
	5/32:4.0	Steel	07381-04701	12.7	2.8	...039*
	3/16:4.8	Steel	07381-04701	12.7	2.8	...039*
	3/16:4.8	Steel	07340-04800	19.0	3.3	...016
	3/16:4.8	Steel	07381-04701	12.7	2.8	...039*
	1/8:3.2	Stainless Steel	71210-16070	12.7	3.3	...039*
	5/32:4.0	Stainless Steel	07381-04701	12.7	2.8	...039*
	3/16:4.8	Stainless Steel	71210-05002	12.7	4.8	...039*
QTM RIVET Large flange Countersunk	1/8:3.2	Any	71210-05002	12.7	3.3	...039*
	5/32:4.0	Any	07340-06201	12.7	3.3	...120
	3/16:4.8	Any	07340-06201	12.7	3.3	...120
KLAMPTITE™ KTR KLAMPTITE™	3/16:4.8	Al Alloy	71220-16060	12.7	4.8	...430
	3/16:4.8	Al Alloy	07381-04701	12.7	2.8	...039

AVSEAL®II NOSE TIPS

FASTENER NAME	Ø1	MATERIAL	NOSE ASSEMBLY	NOSE TIP (mm) PART N°	“A”	“B”	see below
AVSEAL®II	5/32	4.0	Standard Al. Alloy - Flush Nose Tip	71213-16100	71210-16102	12.7	2.5
	5/32	4.0	Standard Al. Alloy - 2mm Extended Nose Tip	71213-16100	71210-16106	12.7	5.4
	5/32	4.0	Standard Al. Alloy - 8mm Extended Nose Tip	71213-16100	71210-16110	12.7	11.4
	-	5.0	Standard Al. Alloy - Flush Nose Tip	71213-16100	71210-16103	12.7	2.5
	-	5.0	Standard Al. Alloy - 2mm Extended Nose Tip	71213-16100	71210-16107	12.7	5.4
	-	5.0	Standard Al. Alloy - 8mm Extended Nose Tip	71213-16100	71210-16111	12.7	11.4
	-	6.0	Standard Al. Alloy - Flush Nose Tip	71213-16100	71210-16104	12.7	2.5
	-	6.0	Standard Al. Alloy - 2mm Extended Nose Tip	71213-16100	71210-16108	12.7	5.4
	-	6.0	Standard Al. Alloy - 8mm Extended Nose Tip	71213-16100	71210-16112	12.7	11.4
	-	6.5	Standard Al. Alloy - Flush Nose Tip	71213-16100	71210-16114	12.7	2.5
	-	6.5	Standard Al. Alloy - 2mm Extended Nose Tip	71213-16100	71210-16115	12.7	5.4
	-	6.5	Standard Al. Alloy - 8mm Extended Nose Tip	71213-16100	71210-16116	12.7	11.4
	-	7.0	Standard Al. Alloy - Flush Nose Tip	71213-16100	71210-16105	12.7	2.5
	-	7.0	Standard Al. Alloy - 2mm Extended Nose Tip	71213-16100	71210-16109	12.7	5.4
	-	7.0	Standard Al. Alloy - 8mm Extended Nose Tip	71213-16100	71210-16113	12.7	11.4

Nose Tips

To fit Nose Tips Type 2/3 or Nose Extension, the 'T' Adaptor 41 must be replaced with Jaw Spreader Housing 9^* .

• Loosen Locknut 40 using 16mm AF Spanner.
• Unscrew and remove 'T' Adaptor 41 together with 'O' Ring 12.

• 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 and 3 Nose Assemblies)
• The Jaw Spreader Housing 9^ must be tightened onto Piston 36 trapping Vacuum Tube 42 finally tighten Locknut 40 against Jaw Spreader Housing 9^ .

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.

To fit Nose Tips Type 2 or 3 remove Male 'T' Adaptor 41 and replace with Jaw Spreader Housing 9^ and 'O' Ring 10^ .

Remove Male 'T' Adaptor 41 from the Tool (see page 11) and replace with Jaw Spreader Housing 9^ (71210-02101) and 'O' Ring 10^ .

Remove Male 'T' Adaptor 41 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.

