32
G3 Instruction Manual Original Instruction Hydro-Pneumatic Power Tool 71223 Removable Bottle and 71224 Fixed Bottle 71224 Tool 71223 Tool Genesis ®
G3
I n s t ruc t i on Manua lOr ig i na l I ns t ruc t i on
Hydro-Pneumat ic Power Too l
71223 Removable Bot t le and 71224 F ixed Bot t le
71224 Too l
71223 Too l
Genesis®
3
Safety Instructions 4
SpecificationsTool Specification 571223 and 71224 Tool Dimensions 5
Intent of UseRange of Fasteners 6Part Numbering 6
Putting into ServiceAir Supply 771223 Tool Removable Bottle 771224 Tool Fixed Bottle 7Adjusting the Vacuum Extraction 7Operating Procedure 8Removable Stem Collector Bottle 71213-05100 8
Nose AssembliesFitting Instructions 9Servicing Instructions 9Nose Tips 10 - 12Type 1 10Type 2 11Type 4, 5 and 6 12
AccessoriesStem Deflector 13Preparing the Base Tool for use with Stem Deflector 13Extension 13Swivel Heads 14Straight Swivel Head capability 14Right-Angle Swivel Head capability 14Preparing the Base Tool for Right-Angle and Straight 15Swivel Head AttachmentBase Tool 71223 15Base Tool 71224 15Swivel Head Fitting Instructions 16Swivel Head Servicing Instructions 17Constant Components 17
Servicing the ToolDaily / Weekly 18MolyLithium Grease EP 3753 Safety Data 18Molykote® 55m Grease Safety Data 19Molykote® 111 Grease Safety Data 19Service Kit 20Maintenance 20Nose Equipment 20Dismantling the Tool 21Head Assembly 21Pneumatic Piston Assembly 22Air Valve 22Rotary Valve 23Trigger 23
Common PartsGeneral Assembly of Common Parts 71223-02000 24and 71224-02000Parts List for Common Parts 71223-02000 25and 71224-02000
Stem Collector Bottles Removable and Fixed71223 Tool Removable 2671224 Tool Fixed 26
PrimingOil Details 27Hyspin® VG32 Oil Safety Data 27Priming Kit 27Priming Procedure 28
Fault DiagnosisSymptom, Possible Cause and Remedy 29
Contents
LIMITED WARRANTY
Avdel makes the limited warranty that its products will be free of defects in workmanship and materials
which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product
being installed, maintained and operated in accordance with product literature and instructions, and (2)
confirmation by Avdel of such defect, upon inspection and testing. Avdel makes the foregoing limited
warranty for a period of twelve (12) months following Avdel’s delivery of the product to the direct purchaser
from Avdel. In the event of any breach of the foregoing warranty, the sole remedy shall be to return the
defective Goods for replacement or refund for the purchase price at Avdel’s option. THE FOREGOING
EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES
AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY
ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.
Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
4
Sa fe ty Ins t ruct ions
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 If the tool is fitted with a stem collector, it 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.
This instruction manual must be read with particular attention to the following safety rules, by any personinstalling, operating, or servicing this tool.
Tool Spec i f icat ion
Spec i f ica t ions
5
Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 4.3 litres
Stroke Minimum 26 mm
Pull Force @ 5.5 bar 12.9 kN
Cycle Time Approximately 1.2 seconds
Noise Level 75 dB(A)
Weight Including nose equipment 2.25 kg
Vibration Less than 2.5 m/s2
30.00 DIA
140.00
320.
00
156.
00
127.00 (71223 Tool)145.00 (71224 Tool)
105.00(71223 Tool)
116.00(71224 Tool)
150.00
54.0
0 D
IA
70.0
0 D
IA
61.00
22.8
0 D
IA
128.00 DIA
Dimensions in millimetres
71223 and 71224 Too l D imens ions
6
I n ten t o f Use
nG3 is a hydro-pneumatic tool designed to place Avdel® breakstem fasteners at high speed making it ideal for batch or flow-lineassembly in a wide variety of applications throughout all industries. It can place all fasteners listed opposite.
The tool features a vacuum system for fastener retention and trouble free collection of the spent stems regardless of tool orientation.
A complete tool is made up of three separate elements which will be supplied individually. See diagram below.
NOSE EQUIPMENT MUST BE FITTEDAS DESCRIBED ON PAGE 9.
1n
COMPLETE TOOL
71223-00 . . . 71224-00 . . .
* *
BASE TOOL
NOSE ASSEMBLY
NOSE TIP
71223-0200071224-02000
71210-15000
see note 3 + + =
1
1 2 3
1
2
2
3
3
*ADD 3 DIGITS FROM THELAST COLUMN OF A NOSETIP TABLE ON PAGES 10 TO 12.FOR TOOLS WITH SWIVEL HEADS USE THE TABLES ONPAGES 14 AND 15.
2n
2n
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assemblypages 24-26. If a swivel head is fitted, the same base tool must be adapted. See details page 14.
The nose tip part number relates to a specific fastener. If access to the application isrestricted, some extended nose tips are available. See table pages 11-12.
This single nose assembly will allow placing of fasteners by simply selecting the appropriate nose tip fromthe range of Type 1 Nose Tips. Other nose assemblies are available for applications with restricted accessand special fasteners. See table pages 11-12. A nose assembly can be substituted by a swivel head (seepages 14, 15). In this case the nose tip is part of the swivel head.
Range of Fasteners
Par t Number ing
FASTENERNAME
MMINFASTENER SIZE ( )
AVEX®
STAVEX®
AVINOX® IIAVIBULB®
ETRBULBEX®
T-LOK®
AVDEL® SRMONOBOLT®
INTERLOCK®
AVTAINER®
*AVSEAL®
II
Q RIVETT RIVET
AVDELMATE®
KLAMP-TITE®
KLAMPTITE KTR®
3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10 – 1/8 5/32 – 3/16 – – – 1/4 – – – – 3/8 –
*For Avseal® equipment refer to separate Data Sheet 07900-00840
7
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators andfiltering systems on the main air supply. These should be fitted within 3 metres of the tool (see diagram below) to ensure maximumtool 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 systemor 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured whereoperating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or 1/4
inch.
