Avdel Genesis G2-s Bedienungsanleitung

Instruction Manual

Manuel d’instructions

Betriebsanleitung

Manuale d’istruzione

Genesis®G2-s

Hydro-Pneumatic Power Tool

Druckluftgerät

Outil oléo-pneumatique

Attrezzo oleopneumatico

Contents

Safety Rules 4

Tool Speciﬁcations

Tool Dimensions 5

Intent of Use

Range of Fasteners 6

Part Numbering 6

Putting into Service

Air Supply 7

Operating Procedure 7

Adjusting the Vacuum Extraction 7

Nose Assemblies

Fitting & Servicing Instructions 8

Selection of Nose Tips 9&10

Accessories

Stem Deﬂector 11

Extension 11

Side Ejector 11

Stem Collector 11

Swivel Heads 12-15

Preparing the Base Tool 13

Fitting Instructions 14

Swivel Head Servicing Instructions 15

Servicing the Tool

Daily / Weekly 16

Moly Lithium Grease EP 3753 Safety Data 16

MolyKote 55m & MolyKote 111 Safety Data 17

Annually 18

Service Kit 18

Head Assembly 19

Trigger 19

Intensiﬁer 19

General Assembly and Parts List

Pistol 22-23

Intensiﬁer 24-25

Priming

Oil Details 24

Hyspin VG 32 Oil Safety Data 24

Priming Procedure 25

Fault Diagnosis

Symptom, Possible Cause & Remedy 26

Français 33

Deutsch 63

Italiano 93

Avdel policy is one of continuous product development and improvement and we reserve the right to change the speciﬁcation of any product without prior notice.

Warranty

Avdel installation tools carry a 12 month warranty against defects caused by faulty

materials or workmanship, the warranty period commencing from the date of delivery

confirmed by invoice or delivery note.

The warranty applies to the user/purchaser when sold through an authorised outlet,

and only when used for the intended purpose. The warranty is invalidated if the

installation tool is not serviced, maintained and operated according to the instructions

contained in the Instruction and Service Manuals.

In the event of a defect or failure, and at its sole discretion, Avdel undertakes only to

repair or replace faulty components.

English

Safety Rules

1Do not use outside the design intent.

2Do not use equipment with this tool/machine other than that recommended and supplied by Avdel.

3Any modiﬁcation undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Avdel

or their representatives, shall be the customer’s entire responsibility. Avdel will be pleased to advise upon any proposed modiﬁcation.

4The 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

procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel with

your training requirements.

5The 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.

6The precautions to be observed when using this tool/machine must be explained by the customer to all operators.

7Always disconnect the airline from the tool/machine inlet before attempting to adjust, ﬁt or remove a nose assembly.

8Do not operate a tool/machine that is directed towards any person(s).

9Always 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 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.

16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against

fastener ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the

application.

17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be

kept dry and clean for best possible grip.

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

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

thoroughly.

This instruction manual must be read with particular attention to the following safety rules, by any person

installing, operating, or servicing this tool.

Tool Specifications

Specifications

Air Pressure Minimum - Maximum 5-7 bar

Free Air Volume Required @ 5.5 bar 3.6 litres

Stroke Minimum 17 mm

Pull Force @ 5.5 bar 10.88 kN

Cycle time Approximately 1 second

Noise Level 75 dB(A)

Weight Without nose equipment or intensiﬁer 0.88 kg

Vibration Less than 2.5 m/s2

Intensiﬁer Ratio 44:1

Dimensions in millimetres

200

417

12°30'

145

116

2150

Tool Dimensions

English

Intent of Use

AVEX®

STAVEX®

AVINOX®

AVIBULB®

ETR

BULBEX®

T-LOK®

AVDEL®SR

MONOBOLT®

INTERLOCK®

TLR®

AVDEL®

MBC

MBC/LC

AVSEAL®

COMPLETE TOOL

71400-00 . . .

BASE TOOL

NOSE ASSEMBLY

NOSE TIP

71400-01000

71210-15000

see note 3

++=

G2-s is a hydro-pneumatic tool designed to place Avdel®

breakstem fasteners at high speed making it ideal for batch or

ﬂow-line assembly in a wide variety of applications throughout all

industries. It can place all fasteners listed opposite.