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 Delector

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:

• Loosen Locknut 40 using 16mm AF Spanner.
• Unscrew and remove both 'T' Adaptor 41 and Locknut 40.
• Replace Locknut 40 with 'Sealed' Nut 71213-02200, screw 'Sealed' Nut onto Piston 36 to disable Vacuum System.
  T' Adaptor 41 must be tightened onto Piston 36, finally tightening 'Sealed' Nut against it.
• Remove the Stop Plate Assembly (page 24) by unscrewing Screws 89 (2 off).

• 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.

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* (71210-02101) 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 onto Head Assembly 4.
• Fit the nose assembly onto the extension.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.
9* refers to illustrations on pages 9, 10 and 12.

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.

IMPORTANT

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

FASTENER NAME	∅1	MATERIAL	SWIVEL HEAD PART N°	NOSE TIP (mm) PART N°	'A'	'B'	JAWS PART N°	see below
AVEX®	1/8	3.2	Al Alloy	07345-03000	07345-03600	7.87	3.81	07340-00213
	1/8	3.2	Steel	07345-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Al Alloy	07345-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Steel	07345-03200	07345-03800	7.87	3.81	07490-04602
	3/16	4.8	Al Alloy	07345-03200	07345-03800	7.87	3.81	07490-04602
BULBEX®	5/32	4.0	Al Alloy	07345-03100	07345-03700	7.87	3.81	07340-00213
	3/16	4.8	Al Alloy	07345-03200	07345-03800	7.87	3.81	07490-04602
AVINOX® II	1/8	3.2	Stainless Steel	07345-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Stainless Steel	07345-03200	07345-03800	7.87	3.81	07490-04602
AVSEAL® II	-	4	Al Alloy	71213-06000	71213-16401	6.35	1.95	07340-00213
	-	4	Al Alloy	71213-06600	71213-16402²	6.35	4.11	07340-00213
	-	5	Al Alloy	71213-06100	71213-16403	7.62	2.00	07340-00213
	-	5	Al Alloy	71213-06700	71213-16404²	7.62	4.11	07340-00213
AVDEL®	1/8	3.2	Al Alloy	07345-03300	07345-03301	5.08	1.17	07340-00229
	1/8	3.2	Al Alloy O	07494-03600	07494-03601	5.08	1.17	07340-00229
	1/8	3.2	Stainless Steel	07494-03000	07494-03011	5.08	3.81	07340-00213
	5/32	4.0	Al Alloy	07345-03400	07345-03401	6.6	0.84	07340-00229
	5/32	4.0	Al Alloy O	07494-03700	07494-03701	6.6	0.84	07340-00229
	3/16	4.8	Al Alloy	07345-03500	07345-03501	8.13	0.25	07498-04401
	3/16	4.8	Al Alloy O	07494-03800	07494-03801	8.13	0.25	07498-04401
MBC®	1/8	3.2	Al Alloy	07345-04000	07165-00701	4.75	1.9	07340-00229
	5/32	4.0	Al Alloy	07345-04100	07165-00702	6.35	2.36	07340-00229
	3/16	4.8	Al Alloy	07345-04200	07165-00703	7.92	2.46	07498-04401
MBC® L/C	1/8	3.2	Al Alloy	07345-04700	07345-04701	7.87	2.03	07340-00229
	5/32	4.0	Al Alloy	07345-04700	07345-04701	7.87	2.03	07340-00229
	5/32	4.0	Al Alloy O	07345-04800	07345-04701	7.87	2.03	07498-04401
	3/16	4.8	Al Alloy	07345-04800	07345-04701	7.87	2.03	07498-04401
STAVEX®	1/8	3.2	Steel	07345-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Steel	07345-03200	07345-03800	7.87	3.81	07498-04602
	1/8	3.2	Stainless Steel	07345-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Stainless Steel	07345-03200	07345-03800	8.13	3.81	07490-04602

360^ rotation

1 In inches then in millimetres.
2 Long nose tip for deep placing.

0 Oversize

COMPLETE TOOL PART NUMBER :

precedewith71213-30

(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.

Remove Male 'T' Adaptor 41 from the Tool (see page 15) and replace with Jaw Spreader Housing (71210-02101).