86
42
0
10121416
G3
TAKE OFF POINTFROMMAIN SUPPLY
STOP COCK(USED DURING MAINTENANCE
OF FILTER/REGULATOR OR LUBRICATION UNITS)
MAIN SUPPLYDRAIN POINT
AIR LUBRICATIONPERMISSABLE
PRESSURE REGULATORAND FILTER (DRAIN DAILY)
3 METRES MAXIMUM
Pu t t i ng in to Serv iceAir Supp ly
71223 Too l Removable Bot t le
86
42
0
10121416
G3
TAKE OFF POINTFROMMAIN SUPPLY
STOP COCK(USED DURING MAINTENANCE
OF FILTER/REGULATOR OR LUBRICATION UNITS)
MAIN SUPPLYDRAIN POINT
AIR LUBRICATIONPERMISSABLE
PRESSURE REGULATORAND FILTER (DRAIN DAILY)
3 METRES MAXIMUM
71224 Too l F ixed Bot t le
• Using a screwdriver, turn Rotary Valve 38 until the air flow at the rear of the tool ceases.
• With the nose of the tool pointing downwards, insert a fastener into the nose and hold it into position.
• Turn the rotary valve either way until there is sufficient suction to retain the fastener.
Adjus t ing the Vacuum Extract ion
8
• 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 thevacuum 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 beprojected to the rear of the tool into the collector bottle.
Quarter turn to Assemble or Remove
• A quarter turn rotation removes or replaces the collector bottle.
Pu t t i ng in to Serv iceOperat ing Procedure
Removable Stem Col lector Bot t le 71213-05100
Do not use tool when Stem
Collector Bottle is removed
Nose Assembl ies
Nose assemblies should be serviced at weekly intervals. You should hold some stock of all internal components of the nose assemblyand nose tips as they will need regular replacement.
Use Spanner 07900-00849 (supplied with tool) to assist when servicing the nose equipment.
• Remove the nose equipment using the reverse procedure to the ‘Fitting Instructions’.
• Any worn or damaged part should be replaced.
• Clean and check wear on jaws.
• Ensure that the jaw spreader is not distorted.
• Check Spring 7 is not distorted.
• Assemble according to Fitting Instructions above.
* Item included in the nG3 Service Kit. For complete list see page 20.
F i t t ing Ins t ruct ions
Serv ic ing Ins t ruct ions
9
I M P O R T A 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 11.
If your application presents no access restriction use a Type ‘1’ Nose Tip. If you are placing Avtainer® fasteners a Type 5 Nose Tipmust be used.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 10.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 11.Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required. See pages 12 to 16 in the ‘Accessories’ section.
I M P O R T A 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 nose tip tables.
• Lightly coat Jaws 4 with Moly Lithium grease*.
• Drop Jaws 4 into Jaw Housing 3 or Chuck Collet 9 depending on which nose assembly you are using.
• Insert Jaw Spreader 5 into Jaw Housing 3 or insert Front Spring Guide 10 into Chuck Collet 9.
• Locate Buffer 6 on Jaw Spreader 5.
• Locate Spring 7 onto Jaw Spreader 5 or onto Front Spring Guide 10.
• Screw Rear Spring Guide 11 into Chuck Collet 9.
• Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool.
• Holding tool pointing down, screw the assembled Jaw Housing 3 or Chuck Collet 9 onto the Jaw Spreader Housing and tighten withspanner*.
• 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*.
10
Nose T ips
Nose Assembl ies
1 In inches then in millimetres.2 Head forming nose tips for use with countersunk headsONLY.
T Y P E 1N O S E T I P S
N O S E A S S E M B LYpart nº 71210-15000
FA S T E N E RMATERIALØ1
N O S E T I P ( m m ) seebelowPART Nº 'A' 'B'NAME
Al AlloySteelAl AlloyAl AlloyAl AlloySteelAl AlloyAl AlloyAl AlloySteelAl AlloyAl AlloyAnyAl AlloyAl AlloyStainless SteelStainless SteelStainless SteelSteelSteelSteelSteelSteelSteelAnyAnyAnyAnyAnyAnySteelSteelSteelSteelSteelStainless SteelStainless SteelStainless SteelAnyAnyAnyAnyAnyAnyAnyAnyAnyAnyAl AlloyAl AlloyAl Alloy/SteelAl Alloy/SteelAl AlloyAl AlloyAl Alloy/SteelAl Alloy/Steel
1/81/81/8–
5/325/325/323/163/163/163/161/4
3/165/32 3/16 1/8
5/32 3/16–
3/16 1/8
5/32 3/16–
1/8 5/32 3/163/161/4
3/161/8
5/323/163/163/161/8
5/323/161/8
5/32 3/161/4
3/161/4 3/161/4
3/161/4
3/163/163/163/161/41/41/41/4
4.83.32.94.83.32.83.32.83.33.34.13.34.13.32.83.32.84.83.33.33.32.84.83.34.83.35.75.73.32.83.32.82.83.32.83.32.82.84.83.33.33.33.33.34.84.82.83.3
6.356.356.356.356.656.656.656.65
12.712.712.712.712.712.712.712.719.012.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.719.012.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.712.7
71210-0500271210-1607007340-064012
71210-0500271210-1607007381-0470107340-065012
07381-0470107340-0480007490-0440107340-066012
07612-0200171210-1602071210-1607007381-0470171210-1607007381-0470107498-0140107340-0620107340-0620171210-1607007381-0470107498-0140107612-0200171210-0500271210-1607007348-0700171210-1605071220-6000107381-0470171210-1607007381-0470107381-0470107340-0480007381-0470171210-1607007381-0470107381-0470171210-0500207340-0620107340-0620107612-0200107340-0620107612-0200171220-1606071220-1606107381-0470107612-02001703-A-25-6TA
703-B-21703-A-25-6T
703-B-26743-A-25-8TA
743-B-21743-A-25-8T
743-B-26
3.23.23.23.04.04.04.04.84.84.84.86.44.84.04.83.24.04.84.34.83.24.04.86.03.24.04.84.86.44.83.24.04.84.84.83.24.04.83.24.04.86.44.86.44.86.44.86.44.84.84.84.86.46.46.46.4
AVEX®
Large flange
MONOBOLT ®
BULBEX®
AVINOX®II
T-LOK ®
AVIBULB®
AVDEL® SR
Countersunk
INTERLOCK®
STAVEX®
Large flange Countersunk
Q RIVET
AVDELMATE®
KLAMPTITEKTR®
KLAMP-TITE®
T RIVETLarge flange
Large flange
Large flange
Large flange
… 0 0 1… 0 0 4… 0 0 3… 0 0 1… 0 0 4… 0 1 0… 0 0 9… 0 1 0… 0 1 6… 0 1 7… 0 1 5… 0 2 1… 2 0 0… 0 0 4… 0 1 0… 0 0 4… 0 1 0… 0 8 2… 1 2 0… 1 2 0… 0 0 4… 0 1 0… 0 8 2… 0 2 1… 0 0 1… 0 0 4… 0 6 2… 0 6 4… 0 6 3… 0 1 0… 0 0 4… 0 1 0… 0 1 0… 0 1 6… 0 1 0… 0 0 4… 0 1 0… 0 1 0… 0 0 1… 1 2 0… 1 2 0… 0 2 1… 1 2 0… 0 2 1… 4 3 0… 4 3 5… 0 1 0… 0 2 1… 3 8 0… 3 8 1… 3 8 3… 3 8 4… 3 8 5… 3 8 6… 3 8 7… 3 8 8
A
B
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07340-00304
4 JAWS 71210-15001
5 JAW SPREADER 07498-04502
6 BUFFER 71210-05001
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
COMPLETE TOOLPART NUMBER :
