GENESIS NG3 - Outil pneumatique AVDEL - Free user manual and instructions

USER MANUAL GENESIS NG3 AVDEL

Specifications Tool Specification Tool Dimensions

Intent of Use Range of Fasteners Part Numbering

Putting into Service Air Supply Operating Procedure

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

General Assembly of Base Tool General Assembly Parts List

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

Fault Diagnosis Symptom, Possible Cause and Remedy

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 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.

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.

Do not use outside the design intent.

Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.

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.

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.

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.

The precautions to be observed when using this tool/machine must be explained by the customer to all operators.

Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.

Do not operate a tool/machine that is directed towards any person(s) or the operator.

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 nG3 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.

Stroke Minimum 26 mm (1.02 in) Pull Force @ 5.5 bar

Cycle Time Approximately Noise Level

75 dB(A) Weight Including nose equipment

Intent of Use Range of Fasteners nG3 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. TIPO RIVETTO DIMENSIONI (

AVEX ® STAVEX ® AVINOX ® II AVIBULB ® ETR BULBEX ® T-LOK ® 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. AVDEL ® SR MONOBOLT ® INTERLOCK ® AVTAINER ® AVDEL ® MBC ® MBC/LC ® AVSEAL ® II Q™ RIVET T™ RIVET CHERRYMATE™ KLAMPTITE™ KLAMPTITE™KTR

The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly pages 26 and 27. If a swivel head is fitted, the same base tool must be adapted. See details pages 14-15.

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 11. A nose assembly can be substituted by a swivel head (see pages 14 and 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 pages 11 and 12. NOSE TIP see note 3

LAST COLUMN OF A NOSE

TIP TABLE ON PAGE 9 - 12.

FOR TOOLS WITH SWIVEL

English 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)

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 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. Lift Trigger to cut-off the vacuum air supply.

Nose Assemblies Fitting Instructions I M P O R TA N T Nose assemblies do NOT include nose tips. Nose tips must be ordered separately. A complete tool must always be fitted with the correct nose assembly and nose tip for your fastener and must be ordered separately, refer to the ‘NOSE TIPS’ tables on pages 9 to 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 or Avtainer® fasteners a Type 5 Nose Tip. Dimensions ‘A’ and ‘B’ in the following Nose Tip tables 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 11. It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. The Type 4 Nose Tip is an alternative to place 1/4 in Monobolt®. Refer to the table on page 12. Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required. See pages 14 to 17 in the ‘Accessories’ section. 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 5 nose tip tables.

Lightly coat Jaws 4 with Moly Lithium grease*.

Drop Jaws 4 into Jaw Housing 3 or Chuck Collet 9 depending on which nose assembly you are using.

Insert Jaw Spreader 5 into Jaw Housing 3 or insert Front Spring Guide 10 into Chuck Collet 9.

Screw Rear Spring Guide 11 into Chuck Collet 9.

Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool.

Holding tool pointing down, screw the assembled Jaw Housing or Chuck Collet onto the Jaw Spreader Housing and tighten with spanner*.

Screw the nose tip into Nose Casing 1 and tighten with spanner*.

Place Nose Casing 1 over Jaw Housing 3 or Chuck Collet 9 and screw onto the tool, tightening with spanner*. 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 assembly.

Remove the nose equipment using the reverse procedure to the ‘Fitting instructions’.

Any worn or damaged part should be replaced.

Clean and check wear on Jaws.

Ensure that neither the Jaw Spreader nor the Front Spring Guide is distorted.

Check Spring 7 is not distorted.

Assemble according to fitting instructions above.

• Item included in the nG3 Service Kit. For complete list see page 20.

TYPE 1 NAME AVEX ® NOSE TIPS

In inches then in millimetres. Head forming nose tips for use with countersunk heads ONLY.

• In ADDITION to the nose assembly shown below, an extra long nose assembly is available to place /4" Monobolt® in applications with restricted access. See type 4 NOSE TIP table. N O S E A S S E M B LY part nº 71210-15000 ITEM DESCRIPTION PART Nº

Nose Assemblies Nose Tips A V S E A L ®I I NOSE TIPS NAME AVSEAL ®II FA S T E N E R MATERIAL

N O S E A S S E M B LY

TO ALLOW ACCESS INTO

Note: Items 9 and 10 are not required when assembling Type 2 or Type 3 Nose Tip to the Base Tool nG3 (71223-02000). TYPE 3 NOSE TIPS NOSE ASSEMBLY FASTENER MATERIAL 1/8

THIS SPECIAL NOSE ASSEMBLY.