Preparing the Base Tool for Right-Angle and Straight Swivel Head Attachment

• Disconnect the air supply.
• Remove any nose assembly items.
• Remove Stem Collector Bottle Assembly 25 (71213-03800).
• Replace assembly 25 with Safety Cap (71213-20201)
• Unscrew Male 'T' Adaptor 41 and remove with 'O' Ring 12, Locknut 40, 'O' Rings 19 and 15, and Seal Housing 52. Do not refit these items.
• Screw Stop Nut (71213-20200) onto the front of Head Piston 36 as far as it will go by hand.
• Fit Jaw Spreader Housing (71210-02101) and 'O' Ring 12, tighten onto Head Piston 36, finally tighten Stop Nut against Jaw Spreader Housing.

The tool is now ready to be fitted with a swivel head. Instructions below.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26-27.

Base tool to receive a nose assembly
Base tool to receive a swivel head

RIGHT-ANGLE SWIVEL HEAD capability

FASTENER NAME	Ø1	MATERIAL	SWIVEL HEAD PART N°	NOSE TIP (mm) PART N°	'A'	'B'	JAWS PART N°	see below
AVEX®	1/8	3.2	Aluminium Alloy	07346-03000	07345-03600	7.87	3.81	07340-00213
	1/8	3.2	Steel	07346-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Aluminium Alloy	07346-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Steel	07346-03200	07345-03800	7.87	3.81	07490-04602
	3/16	4.8	Aluminium Alloy	07346-03200	07345-03800	7.87	3.81	07490-04602
BULBEX®	5/32	4.0	Aluminium Alloy	07346-03100	07345-03700	7.87	3.81	07340-00213
	3/16	4.8	Aluminium Alloy	07346-03200	07345-03800	7.87	3.81	07490-04602
AVINOX® II	1/8	3.2	Stainless Steel	07346-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Stainless Steel	07346-03200	07345-03800	7.87	3.81	07490-04602
AVSEAL® II	-	4	Aluminium Alloy	71213-04000	71213-16401	6.35	1.95	07340-00213
	-	4	Aluminium Alloy	71213-04700	71213-164022	6.35	4.11	07340-00213
	-	5	Aluminium Alloy	71213-04100	71213-16403	7.62	2.00	07340-00213
	-	5	Aluminium Alloy	71213-04800	71213-164042	7.62	4.11	07340-00213
STAVEX®	1/8	3.2	Steel	07346-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Steel	07346-03200	07345-03800	7.87	3.81	0749O-04602
	1/8	3.2	Stainless Steel	07346-03100	07345-03700	7.87	3.81	07340-00213
	5/32	4.0	Stainless Steel	07346-03200	07345-03800	T. 7.87	3.81	07490-04602
AVDEL®	1/8	3.2	Aluminium Alloy	07346-03300	07345-03301	5.08	1.17	07340-00229
	1/8	3.2	Aluminium Alloy O	07495-03600	07494-03601	5.08	1.17	07340-00229
	1/8	3.2	Stainless Steel	07495-03000	07494-03011	5.08	3.81	07340-00213
	5/32	4.0	Aluminium Alloy	07346-03400	07345-03401	6.6	0.84	07340-00229
	5/32	4.0	Aluminium Alloy O	07495-03700	07494-03701	6.6	0.84	07340-00229
	3/16	4.8	Aluminium Alloy	07346-03500	07345-03501	8.13	0.25	07498-04401
	3/16	4.8	Aluminium Alloy O	07495-03800	07494-03801	8.13	0.25	07498-04401
MBC®	1/8	3.2	Aluminium Alloy	07346-04000	07165-00701	4.75	1.9	07340-00229
	5/32	4.0	Aluminium Alloy	07346-04100	07165-00702	6.35	2.36	07340-00229
	3/16	4.8	Aluminium Alloy	07346-04200	07165-00703	7.92	2.46	07498-04401
MBC L/C®	1/8	3.2	Aluminium Alloy	07346-04500	07345-04701	7.87	2.03	07340-00229
	5/32	4.0	Aluminium Alloy	07346-04500	07345-04701	7.87	2.03	07340-00229
	5/32	4.0	Aluminium Alloy O	07346-04600	07345-04701	7.87	2.03	07498-04401
	3/16	4.8	Aluminium Alloy	07346-04600	07345-04701	7.87	2.03	07498-04401

360^ rotation

1 In inches then in millimetres.
2 Long nose tip for deep placing.

0 Oversize

COMPLETE TOOL PART NUMBER :

precede with 71213-40

(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.