precede with71223-00 or71224-008 7 6 5 4 23 1 61
22.9
I M P O R T A N T
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
11
Nose Assembl iesNose T ips
1 In inches then in millimetres.
COMPLETE TOOLPART NUMBER :
precede with71223-00 or71224-00
N O S E A S S E M B LYpart nº 71210-15200
A
B
TYPE 2 NOSE TIPS ARE EXTENDEDTO ALLOW ACCESS INTOAPPLICATIONS WHERE TYPE 1NOSE TIPS WILL NOT REACH.
T Y P E 2N O S E T I P S
8 7 6 5 4 2314 15 1 58.3
22.9
FA S T E N E RMATERIALØ1
N O S E T I P ( m m ) seebelowPART Nº 'A' 'B'NAME
Aluminium AlloySteelAluminium AlloySteelAluminium AlloySteelAluminium AlloyAluminium AlloySteelSteelSteelSteelSteelStainless SteelStainless SteelStainless SteelSteelSteelSteel/Brass
1/81/8
5/325/323/163/165/32 3/16
–3/161/8
5/323/161/8
5/323/161/8
5/32–
12.9511.411.410.010.011.811.410.010.010.011.410.010.011.410.010.011.410.010.0
9.59.59.5
12.712.712.79.5
12.712.712.79.5
12.712.79.5
12.712.79.5
12.712.7
07340-0280507340-0280607340-0280607340-0280707340-0280707340-0730107340-0280607340-0280707241-0710107241-0710107340-0280607340-0280707340-0280707340-0280607340-0280707340-0280707340-0280607340-0280707340-02807
3.23.24.04.04.84.84.04.84.34.83.24.04.83.24.04.83.24.05.2
AVEX®
BULBEX®
T-LOK ®
STAVEX®
AVIBULB®
E.T.R
… 0 0 2… 0 0 8… 0 0 8… 0 1 4… 0 1 4… 0 1 8… 0 0 8… 0 1 4… 1 2 1… 1 2 1… 0 0 8… 0 1 4… 0 1 4… 0 0 8… 0 1 4… 0 1 4… 0 0 8… 0 1 4… 0 1 4
ITEM DESCRIPTION PART Nº1 NOSE CASING 07340-028042 'O' RING 07003-000673 JAW HOUSING 07340-003044 JAWS 71210-150015 JAW SPREADER 07498-045026 BUFFER 71210-050017 SPRING 07500-004188 LOCKING RING 07340-0032714 JAW SPREADER HOUSING 71210-0210115 'O' RING 07003-00277
Note: Items 14 and 15 are not required when assembling a Type 2 Nose Tip to the Base Tool nG3 (71223-02000 or 71224-02000).
12
Nose Assembl iesNose T ips
N O S E A S S E M B LYpart nº 71230-15800
A
B
8 7 6 5 4 23 1 61
22.9
... 201
... 261
... 261
1 In inches then in millimetres
FA S T E N E RMATERIALØ1
NOSE T IP (mm) seeabovePART Nº 'A' 'B'NAME
1/41/41/4
MONOBOLT ®
INTERLOCK®
STAVEX®
T Y P E 6N O S E T I P S ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-003062 'O' RING 07003-000673 JAW HOUSING 07612-020034 JAWS 07612-020025 JAW SPREADER 07498-045026 BUFFER 07498-030037 SPRING 07500-004188 LOCKING RING 07340-00327
AnyAnyAny
4.13.63.6
14.314.314.3
71220-1602107612-0200107612-02001
6.46.46.4
COMPLETE TOOLPART NUMBER
PRECEDED WITH:71223-00 or 71224-00
T Y P E 4N O S E T I P
COMPLETE TOOLPART NUMBER :
precede with71223-00 or 71224-00
1
1 In inches then in millimetres
N O S E A S S E M B LY part nº 71220-15400ITEM DESCRIPTION PART Nº1 NOSE CASING 07498-005012 'O' RING 07003-000679 CHUCK COLLET 07498-005024 JAWS 07497-03002
ITEM DESCRIPTION PART Nº10 FRONT SPRING GUIDE 07498-005077 SPRING 07500-0200511 REAR SPRING GUIDE 07498-005038 LOCKING RING 07340-00327
FITTED TO THIS LONG NOSEASSEMBLY, THE TYPE 4 NOSE TIPWILL ALLOW THE PLACING OF1/4 " MONOBOLT ® FASTENERSIN APPLICATIONS REQUIRINGVERY DEEP ACCESS.
FA S T E N E RMATERIALØ1
N O S E T I P ( m m ) seebelowPART Nº 'A' 'B'NAME
Any1/4 4.114.371220-160216.4MONOBOLT ® … 2 0 2
11 7 10 4 298
A
B
20.6
98.5
13
T Y P E 5N O S E T I P
COMPLETE TOOLPART NUMBER :
precede with71223-00 or 71224-00
1
1 In inches then in millimetres
N O S E A S S E M B LY part nº 71220-15500ITEM DESCRIPTION PART Nº1 NOSE CASING 07498-005012 'O' RING 07003-000679 CHUCK COLLET 07498-008014 JAWS 07220-0230210 FRONT SPRING GUIDE 07498-00803
ITEM DESCRIPTION PART Nº7 SPRING 07500-0200511 REAR SPRING GUIDE 07498-005038 LOCKING RING 07340-0032712 SIDE EJECTION ADAPTOR 07498-00900
THERE IS ONLY ONE TYPE 5 NOSETIP, SPECIFICALLY DESIGNED TOPLACE AVTAINER® FASTENERS WITHTHIS SPECIAL NOSE ASSEMBLY.
FA S T E N E RMATERIALØ1
N O S E T I P ( m m ) seebelowPART Nº 'A' 'B'NAME
Steel3/8 4.119.107498-008029.6AVTAINER ® … 2 4 3
98.5
20.6
90 12 11 7 10 4 298
A
B
28.6
13 71233-20200VAC SHUT-OFF STOP NUT ASSY
13
• Fit Stem Deflector (07340-00342) into Adaptor (71213-20103).
