Instruction Manual Original Instruction 7 1 2 3 4 To o l 7 1 2 3 3 To o l G4 Genesis ® 4 H y d ro - P n e u m a t i c P o w e r To o l 71233 Removable Bottle and 71234 Fixed Bottle
Contents Safety Instructions 4 Specifications Tool Specification 71233 and 71234 Tool Dimensions 5 5 Intent of Use Range of Fasteners Part Numbering 6 6 Putting into Service Air Supply 71233 Tool Removable Bottle 71234 Tool Fixed Bottle Adjusting the Vacuum Extraction Operating Procedure Avtainer® and Maxlok® Removable Stem Collector Bottle 71233-05100 7 7 7 7 8 8 8 Nose Assemblies Nose Tip Selection Fitting Instructions - All Nose Assemblies except Avtainer® and Maxlok® Servicing Instructions Nose
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. 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.
Specifications To o l S p e c i f i c a t i o n Air Pressure Minimum - Maximum Free Air Volume Required @ 5.5 bar 5-7 bar 4.3 litres Stroke Minimum 17 mm Pull Force @ 5.5 bar 18.68 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 7 1 2 3 3 a n d 7 1 2 3 4 To o l D i m e n s i o n s 116.0 (7123 0 4 Too l) 320.00 54.00 DIA 105.0 (7123 0 3 Too l) 15 DIA 30.00 DIA 127.0 0 (71 233 T 145.
Intent of Use Range of Fasteners nG4 is a hydro-pneumatic tool designed to place Avdel® breakstem fasteners at high speed making it ideal for batch or flow-line assembly in a wide variety of applications throughout all industries. It can place all fasteners listed opposite. The tool features a vacuum system for fastener retention and trouble free collection of the spent stems regardless of tool orientation. FASTENER NAME FASTENER SIZE ( MM IN ) 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.
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.
Putting into Service O p e r a t i n g P ro c e d u r e • 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.
Nose Assemblies Nose Tip Selection I M P O R TA N T Nose assemblies do NOT include nose tips. Nose tips must be ordered separately. A 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 10 to 13. If your application presents no access restriction use a Type 1 nose tip. If you are placing Avtainer® a Type 5, Hemlok® and 1/4” Interlock® a Type 6 must be used.
Nose Assemblies Nose Tips TYPE 1 NOSE TIPS 1 In inches then in millimetres. 2 Head forming nose tips for use with countersunk heads ONLY. 4 Material of the body then of the stem. 'Al' is the abbreviation for Aluminium. 5 Domehead. 6 Countersunk.
Nose Assemblies Nose Tips TYPE 2 NAME AVEX ® NOSE TIPS BULBEX ® T-LOK ® N O S E A S S E M B LY Q RIVET part nº 71210-15200 ITEM DESCRIPTION 1 NOSE CASING 2 'O' RING 3 JAW HOUSING 4 JAWS 5 JAW SPREADER 6 BUFFER 7 SPRING 8 LOCKING RING 17 JAW SPREADER HOUSING 18 'O' RING 1 PART Nº 07340-02804 07003-00067 07340-00304 71210-15001 07498-04502 71210-05001 07500-00418 07340-00327 71210-02101 07003-00277 NOSE TIP (mm) PART Nº 'A' 'B' 0 7 3 4 0 -0 2 8 0 7 1 2 . 7 1 0 . 0 0 7 3 4 0 -0 7 3 0 1 1 2 . 7 1 1 .
Nose Assemblies Nose Tips TYPE 7 FA S T E N E R MATERIAL Ø1 1/4 6.4 Any 1/4 6.4 Any NAME AVIBULB ® AVINOX ® NOSE TIPS 1 s ee NOSE TIP (mm) below PART Nº 'A' 'B' 7 1 2 3 3 -1 5 0 0 1 1 4 . 3 3 . 0 … 0 8 4 7 1 2 3 3 -1 5 0 0 2 1 4 . 3 3 . 0 … 0 8 3 In inches then in millimetres.
Nose Assemblies Fitting instruction for Avtainer® and Maxlok® Nose Assemblies I M P O R TA N T The air supply must be disconnected when fitting or removing any nose assembly unless specifically instructed otherwise. The air vacuum extraction system MUST be disabled by fitting Vacuum ‘Shut-Off’ Stop Nut 71233-20200 before operating an nG4 tool with a Maxlok® or Avtainer® nose assembly. Refer to the ‘Operating Procedure’ for Avtainer® and Maxlok®, page 8.