The tool features an adjustable vacuum system for fastener

retention and trouble free collection of the spent stems

regardless of tool orientation.

See the ‘Operating Procedure’, page 7, for adjustment

instructions.

A complete tool, except the 71400-00039, is made up of three

separate elements which must be ordered individually.

See diagram below.

If you wish to place most of the fasteners in the table

opposite, you can order the 71400-00039 complete tool

comprising:

•71400-01000 base tool.

•71210-15000 nose assembly.

•Nose tips 71210-05002, 71210-16070 and 07381-

04701.

Two of the nose tips will be stored in the intensiﬁer body.

Fit nose tips as indicated on pages 8-10.

FASTENER

NAME

FASTENER SIZE ( )

3.2

1/8

4.0

5/32

4.3

4.8

3/16

5.2

6.5

The part number of the base tool remains the same whichever nose assembly, or nose tip is ﬁtted. For details of the pistol, see

page 20. If a swivel head is ﬁtted, the same base tool must be adapted. See details page 13.

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 tables pages 8 and 10. A nose assembly can

be substituted by a swivel head (see pages 12-15). 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 page 10 for selection table.

* ADD 3 DIGITS FROM THE

LAST COLUMN OF A NOSE

TIP TABLE ON PAGE 8 OR 10.

FOR TOOLS WITH SWIVEL

HEADS USE TABLE PAGES

12-13.

You can order the above three nose tips and nose assembly as a nose assembly kit part number 71210-15100. For some

fasteners, the base tool, nose assembly and nose tip must be ordered separately.

NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGE 9.

Air Supply

Putting into Service

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 working effective pressure rating of 150% of the maximum pressure produced in the system

or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where

operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or 1/4

inch.

Read servicing daily details page 16.

•Before you use the tool, remove screw 57 on top of the oil reservoir of the intensiﬁer to allow venting. Replace screw when transporting

the intensiﬁer.

•Ensure that either a nose assembly or a swivel head suitable for the fastener is ﬁtted (see pages 8-10 and 12-15).

•Connect the tool to the intensiﬁer and the intensiﬁer to the air supply.

•Insert the fastener stem into the nose of the tool. If using a nose assembly, the fastener should remain held in by the vacuum system. If

not, adjust the vacuum extraction rotary valve 46.

•If using a swivel head, the vacuum extraction is disabled but the jaws themselves will grip the fastener.

•Bring the tool with the fastener to the application so that the protruding fastener enters squarely 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, when the trigger is released.

ADJUSTING THE VACUUM EXTRACTION

•Using a screwdriver, turn rotary valve 46 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.

Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.

TAKE OFF POINT

FROM MAIN SUPPLY

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR

OR LUBRICATION UNITS)

MAIN SUPPLY

DRAIN POINT

PRESSURE REGULATOR

AND FILTER

(DRAIN DAILY)

3 METRES MAXIMUM

Operating Procedure

English

Nose Assemblies

Fitting Instructions

IMPORTANT

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

Item numbers in bold refer to nose assembly components in all 3 nose tip tables.

•Lightly coat jaws 4with Moly lithium grease*.

•Drop jaws 4into jaw housing 3.

•Insert jaw spreader 5into jaw housing 3.

•Locate buffer 6on jaw spreader 5.

•Locate spring 7onto jaw spreader 5.

•Fit locking ring 8onto the jaw spreader housing of the tool.

•Holding tool pointing down, screw the assembled jaw housing onto the jaw spreader housing and tighten with spanner.

•Screw the nose tip into nose casing 1and tighten with spanner*.

•Place nose casing 1over jaw housing 3and screw onto the tool, tightening with spanner*

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.

•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 7is not distorted.

•Assemble according to ﬁtting instructions above.

* Item included in the G2-s service kit. For complete list see page 18.

Item numbers in bold refer to the illustrations on pages 8 and 10.

Servicing Instructions

Nose Assemblies

A tool (except part number 71400-00039) 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 below and page 10.

If your application presents no access restriction use a type ‘1’ nose tip unless you are placing aerospace fasteners which requires a

type ‘3’ nose tip.

Dimensions ‘A’ and ‘B’ below will help you assess the suitability of a particular nose tip.