• Screw Adaptor onto End Cap Assembly 71213-05103.• Rotate the stem deflector until the aperture faces away from
the operator and any other person(s) in the vicinity.• Turn off air supply to the vacuum system by adjusting Rotary
Valve 38.
Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.
ADAPTOR NUT71210-20101
STEM DEFLECTOR07340-00342
71224 Tool
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.
• Remove stem collector bottleassembly 71213-05100 or71210-20400.
Stem Def lector
Accessor ies
Extens ion
Preparing the Base Tool for use with Stem Deflector
41 40
3607340-00342
STEM DEFLECTOR
71213-20103
71210-20101or
ADAPTOR
The airline must be diconnected before any servicing or dismantling.
The stem deflector is a very simple alternative to the standard stem collector and allows access in restricted areas. To replace thestem collector with the stem deflector proceed as follows:
ADAPTOR71213-20103
STEM DEFLECTOR07340-00342
71223 Tool
• Fit Stem Deflector (07340-00342) into Adaptor (71210-20101).
• Screw Adaptor onto End Cap Assembly 71403-02102.• Rotate the stem deflector until the aperture faces away from
the operator and any other person(s) in the vicinity.• Turn off air supply to the vacuum system by adjusting Rotary
Valve 38.
Swive l 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 allowsaccess into many applications otherwise too restrictive. There are two types of swivel heads: the straight swivel head with the nose tipslightly 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 headof the tool. See drawings below for dimensions and pages 15-16 for detail.
INNER OUTER
EXTENSION 71210-20300
14
FASTENERMATERIALØ1
NOSE TIP (mm)SWIVEL HEADPART Nº
JAWS seebelow'A' 'B'NAME
Aluminium AlloySteelAluminium AlloySteelAluminium AlloyAluminium AlloyAluminium AlloyStainless SteelStainless SteelAluminium AlloyAluminium AlloyAluminium AlloyAluminium AlloySteelSteelStainless SteelStainless Steel
1/81/8
5/325/323/165/32 3/16 1/8
5/32––––
1/85/321/8
5/32
3.813.813.813.813.813.813.813.813.811.954.112.004.113.813.813.813.81
7.877.877.877.877.877.877.877.877.876.356.357.627.627.877.877.877.87
07346-0300007346-0310007346-0310007346-0320007346-0320007346-0310007346-0320007346-0310007346-0320071213-0400071213-0470071213-0410071213-04800
PART Nº07340-0021307340-0021307340-0021307490-0460207490-0460207340-0021307490-0460207340-0021307490-0460207340-0021307340-0021307340-0021307340-0021307340-0021307490-0460207340-0021307490-04602
PART Nº07345-0360007345-0370007345-0370007345-0380007345-0380007345-0370007345-0380007345-0370007345-0380071213-1640171213-164022
71213-1640371213-164042
07345-0370007345-0380007345-0370007345-03800
3.2 3.2 4.0 4.0 4.8 4.0 4.8 3.2 4.0 4.0 4.0 5.0 5.0 3.2 4.0 3.2 4.0
AVEX®
BULBEX®
AVINOX® II
AVSEAL® II
STAVEX®
… 0 0 1… 0 0 4… 0 0 4… 0 1 0… 0 1 0… 0 0 4… 0 1 0… 0 0 4… 0 1 0… 1 6 0… 1 8 0… 1 6 1… 1 8 1… 0 0 4… 0 1 0… 0 0 4… 0 1 0
R IGHT-ANGLE SWIVEL HEAD capab i l i t y
1 In inches then in millimetres. 2 Long nose tip for deep placing.
COMPLETE TOOL PART NUMBER :precede with 71223-40 or 71224-40
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete toolswith nose assemblies, those fitted with swivel
heads include the nose tip as a part of the head.
7.6
32 205256
74
97
A
B360o rotation
07346-0310007346-0320007346-0310007346-03200
Swive l Heads
Accessor ies
I M P O R T A N TPRIOR 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 andnose tips vary depending on the fastener to be placed but all other components remain the same within each type of swivel head. Seethe ‘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.
1 In inches then in millimetres. 2 Long nose tip for deep placing.
FA S T E N E RMATERIALØ1
N O S E T I P ( m m )S W I V E L H E A DPART Nº
J A W S seebelow'A' 'B'NAME
Al AlloySteelAl AlloySteelAl AlloyAl AlloyAl AlloyStainless SteelStainless SteelAl AlloyAl AlloyAl AlloyAl AlloySteelSteelStainless SteelStainless Steel
1/8 1/8
5/32 5/32 3/16
5/32 3/16
1/8 5/32
– – – –
1/8 5/32 1/8
3.813.813.813.813.813.813.813.813.811.954.112.004.113.813.813.813.81
7.877.877.877.877.877.877.877.877.876.356.357.627.627.877.877.877.87
07345-0300007345-0310007345-0310007345-0320007345-0320007345-0310007345-0320007345-0310007345-0320071213-0600071213-0660071213-0610071213-0670007345-0310007345-0320007345-0310007345-03200
PART Nº07340-0021307340-0021307340-0021307490-0460207490-0460207340-0021307490-0460207340-0021307490-0460207340-0021307340-0021307340-0021307340-0021307340-0021307490-0460207340-0021307490-04602
PART Nº07345-0360007345-0370007345-0370007345-0380007345-0380007345-0370007345-0380007345-0370007345-0380071213-1640171213-164022
71213-1640371213-164042
07345-0370007345-0380007345-0370007345-03800
3.2 3.2 4.0 4.0 4.8 4.0 4.8 3.2 4.0 4.0 4.0 5.0 5.0 3.2 4.0 3.2 4.0
AVEX®
BULBEX®
AVINOX® II
AVSEAL® II
STAVEX ®
… 0 0 1… 0 0 4… 0 0 4… 0 1 0… 0 1 0… 0 0 4… 0 1 0… 0 0 4… 0 1 0… 1 6 0… 1 8 0… 1 6 1… 1 8 1… 0 0 4… 0 1 0… 0 0 4… 0 1 0
COMPLETE TOOL PART NUMBER :precede with 71223-30 or 71224-30
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete toolswith nose assemblies, those fitted with swivel heads
include the nose tip as a part of the head.