Remove Male 'T' 41 Adaptor from the Tool and replace with Jaw Spreader Housing (71210-02101) See 'Preparing the Base Tool' above.

The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.

IMPORTANT

PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the base tool opposite. 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 Moly Lithium 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.

STRAIGHT SWIVEL HEAD

RIGHT-ANGLE HEAD

A Fit Locking Ring 10 over Jaw Spreader Housing 41 (71210-02101). See pages 24 and 25.
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.

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.
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.
N Screw the assembly over Spindle 11 onto the tool handle. Replace Pin(s) 6.
0 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.

9* refers to illustrations on pages 9, 10 and 12.

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^ .
  If guard 1 is at all damaged it must be replaced by a new one.
  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.

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 within the table on pages 14-15.

CONSTANT COMPONENTS
ITEM	DESCRIPTION	STRAIGHT SWIVEL	RIGHT-ANGLE SWIVEL
1	GUARD	07494-05000	07495-03003
2	CIRCLIP	-	07004-00105
3	JAW CARRIER	07494-03026	07494-03026
4	LEVER	-	07495-03004
5	BODY	07494-03015	07495-03002
6	PIVOT PIN	07343-02207	07343-02207
7	SPRING CLIP	07495-03900	07495-03900
8	ROLLER	07007-00039	07007-00039
9	ADAPTOR	07345-03001	07345-03001
10	LOCKING RING	07345-03003	07345-03003
11	SPINDLE	07345-03002	07345-03002
12	DOWEL PIN	07007-00038	07007-00038
13	SCREW	07342-02207	07342-02207
15	PIVOT PIN	-	07343-02207
16	SCREW	07494-03028	07494-03028
18	JAW SPREADER	07346-03101	07346-03101
19	SPRING	07165-00305	07165-00305
20	SPRING GUIDE	07494-03027	07494-03027
21	SCREW	07001-00368	-
22	PLATFORM	07345-00401	-
23	SCREW	-	07210-00804

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

• 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 using a swivel head is fitted.
• Check that base cover 31 is fully tightened onto body 30.
  Stem Collector bottle: 'O'Rings 20 & 28 to be checked for wear, cleaned and lubricated with Molykote® 55m

Weekly

• 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.

Moly Lithium 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^ .

Not classified as flammable.

Suitable extinguishing media: CO_2 , 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 oxidising agent.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26-27.

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^ . (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^ . (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.

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

SERVICE KIT : 71210-99990 Spanners are specified in inches and across flats unless otherwise stated
PART N	DESCRIPTION	PART N	DESCRIPTION
07900-00667	PISTON SLEEVE	07900-00008	7/16 x 1/2 SPANNER
07900-00692	TRIGGER VALVE EXTRACTOR	07900-00012	9/16 x 5/8 SPANNER
07900-00670	BULLET	07900-00015	5/8 x 11/16 SPANNER
07900-00672	'T' SPANNER	07900-00686	PEG SPANNER
07900-00706	'T' SPANNER SPIGOT	07900-00677	SEAL EXTRACTOR
07900-00684	GUIDE TUBE	07900-00698	STOP NUT
07900-00685	INSERTION ROD	07900-00700	PRIMING PUMP
07900-00351	3 MM ALLEN KEY	07992-00020	GREASE - MOLYLITHIUM E.P.3753
07900-00469	2.5 MM ALLEN KEY	07992-00075	GREASE - MOLYKOTE® 55M
07900-00158	2 MM PIN PUNCH	07900-00755	GREASE - MOLYKOTE® 111
07900-00164	CIRCLIP PLIERS	07900-00850	PIN SPANNER
		07900-00898	VALVE HOOK

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.

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.

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 three 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 Moly Lithium Grase 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.

Dismantling 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.

Ensure the bleed screw orifice is facing away from the person performing this operation.