You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted type

‘2’ nose tips are available for some fasteners. Refer to the table on page 10.

It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a

71400-00039 complete tool, it is important that you check that the nose tip already ﬁtted to the nose assembly is the correct one to

place your fastener by sliding the fastener stem into the nose tip. No force should be required and play should be minimal. The two

alternative nose tips are screwed into the side of the intensiﬁer.

Swivel heads are available as an alternative to nose assemblies when further reach is required. See pages 12-15 in the ‘Accessories’

section.

IMPORTANT

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

In inches then in millimetres.

Head forming nose tips for use with countersunk

heads ONLY.

Long nose tip for deep placing.

Domed Head.

Countersunk.

TYPE 1

NOSE TIPS

NOSE ASSEMBLY

part nº 71210-15000

(+ 3 nose tips above = 71210-15100)

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 tool part number 71400-00039

does not only include the 71210-15000 nose

assembly below but also the following three

nose tips: 71210-05002, 71210-16070 and

07381-04701 making up a nose assembly kit

part number 71210-15100. Use the nose tip

listed in the table.

COMPLETE TOOL

PART NUMBER :

precede with 71400-00.

* See top left

8 7 6 5 4 23 1

22.9

FASTENER

MATERIAL

NOSE TIP (mm) see

below

PART Nº 'A' 'B'NAME

Al Alloy

Steel

Al Alloy

Steel

Al Alloy

Steel

Al Alloy

Any

Al Alloy

Stainless Steel

Steel

Any

Steel

Stainless Steel

Any

1/8

–

5/32

3/16

5/32

3/16

–

3/16

1/8

5/32

3/16

–

3/16

1/8

5/32

3/16

1/8

5/32

3/16

1/8

5/32

3/16

1/8

5/32

3/16

1/8

5/32

3/16

6.35

3.3

2.9

6.35

3.3

2.8

3.3

2.8

3.3

4.1

3.3

2.8

4.9

6.9

4.7

6.9

5.3

7.2

5.4

7.3

5.4

7.3

4.1

3.3

2.8

4.8

3.3

2.8

4.8

6.35

3.3

5.7

2.8

3.3

2.8

3.3

2.8

3.3

2.8

6.35

3.3

12.7

19.0

12.7

19.0

12.7

71210-05002

71210-16070

07340-06401

71210-05002

71210-16070

07381-04701

07340-06501

07381-04701

07340-04800

07490-04401

07340-06601

71210-16020

71210-16070

07381-04701

71210-16001

71210-16006

71210-16002

71210-16007

71210-16003

71210-16008

71210-16004

71210-16009

71210-16005

71210-16010

07605-00220

71210-16070

07381-04701

07498-01401

07340-06201

71210-16070

07381-04701

07498-01401

71210-05002

71210-16070

07348-07001

71210-16050

07381-04701

71210-16070

07381-04701

07340-04800

07381-04701

71210-16070

07381-04701

71210-05002

07340-06201

3.2

4.0

4.8

4.0

4.8

6.5

4.8

3.2

4.0

4.8

4.3

4.8

3.2

4.0

4.8

3.2

4.0

4.8

1.8

4.8

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

AVEX

Large flange

MONOBOLT

BULBEX

AVSEAL

TLR

AVINOX

T-LOK

AVIBULB

AVDEL®SR

INTERLOCK

STAVEX

Large flange

Countersunk

Q™RIVET

…039*

…003

…039

…039*

…009

…039

…016

…017

…015

…200

…039*

…160

…180

…161

…181

…162

…182

…163

…183

…164

…184

…140

…039*

…082

…120

…039*

…082

…039*

…062

…064

…039

…016

…039

…120

English

Nose Assemblies

In inches then in millimetres.