STRA IGHT SWIVEL HEAD capab i l i t y
A
B360o rotation
56 92
6
20
5/32
15
41 12 40 52
1915
36
71213-20200STOP NUT
71213-20102SAFETY CAP
71210-05100
• Disconnect the air supply.• Remove any nose assembly items.• Remove Stem Collector Bottle Assembly (71213-05100) or 71210-20400.• Replace assembly with Safety Cap (71213-20102 or 71210-20101).• Unscrew Jaw Spreader Housing 41 and remove with ‘O’ Ring 12• Remove Locknut 40, ‘O’ Rings 15 and 19, 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.• Refit Jaw Spreader Housing 41 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 page 16.
Item numbers in bold refer to the general assembly drawing and parts list on pages 24-25.
Base tool to receive a nose assembly
Base tool to receive a swivel head
Preparing the Base Tool for Right-Angle and Straight Swivel Head At tachment
Accessor ies
Base Too l 71223
Base Too l 71224
41 12 40 52
1915
36
71213-20202STOP NUT
71210-20201SAFETY CAP
71210-20400
Base tool to receive a nose assembly
Base tool to receive a swivel head
16
Accessor ies
The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.
I M P O R T A 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.
16
1
3
12
1413
16
6
5
21
22 117
9
88
8
10
17 18
19 20
STRAIGHT SWIVEL HEAD
21
15
9
88
10
7
11
172318 19 20
316
16
4
12
14
13
6
6
5
RIGHT-ANGLE SWIVEL HEAD
A Fit Locking Ring 10 over Jaw Spreader Housing 41*(71210-02102). *See page 15.
B Coat Screw 13 with thread locking adhesive and use tosecure Nose Tip 14 onto Body 5.
C Lightly lubricate items 17, 18, 19, 20 and insert intoJaw Carrier 3 as shown. Secure with Screws 16.
D Position Lever 4 into Body 5 and hold in place with pin15 through the hole of Body 5 (not a slot).
E Lubricate the sides of the Jaw Carrier Assembly andinsert into Body 5.
F Lubricate Rollers 8 and ENSURE that they will freelyrotate in the holes of Adaptor 9. If necessary ream theholes.
G Position Spring Clip 7 over Adaptor 9 past the holes forthe rollers and rotate until the locating peg is alignedwith the corresponding hole in Adaptor 9 (smallesthole).
H Fit Adaptor 9 over the end of Body 5 and drop Rollers 8into place. Push Spring Clip 7 over Rollers 8.
I Insert Spindle 11 through Adaptor 9 into Jaw Carrier 3until the hole lines up with slot in Body 5. Temporarilyhold in place with Pin 6.
J Insert Pin 12 through the front slot of Body 5 into JawCarrier 3.
K Hold the assembly vertical to prevent all pins droppingout and slide the jaw carrier assembly back and forth afew times to ensure free movement. Go to M.
L Remove Screws 23 (4 off) and Guard 1. On a straightswivel head also remove Screw 21 and Platform 22.
M Push Pin(s) 6 out and let Spindle 11 drop out. ScrewSpindle 11 onto the Jaw Spreader Housing of the tool,leaving the small screw fixing hole uppermost forstraight swivel. Tighten gently with a tommy bar.
N Screw the assembly over Spindle 11 onto the toolhandle. Replace Pin(s) 6.
O On straight swivel heads attach Platform 22 onto thetop of the Spindle 11 with Screw 21. Deburr the backend of Platform 22 so that it cannot catch on Guard 1.
P Snap Guard 1 over the assembly, align screw holes inguard with tapped holes in body assembly.
Q Insert Pivot Pin 15 through slots in guard and hole inbody. Fit Circlip 2 onto pivot pin so that the circlip seatsin groove provided.
R Coat the thread of Screws 23 (4 off) with thread lockingadhesive and screw into body assembly securing guardto body assembly.
Swive l Head F i t t ing Ins t ruct ionsThe following procedure will allow you to assemble and fit either of the swivel heads to the tool. If you order a complete swivel headrather than individual components, you will only need to start at stage ‘L’.All moving parts should be lubricated. Unless stated otherwise use MolyLithium grease (details page 18).When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.
17
Swive l Head Serv ic ing Ins t ruct ions
Accessor ies
57
1718
1920
Swivel heads should be serviced at weekly intervals.
• Remove the complete head using the reverse procedure tothe ‘Fitting instructions’ omitting step ‘L’.
• If Guard 1 is at all damaged it must be replaced by a newone.
• Any worn or damaged parts should be replaced.
• Pay particular attention to jaw carrier items in the upperillustration 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 removingSpring Clip 7, use two screwdrivers as shown in the lowerillustration opposite.
• Check for excessive wear on slots of Body 5.
• Assemble according to fitting instructions.
Item numbers in bold refer to Swivel Head illustrations onthis 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 tables on pages 10, 11 and 12.
C O N S T A N T C O M P O N E N T SITEM DESCRIPTION STRAIGHT SWIVEL RIGHT-ANGLE SWIVEL
123456789101112131516181920212223
GUARDCIRCLIPJAW CARRIERLEVERBODYPIVOT PINSPRING CLIPROLLERADAPTORLOCKING RINGSPINDLE DOWEL PINSCREWPIVOT PINSCREWJAW SPREADERSPRINGSPRING GUIDESCREWPLATFORMSCREW
07494-05000-
07494-03026-
07494-0301507343-0220707495-0390007007-0003907345-0300107345-0300307345-0300207007-0003807342-02207
-07494-0302807346-0310107165-0030507494-0302707001-0036807345-00401
-
07495-0300307004-0010507494-0302607495-0300407495-0300207343-0220707495-0390007007-0003907345-0300107345-0300307345-0300207007-0003807342-0220707346-0310207494-0302807346-0310107165-0030507494-03027
––
07210-00804
18
Serv ic ing the Too l
• 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 hoseto 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 28 explainshow 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.
• Dismantle and clean the nose assembly with special attention to the jaws. Lubricate with MolyLithium grease before assembling.
• Check for oil leaks and air leaks in the air supply hose and fittings.
Grease can be ordered as a single item, the part number is shown in the Service Kit page 20.
First Aid
SKIN:
As the grease is completely water resistant it is best removed with an approved emulsifying skin cleaner.
INGESTION:
Ensure the individual drinks 30ml Milk of Magnesia, preferably in a cup of milk.
EYES:
Irritant but not harmful. Irrigate with water and seek medical attention.
Fire
FLASH POINT: Above 220°C.
Not classified as flammable.
Suitable extinguishing media: CO2, Halon or water spray if applied by an experienced operator.
Environment
Scrape up for incineration or disposal on approved site.
Handling
Use barrier cream or oil resistant gloves
Storage
Away from heat and oxidising agent.
Item numbers in bold refer to the general assembly drawing and parts list on pages 24-25.
I M P O R T A N TRead 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.