Head Assembly

• Twist and pull off Stem Collector Bottle Assembly 25. See illustration on page 7.
• Remove Stop Plate Assembly 104 by unscrewing Screws 892 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 Male 'T' Adaptor 41 together with 'O' Ring 12.
• With draw Vacuum Sleeve 42.
• Remove Locknut 40 together with 'O' Rings 19 and 15.
• Push Head Piston 36 to the rear and out of Head Assembly 58 taking care not to damage the cylinder bore
• Using circlip pliers* 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.
• The chamfered edge of Seal Retainer 43 must face forward with the gap at the bottom.
  After fitting Lip Seals 11, 10, 'O' Ring 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*.
  Male T' Adaptor 41 must be fully tightened onto Head Piston 36 before tightening Locknut 40 against it.
• Reprime in accordance with the instructions on page 29.

Servicing the Tool

Pneumatic Piston Assembly

• 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 Seal Assembly 60 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 and hydraulic seals with Molykote® 111.

Air Valve

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 Assy 44 together with Tie Rods 56, Transfer Tube Assembly 61, 'O' Rings 14 and Silencer Pads 53.
• Remove tool from vice and separate Body 30 from Handle 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 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.

Rotary Valve

Dismantling

Using a 4mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger Assembly 33.
- Remove Pneumatic Piston Assembly 57 as described 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, Seperate Body 30 from Handle 64. Remove 'O' Rings 16 and 17.
- Seperate Head Assembly 58 from Handle 64. NOTE ORIENTATION OF ROTARY VALVE 38
- Push out Rotary Valve 38 together with 'O' Rings 5.

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 38 is assembled in correct orientation to align valve pins with forks on the Trigger 33. See illustration below.

Trigger

Dismantling

Using a 4mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger 33.
- Unscrew Trigger Valve 21 using trigger valve extractor (0900-00692).

Assemble in reverse order to Dismantling Instructions noting the following:

• When assembling Trigger 33 the trigger forks locate on the pins each side of the Rotary Valve 38.
• Ensure Rotary Valve 38 is orientated correctly. See illustration below.

Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

Assembly (see illustration below)

• Place 'O' Ring 2 into the recess in Housing 5 retain in position using grease Molykote ^ 55 m .
• 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 ^ 55 m .
• Place spring 7 into position, locate using the recesses in both Plate Shut Off 3 and Bottle Adaptor Assembly 32^ * .
• Position the above assembled parts onto Bottle Adaptor Assembly 32^* .
• Secure in position using two Screws 89^* .

*see pages 26 and 27.