In inches then in millimetres PART Nº 07340-00306 07003-00067 07612-02003 07612-02002 07498-04502 07498-03003 07500-00418 07340-00327 Accessories English 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 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 Jaw Spreader Housing 41 and Locknut 40. Replace Locknut 40 with ‘Sealed’ Nut 71213-02200, screw ‘Sealed’ Nut onto Piston 36 to disable Vacuum System. Jaw Spreader Housing 41 must be tightened onto Piston 36, finally tightening ‘Sealed’ Nut against it. Remove Stop Plate Assembly (page 24) by unscrewing Screws 89 (2off).

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. SEALED NUT 71213-02200 ADAPTOR 71213-20101 Extension Fitted between the tool and the nose assembly the extension allows access into deep channels.

To fit the extension, remove any nose assembly components. Screw the inner extension to Jaw Spreader Housing 41. Screw the outer onto Head Assembly 58. Fit the nose assembly onto the extension. INNER 71210-20301 OUTER 71210-20302

EXTENSION PART NUMBER: 71210-20300

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

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 16 and 17 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 FASTENER MATERIAL 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 5 / 32 4.0 Al Alloy BULBEX ® 3 / 16 4.8 Al Alloy AVINOX ® II 1/8 3.2 Stainless Steel 5 / 32 4.0 Stainless Steel 4 Al Alloy AVSEAL ® II 4 Al Alloy 5 Al Alloy 5 Al Alloy

2 Long nose tip for deep placing. IMPORTANT: in contrast to complete tools with nose assemblies, those fitted with swivel heads include the nose tip as a part of the head.

O Oversize Accessories English 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 25 (71213-03800). Replace assembly 25 with Safety Cap (71213-20201) Unscrew Jaw Spreader Housing 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 41 and ‘O’ Ring 12, tighten onto Head Piston 36, finally tighten Stop Nut against Jaw Spreader Housing 41. The tool is now ready to be fitted with a swivel head, see page below. Base tool to receive a nose assembly

Base tool to receive a swivel head 71213-20201 SAFETY CAP 71213-20200 STOP NUT View with 25 removed and stop nut replacing removed items 19, 15, 52, 40 Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and

1 In inches then in millimetres. 'B'

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 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.

Coat Screw 13 with thread locking adhesive and use to secure Nose Tip 14 onto Body 5.

Lightly lubricate items 17, 18, 19, 20 and insert into Jaw Carrier 3 as shown. Secure with Screws 16.

Position Lever 4 into Body 5 and hold in place with pin 15 through the hole of Body 5 (not a slot).

Lubricate the sides of the Jaw Carrier Assembly and insert into Body 5.

Lubricate Rollers 8 and ENSURE that they will freely rotate in the holes of Adaptor 9. If necessary ream the holes.

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).

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.

Insert Pin 12 through the front slot of Body 5 into Jaw Carrier 3.

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.

Remove Screws 23 (4 off) and guard 1. On a straight swivel head also remove Screw 21 and Platform 22.

On straight swivel heads attach Platform 22 onto the top of the Spindle with Screw 21. Deburr the back end of Platform 22 so that it cannot catch on Guard 1.

Snap Guard 1 over the assembly, align screw holes in guard with tapped holes in body assembly.

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.

Coat the thread of Screws 23 (4 off) with thread locking adhesive and screw into body assembly securing guard to body assembly.

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.

Accessories English 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 9 to 12. C O N S TA N T C O M P O N E N T S ITEM

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 using a swivel head.

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

Stem Collector Bottle: ‘O’ Rings 20 and 28 to be checked for wear, cleaned and lubricated with Molykote® 55m. We e k l y

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 19. 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 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 26 and 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°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.

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.

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 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 28. Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 9 to 12 or if a swivel head was fitted pages 14 and 15. 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.

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

Inspect all components. Renew all damaged or worn parts.

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

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

Screw Nose Tip into Nose Casing and tighten. Item numbers in bold refer to Nose Tip Tables on pages 9 to 12. 41* refers to illustration on page 25.

S e r v i c i n g t h e To o l English 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 62 remove Bleed Screw 1 and Bonded Seal 6.

Insert tool over a suitable container, switch air supply ON and actuate tool.

Oil will expel from bleed screw orifice into container.

Switch air supply OFF after all oil is expelled. This operation must have the Bleed Screw orifice facing away from the person performing this operation. Head Assembly

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

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

Unscrew Retaining Nut 50.