Da i ly
Weekly
MolyL i th ium Grease EP 3753 Safety Data
19
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 extremelyslippery surface.
Harmful to aquatic organisms and may cause long-term adverse effects in the aquatic environment. However, due to the physicalform and water - insolubility of the product the bioavailability is negligible.
Handling
General ventilation is recommended. Avoid skin and eye contact.
Storage
Do not store with oxidizing agents. Keep container closed and store away from water or moisture.
First Aid
SKIN:
No first aid should be needed.
INGESTION:
No first aid should be needed.
EYES:
No first aid should be needed.
INHALATION:
No first aid should be needed.
Fire
FLASH POINT: Above 101.1°C. (closed cup)
Explosive Properties: No
Suitable Extinguishing Media: Carbon Dioxide Foam, Dry Powder or fine water spray.
Water can be used to cool fire exposed containers.
Environment
No adverse effects are predicted.
Handling
General ventilation is recommended. Avoid eye contact.
Storage
Do not store with oxidizing agents. Keep container closed and store away from water or moisture.
Molykote® 111 Grease Safety Data
Serv ic ing the Too l
20
Serv ice K i t
For an easy complete service, Avdel offers the complete service kit below.
PART Nº DESCRIPTIONPART Nº DESCRIPTION
SERVICE KIT : 71210-99990 Spanners are specified in inches and across flats unless otherwise stated
07900-00667 PISTON SLEEVE07900-00692 TRIGGER VALVE EXTRACTOR07900-00670 BULLET07900-00672 'T' SPANNER07900-00706 LOCATION SPIGOT07900-00684 GUIDE TUBE07900-00685 INSERTION ROD07900-00351 3 MM ALLEN KEY07900-00469 2.5 MM ALLEN KEY07900-00158 2 MM PIN PUNCH07900-00224 4 MM ALLEN KEY07900-0073407900-00164
STOP NUT - MAXLOKCIRCLIP PLIERS
07900-00008 7/16" x 1/2" SPANNER07900-00012 9/16" x 5/8" SPANNER07900-00015 5/8" x 11/16" SPANNER07900-00686 PEG SPANNER07900-00677 SEAL EXTRACTOR07900-00698 STOP NUT07900-00700 PRIMING PUMP07992-00020 GREASE - MOLY LITHIUM E.P.375307992-00075 GREASE - MOLYKOTE 55M07900-00755 GREASE - MOLYKOTE 11107900-00850 PIN SPANNER07900-00898 ROTARY VALVE HOOK
®
®
®
®
Serv ic ing the Too l
Maintenance
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 four 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 10 to12 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.
(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, damagedor recommended. All ‘O’ rings and seals should be renewed and lubricated with Molykote® 55m grease for pneumatic sealing orMolykote® 111 for hydraulic sealing.
I M P O R T A N TRead Safety Instructions on page 4.
The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.The operator should not be involved in maintenance or repair of the tool unless properly trained.
The tool shall be examined regularly for damage and malfunction.
Nose Equ ipment
• 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 MolyLithium Grease EP 3753 (07992-00020) to taper bore of Jaw Housing.
• Reassemble in reverse order to above.
Item numbers in bold refer to Nose Tip Table on page 10.
21
Dismant l ing the Too l
Serv ic ing the Too 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.
Ensure the bleed screw orifice is facing away from the person performing this operation.
71223 Tool with Removable Stem Collector Bottle
• Quarter turn and pull off Stem Collector Bottle Assembly 9. See illustration on page 8.
• Unscrew retaining Nut 8 together with Deflector 7.
• Pull off Bottle Adaptor Assembly 6.
• Unscrew End Cap Assembly 4 together with ‘O’ Rings 2, 3 and Lip Seal 1.
or
71224 Tool with Fixed Stem Collector Bottle
• Rotate the Stem Collector Outer so that the aperture in the stem Collector Body is fully exposed.
• Unscrew the Retaining Nut 3.
• Remove the Bottle Assembly 4.
• Remove the Bottle Adaptor Assembly 8.
• Unscrew and remove the End Cap Assembly 2 together with Lip Seal 1, ‘O’ Ring 7 and Seal 6 .
Item numbers in bold above refer to the Stem Collector Bottles Removable and Fixed on page 26.
then
• Remove Spring 91.
• Loosen Locknut 40 with a spanner* and unscrew Jaw Spreader Housing 41 together with ‘O’ Ring 12.
• Withdraw 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 takingcare 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 theinsertion 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 ‘O’ Rings 18 (x2) and Bearing Tape 27 onto the Head Piston 36 ensuring correct orientation, lubricate thecylinder bore and place the piston sleeve* into the back of Head Assembly 58. Slide the bullet* onto the threaded part of Head Piston36 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 pistonsleeve*.
• 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 28.
* Item included in the nG3 Service Kit. For complete list see page 20.Item numbers in bold refer to the General Assembly and Parts List of Common parts on pages 24 and 25.
Head Assembly
22
• 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 withMolykote® 111.
Dismantling
• Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Piston Assembly.
• Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706). Unscrew Clamp Nut 39 and remove together with TopPlate Assembly 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).
I M P O R T A 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 24 and 25.
Pneumat ic P is ton Assembly
Serv ic ing the Too l
Air Va lve
23
Serv ic ing the Too l
Dismantling
• Remove Pneumatic Piston Assembly 57 as described in Pneumatic Piston Assembly.
• Using Spanner (07900-00672), and Location Spigot Assembly (07900-00706), unscrew Clamp Nut 39 and remove togetherwith 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.
• 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.
Rotary Va lve
Dismantling
• Using a 2mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger 33.
• Unscrew Trigger Valve 21 using trigger valve extractor (07900-00692).
Assemble in reverse order to Dismantling Instructions.
Tr igger
Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.