ITEM	DESCRIPTION
1	PISTON
2	‘O’ RING
3	PLATE SHUT OFF
4	‘O’ RING
5	HOUSING
6	COVER PLATE
7	SPRING

71213-02000 PARTS LIST
ITEM	PART N°	DESCRIPTION	QTY	SPARES	ITEM	PART N°	DESCRIPTION	QTY	SPARES
01	07001-00405	M5x5 HEX SOCKET BUTTON HD SCREW	1		43	71210-02019	SEAL RETainer	1
02	07003-00333	LIP SEAL	1		44	71213-02010	TOP PLATE ASSEMBLY	1
04	07003-00127	‘O’ RING	1		45	71210-02022	SUSPENSION RING	1
05	07003-00189	‘O’ RING	2		46	71210-02024	TRIGGER PIN	1
06	07003-00194	M5 BONDED SEAL	1		48	71210-02055	RUBBER BOOT	1
07	07003-00271	‘O’ RING	1		49	71213-02027	LABEL	1
08	07003-00273	LIP SEAL	1		50	71213-02028	RETAINING NUT	1
09	07003-00274	LIP SEAL	1		51	71210-03205	GUIDE RING	1
10	07003-00275	LIP SEAL	1		52	71210-02104	SEAL HOUSING	1
11	07003-00341	LIP SEAL	1		53	71210-02031	SILENCER	2
12	07003-00277	‘O’ RING	1		56	71211-02004	TIE ROD	2
13	07003-00278	‘O’ RING	1		57	71211-03200	PNEUMATIC PISTON ASSEMBLY	1
14	07003-00281	‘O’ RING	3		58	71213-03320	HEAD ASSEMBLY	1
15	07003-00204	‘O’ RING	1		59	71210-03400	VALVE SPOOL ASSEMBLY	1
16	07003-00287	‘O’ RING	1		60	71210-03800	SEAL ASSEMBLY	1
17	07003-00288	‘O’ RING	2		61	71210-03600	TRANSFER TUBE ASSEMBLY	1
18	07003-00342	‘O’ RING	1		62	71210-03700	ON/OFF VALVE ASSEMBLY	1
19	07003-00310	‘O’ RING	1		64	71213-02013	HANDLE ASSEMBLY	1
20	07003-00415	‘O’ RING	1		65	71221-02014	BASE PLATE ASSEMBLY	1
21	07005-00088	TRIGGER VALVE	1		66	07003-00027	‘O’ RING	2
22	07005-01274	1/8' BSP PLUG	1		67	07002-00108	M6 NYLOC NUT	2
23	07008-00010	6" FLEXIBLE HOSE	1		71	71221-20105	MODIFIED COUNTER	1
24	07007-00224	3mm DIaX10mm SPIROL PIN	2		72	71221-20101	COUNTER MOULDING	1
25	71213-03800	STEM COLLECTOR BOTTLE ASSEMBLY	1		73	71221-20103	MOULDING RETAINING NUT	2
26	71213-02021	BEARING TAPE - PISTON ROD	1		74	71221-20102	SPECIAL M4 SCREW	2
27	71213-02022	BEARING TAPE - PISTON	1		75	07003-00280	‘O’ RING	1
28	07003-00416	‘O’ RING	1		76	07002-00163	WASHER	2
29	71221-02006	SEALING WASHER	2		77	07007-01993	CENTRE POLE MAGNET	1
30	71213-02001	BODY MACHINED	1		79	71221-20104	M5 X 19 COUNTERSUNK SCREW	1
31	71211-02002	BASE COVER	1		80	07002-00098	M5 NYLOC NUT	1
32	71213-03000	BOTTLE ADAPTOR ASSEMBLY	1		89	07001-00677	SCREW	2
33	71213-02008	TRIGGER ASSEMBLY	1		90	07003-00274	LIP SEAL	3
34	71210-02009	VALVE SEAT	1		91	07490-03002	SPRING	1
35	71213-02025	END CAP ASSEMBLY	1		96	07003-00268	‘O’ RING	1
36	71213-02121	HEAD PISTON	1		97	07003-00398	‘O’ RING	2
37	71211-02008	CYLINDER LINER	1		98	07003-00042	‘O’ RING	1
38	71213-02012	ROTARY VALVE	1		99	71210-03401	VALVE BODY	1
39	71210-02014	CLAMP NUT	1		100	07007-01503	LABEL BOOK SYMBOL	1
40	71210-02103	LOCKNUT	1		103	07900-00841	TOOL INSTRUCTION MANUAL	1
41	71213-02020	MALE 'T' ADAPTOR	1		104	71213-03900	STOP PLATE ASSEMBLY	1
42	71210-02102	VACUUM SLEEVE	1

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 containers (part number 07992-00006). Please see safety data below.

Hyspin® VG 32 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^ . 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.

Priming Kit

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

PRIMING KIT : 07900-00688
PART №	DESCRIPTION
07900-00351	3mm ALLEN KEY
07900-00700	PRIMING PUMP
07900-00224	4mm ALLEN KEY
07900-00698	STOP NUT
07900-00734	STOP NUT - MAXLOK®

IMPORTANT

DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 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 62.
• Remove all nose equipment. (see page 8)
• Remove Bleed Screw 1 and Bonded Seal 6.
• Invert tool over suitable container, switch ON air supply at ON/OFF Valve Assembly 62 and actuate tool.
• Residual oil in the tools hydraulic system will empty through bleed screw orifice.

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 62.
• Screw priming pump (07900-00700) into bleed screw port, utilising Bonded Seal 6.
• 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 PROMING PUMP.

• Remove the priming pump, surplus oil will expel from bleed screw port.
• Replace the Bleed Screw 1 together with Bonded Seal 6.
• Switch ON air supply at ON/OFF Valve Assembly 62.
• 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).