FASTENER

MATERIAL

NOSE TIP (mm) see

below

PART Nº 'A' 'B'NAME

Aluminium Alloy

Steel

Aluminium Alloy

Steel

Aluminium Alloy

Steel

Aluminium Alloy

Steel

Stainless Steel

Steel

Steel/Brass

1/8

5/32

3/16

5/32

3/16

–

3/16

1/8

5/32

3/16

1/8

5/32

3/16

1/8

5/32

–

12.95

11.4

10.0

11.8

11.4

10.0

11.4

10.0

11.4

10.0

11.4

10.0

9.5

12.7

9.5

12.7

9.5

12.7

9.5

12.7

9.5

12.7

07340-02805

07340-02806

07340-02807

07340-07301

07340-02806

07340-02807

07241-07101

07340-02806

07340-02807

07340-02806

07340-02807

07340-02806

07340-02807

3.2

4.0

4.8

4.0

4.8

4.3

4.8

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

5.2

AVEX

BULBEX

T-LOK

STAVEX

AVIBULB

E.T.R

…002

…008

…014

…018

…008

…014

…121

…008

…014

…008

…014

…008

…014

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07340-02804

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 TOOL

PART NUMBER :

precede with

71400-00

NOSE ASSEMBLY

part nº 71210-15200

TYPE 2 NOSE TIPS ARE EXTENDED

TO ALLOW ACCESS INTO

APPLICATIONS WHERE TYPE 1

NOSE TIPS WILL NOT REACH.

TYPE 2

NOSE TIPS

8 7 6 5 4231

58.3

22.9

TYPE 3

NOSE TIPS

COMPLETE TOOL

PART NUMBER :

precede with

71400-00

56.3

22.9

In inches then in millimetres.

Oversize

NOSE ASSEMBLY

part nº 71210-15300

ITEM DESCRIPTION PART Nº

1 NOSE CASING 07344-02001

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

TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE

FASTENERS LISTED BELOW.

FASTENER

MATERIAL

NOSE TIP (mm) see

below

PART Nº 'A' 'B'NAME

Aluminium Alloy

Stainless Steel

Aluminium Alloy

Stainless Steel

Aluminium Alloy

Any

Aluminium Alloy

Any

Aluminium Alloy

1/8

5/32

3/16

1/8

5/32

3/16

1/8

5/32

3/16

2.5

3.3

2.5

3.3

2.5

4.8

5.0

5.1

4.6

12.7

71210-16030

71210-16031

71210-16032

71210-16033

71210-16034

71210-16035

71210-16036

71210-16037

07340-06701

07340-06801

07340-06901

07344-04701

3.2

4.0

4.8

3.2

4.0

4.8

3.2

4.0

4.8

AVDEL

MBC

MBC L/C

…283

…284

…285

…288

…289

…290

…293

…294

…300

…305

…310

…320

8 7 6 5 423

Stem Deflector

Accessories

Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.

Fitted between the tool and the nose assembly, the side ejector

forces fastener stems to eject at the front of the tool and

reaches into deep channels.

It cannot be used in conjunction to a swivel head. Select the

correct part number (below right) according to the stem diame-

ter of the fastener.

For greater ease of use, it is recommended that the stem

collector or deﬂector is replaced with safety cap part number

71210-20201 as used with swivel heads. See page 13 for ﬁtting

instructions, but note that the stop nut is not ﬁtted in this case.

•To ﬁt the side ejector, remove any nose assembly compo-

nents.

•Remove the socket cap screw from the side ejector.

•Screw the inner extension onto jaw spreader housing 1.

•Screw the outer casing onto head assembly 4.

•Replace the socket cap screw securing with Loctite

Screwlock 222, part number 07900-00371.

•Screw the nose assembly onto the side ejector.

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:

•Unscrew retaining nut 26 by inserting a 3 millimetre diameter

rod into one of the holes.

•Remove retaining nut 26 and the stem collector assembly,

items 18, 20, 21, 22, 23, 24, and 25.

•Screw the adaptor nut onto end cap 27.

•Push the boss end of the stem deﬂector into the internal

groove of the adaptor nut.

•Rotate the stem deﬂector until the aperture faces away from

the operator and other person(s) in the vicinity.

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 1.

•Screw the outer onto head assembly 4.

•Fit the nose assembly onto the extension.

ADAPTOR NUT

71210-20101

STEM DEFLECTOR

07340-00342

INNER

71210-20301

OUTER

71210-20302

STEM DEFLECTOR: 71210-20100

EXTENSION: 71210-20300

INNER

EXTENSION

OUTER CASING

8-32 x

" SOCKET

CAP HEAD SCREW

Part number: 07498-00900

for fasteners with a stem larger than 3.1 mm (1/8") Ø

Extension

Side Ejector

English

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