24
Common Par ts
A -
A
49 30 3175
17
1660
A
A
Assy
61
37
Assy
57
90
39
44 51
BB
4112
401,
6 4
352
Assy
582
8
17 64 A
ssy
2146 33
4219 15
36
91
7122
3-02
000
Rem
ovab
le S
tem
Col
lect
or B
ottle
see
page
26
7122
4-02
000
Fixe
d St
emC
olle
ctor
Bot
tlese
e pa
ge 2
6
11
'X'
26
A
79 80
65 A
ssy
5314
5334
14
798
99
Assy
59 96
422
14
23
62 A
ssy
24
56
48
9067
2966
77
100
109
7676
Susp
ensi
onR
ing
H -
H
45
71
74 73
72
HH
HH
Det
ail '
X'2718
B -
B
538
Genera l Assembly o f Common Par ts 71223-02000 and 71224-02000
25
Common Par ts01 02 04 05 06 07 08 11 12 14 15 16 17 18 19 21 22 23 24 26 27 29 30 31 33 34 36 37 38 39 40 41 42 43 44
0700
1-00
405
0700
3-00
333
0700
3-00
127
0700
3-00
189
0700
3-00
194
0700
3-00
271
0700
3-00
273
0700
3-00
341
0700
3-00
277
0700
3-00
281
0700
3-00
204
0700
3-00
287
0700
3-00
288
0700
3-00
342
0700
3-00
310
0700
5-00
088
0700
5-01
274
0700
8-00
010
0700
7-00
224
7121
3-02
021
7121
3-02
022
7122
1-02
006
7122
3-02
001
7122
1-02
002
7121
3-02
051
7121
0-02
009
7122
3-02
121
7122
1-02
008
7121
0-02
013
7121
0-02
014
7121
0-02
103
7121
0-02
101
7122
0-02
102
7121
0-02
019
7121
3-02
010
M5x
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VECL
AMP
NUT
LOCK
NUT
JAW
SPR
EADE
R HO
USIN
G
SEAL
RET
AIN
ERTO
P PL
ATE
ASSE
MBL
Y
VACU
UM S
LEEV
E
13 2 2 3
1 1 2 1 1 1 1 1 3 1 1 2 2 1 1 1 1 2 1 1 2 1 1 1
3 1 1 1 11 1 1 1 1 1 1 1 1 1
45 46
48 49 51 52 53 56 57 58 59 60 61 62 64 65 66 67 71 72 73 74 75 76 77 79 80 90 91 96 97 98 99 100
103
105
106
107
108
109
7121
0-02
022
7121
0-02
024
7122
1-02
007
7122
3-02
027
7121
0-03
205
7121
0-02
104
7121
0-02
031
7122
1-02
004
7122
1-03
210
7121
3-03
330
7121
0-03
400
7121
0-03
800
7123
0-03
600
7121
0-03
700
7121
3-02
016
7122
1-02
014
0700
3-00
027
0700
2-00
108
7122
1-20
105
7122
1-20
101
7122
1-20
103
7122
1-20
102
0700
3-00
182
0700
2-00
163
0700
7-01
993
7122
1-20
104
0700
2-00
098
0700
3-00
274
0749
0-03
002
0700
3-00
268
0700
3-00
398
0700
3-00
042
7121
0-03
401
0700
7-01
503
0790
0-00
930
0790
0-00
849
0790
0-00
890
7121
3-05
101
7121
3-03
001
7121
0-03
402
SUSP
ENSI
ON
RIN
GTR
IGGE
R PI
N
RUBB
ER B
OO
TLA
BEL
GUID
E RI
NG
SEAL
HO
USIN
GSI
LEN
CER
TIE
ROD
PNEU
MAT
IC P
ISTO
N A
SSEM
BLY
(ITEM
S 51
, 75
& 90
)HE
AD A
SSEM
BLY
VALV
E SP
OO
L AS
SEM
BLY
(ITEM
S 96
, 98,
99
& 10
9)SE
AL A
SSE M
BLY
TRAN
SFER
TUB
E AS
SEM
BLY
ON
/OFF
VAL
VE A
SSEM
BLY
HAN
DLE
ASSE
MBL
YBA
SE P
LATE
ASS
EMBL
Y'O
' RIN
GM
6 N
YLO
C N
UTM
ODI
FIED
CO
UNTE
RCO
UNTE
R M
OUL
DIN
GM
OUL
DIN
G RE
TAIN
ING
NUT
SPEC
IAL
M4
SCRE
W'O
' RIN
GW
ASHE
R CE
NTR
E PO
LE M
AGN
ETM
5 X
19 C
OUN
TERS
UNK
SCRE
WM
5 N
YLO
C N
UTLI
P SE
ALSP
RIN
G'O
' RIN
G'O
' RIN
G 'O
' RIN
GVA
LVE
BODY
LABE
L BO
OK
SYM
BOL
TOO
L IN
STRU
CTIO
N M
ANUA
L (N
OT
SHO
WN
)N
OSE
EQ
UIPM
ENT
SPAN
NER
(NO
T SH
OW
N)
STEM
DEF
LECT
OR
WAR
NIN
G LA
BEL
VALV
E SP
OO
L
SEAL
KIT
DAT
A SH
EET
(NO
T SH
OW
N)
1 12
1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 2 1 1 1 3
1 1 2 31 1 2 1 1 1 1 1 1 1 1 1
ITEM
PAR
T N
ºD
ESC
RIP
TIO
NIT
EMPA
RT
Nº
DES
CR
IPTI
ON
71
22
3-0
20
00
an
d 7
12
24
-02
00
PA
RT
S L
IST
* T
he
se a
re m
inim
um
re
co
mm
en
de
d l
eve
ls o
f sp
are
s b
ase
d o
n r
eg
ula
r se
rvic
ing
QTY
SPAR
ESQ
TYSP
ARES
Par ts L is t for Common Par ts 71223-02000 and 71224-02000
26
S tem Co l lec tor Bot t les Removab le and F ixed
4
1
91 Ref see page 24
25
7 9
83 6
ITEM DESCRIPTION PART NUMBER123456789
LIP SEALO-RINGO-RING
END CAP ASSEMBLYWARNING LABELBOTTLE ADAPTOR
DEFLECTORRETAINING NUT
COLLECTOR BOTTLE ASSEMBLY
07003-0027407003-0027807003-0039871213-0510371213-0300171213-0510471213-0510171213-0510271213-05100
REMOVABLE STEM COLLECTOR BOTTLE
91 Ref see page 24
ITEM DESCRIPTION PART NUMBER12345678
LIP SEALEND CAP ASSEMBLY
FIXED COLLECTOR BOTTLE ASSEMBLYëO ’ RING
SEAL‘O’ RING
BOTTLE ADAPTOR ASSEMBLY
07003-0027471403-0212071210-0202871210-2040007003-0006771210-02O2907003-0027871403-02110
FIXED STEM COLLECTOR BOTTLE
21
8 7 6
3
45
RETAINING NUT
71223 Too l Removable
71224 Too l F ixed
Pr im ing
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full strokeafter considerable use, when the stroke may have been reduced and fasteners are not now being fully placed by one operation of the trigger.
The recommended oil for priming is Hyspin® VG32 available in 0.5 litre (part number 07992-00002) or one gallon containers (part number07992-00006). Please see safety data below.
First AidSKIN:Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact requires noimmediate 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.
FireFlash point 232°C. Not classified as flammable.Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets.
EnvironmentWASTE 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.
HandlingWear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.