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

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

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

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

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

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 Seal 11, ‘O’ Rings 18 and Bearing Tape 27 onto the Head Piston 36 ensuring correct orientation, lubricate the cylinder bore and place the piston sleeve* into the back of Head Assembly 58. Slide the bullet* onto the threaded part of Head Piston 36 and push the piston with the seals through the piston sleeve* as far as it will go. Slide the bullet* off the piston and remove piston sleeve*.

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

Reprime in accordance with the instructions on page 29.

• Item included in the nG3 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.

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.

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 63 and withdraw Seal Assembly from intensifier tube of the Head Assembly 58. Assemble in reverse order to dismantling.

• seals should be checked for damage and replaced as necessary. Lubricate Pneumatic seals with Molykote® 55m Grease and Hydraulic seals with Molykote® 111 Grease. A i r Va l v e Dismantling

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

Using Spanner (07900-00672), and Location Spigot (07900-00671). Unscrew Clamp Nut 39 and remove together with Top Plate Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, ‘O’ Rings 14 and Silencer 53.

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

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

Pull out Valve Spool Assembly 59 from Handle Assembly 64. Remove ‘O’ Ring 7 from handle counterbore. Assembly Assemble in reverse order to Dismantling Instructions

Seals should be checked for damage and replaced if necessary, lubricated with Molykote® 55M Grease.

Apply Loctite® 243 to Clamp Nut 39 and tighten to torque 11ftlb (14.91 Nm) 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 nG3 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.

Remove Pneumatic Piston Assembly 57 as described in Pneumatic Piston Assembly, see page 22.

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 Assembly 64. Remove ‘O’ Rings 16 and 17.

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, align pins with forks on the Trigger 33. See illustration below. Tr i g g e r Dismantling

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.

Place ‘O’ Ring 2 into the recess in Housing 5 retain in position using grease Molykote® 55.

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® 55.

Place ‘O’ Ring 4 into the recess of Cover Plate 6 retain in position using grease Molykote® 55.

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*.

'O' RING SEALING WASHER BODY MACHINED BASE COVER

VALVE SPOOL ASSEMBLY

TRANSFER TUBE ASSEMBLY

ON/OFF VALVE ASSEMBLY

T h e s e are m i n i m u m re co m m e n d e d lev els of s p are s based on re gu lar serv ic in g PART Nº

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 be reduced and fasteners are not 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°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:

English 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 55. 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 PRIMING 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 Asembly 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). Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27.

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

trigger needed to Worn or broken jaws Fit new jaws

place fastener Low oil level or air in oil Prime tool 28 and 29 Build up of dirt inside the nose assembly Service nose assembly

Tool will not grip Worn or broken jaws Fit new jaws 8 to 12 stem of fastener Build up of dirt inside the nose assembly Service nose assembly

Loose jaw housing Tighten against locking ring

Weak or broken spring in nose assembly Fit new spring 8 to 12 Incorrect component in nose assembly Identify and replace 9 to 12 Jaws will not release Build up of dirt inside the nose assembly Service nose assembly

broken stem of Jaw housing, nose tip or nose casing fastener not properly seated Tighten nose assembly 9 to 12 Weak or broken spring in nose assembly Fit new spring 9 to 12 Air or oil leak Tighten joints or replace components Low oil level or air present in oil Prime tool 28 and 29 Broken stems jammed inside tool Empty stem collector

Cannot feed next fastener Slow cycle Tool fails to operate Check jaw spreader is correct 9 to 12 Adjust air pressure to within specification

Low air pressure Adjust air pressure to within specification

Build up of dirt inside the nose assembly Service nose assembly

No air pressure Connect and adjust to within specification

Adjust air pressure to within specification

Fastener fails to break Insufficient air pressure Fastener outside tool capability Use more powerful Genesis tool Contact Avdel Low oil level or air present in oil Prime tool † Page 17 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.

28 and 29 English 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 nG3 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 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.

BESCHRÄNKTE GARANTIE

08/171 Email: infoAvdel-USA@acument.com Avdel®, Avdel® SR, Avex®, Avibulb®, Avinox®, Avseal®, Bulbex®, Genesis®, Interlock®, MBC®, MBC®/LC, Monobolt®, Stavex®, T-Lok®, TLR® are trademarks of Avdel UK Limited. www.avdel-global.com © 2008 Acument Intellectual Properties, LLC. Printed June 08 AUSTRALIA