Symptom	Possible Cause	Remedy	Page Ref
More than one operation of the trigger needed to place fastener	Air leak	Tighten joints or replace components
	Insufficient air pressure	Adjust air pressure to within specification	5
	Worn or broken jaws	Fit new jaws	8
	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 stem of fastener	Worn or broken jaws	Fit new jaws	8, 9, 10, 12
	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 broken stem of fastener	Build up of dirt inside the nose assembly	Service nose assembly	8†
	Jaw housing, nose tip or nose casing 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
Cannot feed next fastener	Broken stems jammed inside tool	Empty stem collector	7
		Check jaw spreader is correct	9, 10, 12
		Adjust air pressure to within specification	5
Slow cycle	Low air pressure	Adjust air pressure to within specification	5
	Build up of dirt inside the nose assembly	Service nose assembly	8†
Tool fails to operate	No air pressure	Connect and adjust to within specification	5
	Damaged trigger valve 21	Replace	23
Fastener fails to break	Insufficient air pressure	Adjust air pressure to within specification	5
	Fastener outside tool capability	Use more powerful Genesis tool. Contact Avdel
	Low oil level or air present in oil	Prime tool	28-29

• 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.

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 nG2

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 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.

NOM DE LA FIXATION	DIMENSION DE LA FIXATION (MMPOUCES)
	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®		●	●		●
ETR							●
BULBEX®			●		●
AVDEL®SR		●	●		●
MONOBOLT®					●
INTERLOCK®					●
AVDEL®		●	●		●
MBC®		●	●		●
MBC®/LC		●	●		●
AVSEAL®II			●			●		●	●	●
KLAMPTITE™KTR					●
KLAMPTITE™					●

EQUIPMENT Ref. 71213-16100

REPÈRE	DESCRIPTION	RÉFERENCE
1	CARTER DE NEZ CONIQUE	71213-00350
2	JOINT TORIQUEO	07003-00067
3	CARTER PORTE-MÂCHORES - CONIQUE	71210-15902
4	MÂCHOIRES	71210-16101
5	PORTE-MÂCHOIRES	07498-04502
6	BUTOIR	71210-05001
7	RESSORT	07500-00418
8	BAGUE DE SERRAGE	07340-00327
9	‘T' DE CARTER GUIDE	71210-20321
10	MANCHON DE DÉTENTE	71210-20322
11	JOINT TORIQUE	07003-00277

BESCHRÄNKTE GARANTIE

TIPO RIVETTO	DIMENSIONI (MM POLLICI)
	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®		●	●		●
ETR							●
BULBEX®			●		●
AVDEL® SR		●	●		●
MONOBOLT®					●
INTERLOCK®					●
AVDEL®		●	●		●
MBC®		●	●		●
MBC®/LC		●	●		●
AVSEAL®II			●			●		●	●	●
KLAMPTITE™KTR					●
KLAMPTITE™					●

Codici parte

Rowville, Victoria 3178

Tel: [phone]

Fax: [phone]

Email: [e-mail]

CANADA

Avdel Canada, a Division of Acument

Canada Limited

87 disco Road

Rexdale

Ontario M9W 1M3

Tel: [phone]

Fax: [phone]

Email: [e-mail]

CHINA

Acument China Ltd.

RM 1708, 17/F., Nanyang Plaza,

57 Hung To Rd., Kwun Tong

Hong Kong

Tel: [phone]

Fax: [phone]

Email: [e-mail]

FRANCE

Avdel France S.A.S.

3-1 Chigasaki-Chuo, Tsuzuki-ku,

Yokohama-city, Kanagawa Prefecture

Japan 224-0032

Tel: [phone]

Fax: [phone]

Email: [e-mail]

SINGAPORE

Acument Asia Pacific (Pte) Ltd.

05-03/06 Techlink

31 Kaki Bukit Road 3

Singapore, 417818

Tel: [phone]

Fax:[phone]

Email: [e-mail]

Manual No.	Issue	Change Note No.
07900-00841	A	05/370
	A2	05/519
	A3	06/536
	B	07/044
	B2	07/103
	B3	07/174

SOUTH KOREA

Acument Korea Ltd.

212-4, Suyang-Ri,

Silchon-Eup, Kwangju-City,

Kyunggi-Do, Korea, 464-874

Tel: [phone]

Fax: [phone]

Email: [e-mail]

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: [phone]

Fax: [phone]

Email:[e-mail]

UNITED KINGDOM

Avdel UK Limited

Pacific House

2 Swiftfields

Watchmead Industrial Estate

Welwyn Garden City

Hertfordshire

AL71LY

Tel: [phone]

Fax: [phone]

Email: [e-mail]

USA

Avdel USA LLC

614 NC Highway 200 South

Stanfield,

North Carolina 28163

Email: [e-mail]