StorageNo special precautions.
To enable you to follow the priming procedure opposite, you will need to obtain a priming kit:
PART Nº DESCRIPTION
PRIMING KIT : 07900-00688
07900-00351 3 mm ALLEN KEY07900-00700 PRIMING PUMP07900-00224 4 mm ALLEN KEY
Oi l Deta i l s
Hysp in® VG32 Oi l Safety Data
Pr iming K i t
27
28
Pr iming Procedure
Pr im ing
I M P O R T A N T
DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT ON/OFF VALVE ASSEMBLY 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 9).
• 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 OTHERPERSONNEL.
• 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 moverearward.
ENSURE PUMP IS KEPT ‘SQUARE’ TO BLEED SCREW PORT DURING PRIMING OPERATION TO PREVENT BREAKAGE OFBLEED 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 9).
• Check that the stroke of the tool meets the minimum specification of 14 millimetres. To chech the stroke, measure the distancebetween the front face of the jaw spreader housing and the front of the head, BEFORE pressing the trigger and when the trigger isfully actuated. The stroke is the difference between the two measurements. If it does not meet the minimum specification, repeat thePriming Procedure.
Item numbers in bold refer to the general assembly drawing and parts list on pages 24 and 25.
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 24 and 25.
SYMPTOM POSSIBLE CAUSE REMEDY PAGE REF
Other symptoms or failures should be reported to your local Avdel® authorised distributor or repair centre.
Symptom Poss ib le Cause Remedy Page Ref
Fau l t D iagnos is
More than one Air leak Tighten joints or replace components
operation of the Insufficient air pressure Adjust air pressure to within specification 5
trigger needed to Worn or broken jaws Fit new jaws 9
place fastener Low oil level or air in oil Prime tool 27, 28
Build up of dirt inside the nose assembly Service nose assembly 9†
Tool will not grip Worn or broken jaws Fit new jaws 9, 10, 11, 12
stem of fastener Build up of dirt inside the nose assembly Service nose assembly 9
Loose jaw housing Tighten against locking ring 9
Weak or broken spring in nose assembly Fit new spring 9, 10, 11, 12
Incorrect component in nose assembly Identify and replace 10, 11, 12
Jaws will not release Build up of dirt inside the nose assembly Service nose assembly 9†
broken stem of Jaw housing, nose tip or nose casing Tighten nose assembly 10, 11, 12
fastener not properly seated
Weak or broken spring in nose assembly Fit new spring 10, 11, 12
Air or oil leak Tighten joints or replace components
Low oil level or air present in oil Prime tool 27, 28
Cannot feed next Broken stems jammed inside tool Empty stem collector 8
fastener Check jaw spreader is correct 10, 11, 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 9†
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 UK Limited
Low oil level or air present in oil Prime tool 27, 28
30
Dec lara t ion o f Conformi ty
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 ISO 11202
BS EN ISO 3744 BS EN 982
ISO EN 792 part 13 - 2000 BS EN 983
following the provisions of the Machine Directive 2006/42/EC.
This box contains a power tool which is inconformity with Machines Directive2006/42/EC. The ‘Declaration of Conformity’is contained within.
A. Seewraj - Product Engineering Manager - Automation Tools
Date of issue
31
Notes
Since 1936 2010 Since 1922
www.avdel-global.comwww.infastech.com
TAUSTRALIAInfastec (Australia) Pty Ltd. 891 Wellington RoadRowvilleVictoria 3178Tel: +61 3 9765 6400
Fax: +61 3 9765 6445
CANADAAvdel Canada Limited1030 Lorimar Drive MississaugaOntario L5S 1R8Tel: +1 905 364 0664 +800 268 9947Fax: +1 905 364 0678 +800 594 7661 [email protected] CHINAInfastech (China) LtdRM 1708, 17/F.,Nanyang Plaza,57 Hung To Rd., Kwun Tong Hong KongTel: +852 2950 0631 Fax: +852 2950 [email protected]
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INDIAInfastech Fastening Technologies India Private LimitedPlot No 0Z-14, Hi Tech SEZ, SIPCOT Industrial Growth Center, Oragadam, Sriperumbudur Taluk, Kanchipuram District,602105 Tamilnadu Tel: +91 44 4711 8001 Fax: +91 44 4711 8009 info-in@infastech. com
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TAIWANInfastech/Tri-Star LimitedNo 269-7, Baodong Rd,Guanmiao Dist.Tainan CityTaiwan, R.O.C. 71841 Tel: +886 6 596 5798 (ext 201)Fax: +886 6 596 [email protected]
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UNITED KINGDOMAvdel UK LimitedPacific House2 SwiftfieldsWatchmead Industrial Estate Welwyn Garden CityHertfordshire AL7 1LYTel: +44 (0) 1707 292000Fax: +44 (0) 1707 [email protected]
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Infastech (Decorah) LLC1304 Kerr DriveDecorah, IA 52101
Tel: +1 563 383 4216Fax: +1 563 387 3540
©2012Infastech
AV™, Autosert ® (equipment), , , , , , , , , , , ,Avbolt® Avdel® Avdelmate ® Avdel TX2000® Avdelok ® Avex® Avibulb® Avinox® Avinut® Avlug ® Avmatic®
Avplas® Avseal ®, , , , , , , , , , , ,Avsert ® Avtainer® Avtronic® Briv ® Bulbex® Chobert® Eurosert ® Fastriv ® Finsert ® Genesis ® Grovit ® Hemlok®, Hexsert ®
Holding your world together® Hydra®, , , , , , , , , , ,Infalok® Interlock® Klamp-Tite ® Klamptite KTR ® Kvex ® Maxlok ® Monobolt ® Monobulb® Neobolt® Nutsert® Nutsert SQ ®, , , , , , , ,Portariv ® Rivmatic ® Rivscrew ® Speed Fastening ® Squaresert ® Stavex ® Supersert®, , ,Thin Sheet Nutsert ® Titan ®
T-Lok ® TLR ®, , , , ,TSN® TX2000 ® Versa-Nut ® Viking® and Viking360 ® are trademarks of Avdel UK Limited. ,eRiv™, Infastech ® NeoSpeed ® and Our Technology, Your Success™ are trademarks of Infastech Intellectual Properties Pte Ltd. The names and logos of other companiesmentioned herein may be trademarks of their respective owners. This document is for informational purposes only. Infastech makes no warranties, expressed or implied, in th is document. Data shown is subject to change without prior notice as a result of continuous product development and improvement policy. Your local Avdel representative is at your disposal should you need to confirm latest information.
, ,
Manual No. Issue Change Note No.
C 12/07407900-00930