Accessories 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 diconnected before any servicing or dismantling. • Remove stem collector bottle assembly 71213-05100 or 71210-20400.
Notes 15
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 • Check for air leaks. If damaged, hoses and couplings should be replaced.
S e r v i c i n g t h e To o l 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.
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. SERVICE KIT : 71210-99990 PART Nº 07900-00667 07900-00692 07900-00670 07900-00672 07900-00706 07900-00684 07900-00685 07900-00351 07900-00469 07900-00158 07900-00224 07900-00734 07900-00164 Spanners are specified in inches and across flats unless otherwise stated DESCRIPTION PISTON SLEEVE TRIGGER VALVE EXTRACTOR BULLET 'T' SPANNER LOCATION SPIGOT GUIDE TUBE INSERTION ROD 3 MM ALLEN KEY 2.
S e r v i c i n g t h e To o l 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.
S e r v i c i n g t h e To o l Pneumatic Piston Assembly • Remove ‘ON/OFF’ Valve Assembly 62. • Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice fitted with soft jaws. • Pull off Rubber Boot 48. • Using the peg spanner* unscrew Base Cover 31. • Unscrew Nyloc Nuts 67 (2 off) and remove Base Plate Assembly 65. • Remove Cylinder Liner 37 together with Sealing Washers 29 (2 off) and ‘O’ Rings 66 (2 off).
S e r v i c i n g t h e To o l R o t a r y Va l v e 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 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. • Seperate Head Assembly 58 from Handle Assembly 64.
19 15 42 90 Assy 57 Assy 61 37 A 21 Assy 33 B B 100 46 40 41 12 A Assy 52 58 2 26 8 1,6 36 'X' 16 60 65 Assy HH 17 64 Assy 17 43 11 77 31 75 30 49 51 HH 79 80 39 44 27 Detail 'X' 18 71233-02000 Removable Stem Collector Bottle see page 24 71234-02000 Fixed Stem Collector Bottle see page 24 91 48 56 76 53 4 99 90 67 34 29 7 14 A-A 98 Suspension Ring Assy 59 22 96 45 14 109 14 24 53 66 B-B 76 38 5 23 62 Assy 72 74 73 H-H 71 Common Part
BEARING TAPE - PISTON ROD BEARING TAPE - PISTON 1/8" BSP PLUG 6" FLEXIBLE HOSE 3mm DIAx10mm SPIROL PIN 1 1 SEAL RETAINER TOP PLATE ASSEMBLY 71230-02019 71213-02010 71210-02022 71210-02024 43 44 45 46 1 1 1 1 JAW SPREADER HOUSING VACUUM SLEEVE SUSPENSION RING TRIGGER PIN * 2 108 71213-03001 109 71210-03402 105 07900-00849 106 07900-00890 103 07900-00841 WARNING LABEL VALVE SPOOL NOSE EQUIPMENT SPANNER (NOT SHOWN) SEAL KIT DATA SHEET (NOT SHOWN) 'O' RING 'O' RING VALVE BODY LABEL BOOK SYMBO
Stem Collector Bottles Removable and Fixed 7 1 2 3 3 To o l R e m o v a b l e 91 Ref see page 22 5 1 3 2 6 4 7 9 8 REMOVABLE STEM COLLECTOR BOTTLE ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION LIP SEAL O-RING O-RING END CAP ASSEMBLY WARNING LABEL BOTTLE ADAPTOR DEFLECTOR RETAINING NUT COLLECTOR BOTTLE ASSEMBLY PART NUMBER 07003-00374 07003-00278 07003-00398 71233-05103 71213-03001 71213-05104 71213-05101 71213-05102 71213-05100 7 1 2 3 4 To o l F i x e d 91 Ref see page 22 8 7 6 4 1 2 FIXED STEM COLLEC
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 have been reduced and fasteners are not now being fully placed by one operation of the trigger. Oil Details The recommended oil for priming is Hyspin® VG32 available in 0.5 litre (part number 07992-00002) or one gallon containers (part number 07992-00006). Please see safety data below.
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 ON/OFF VALVE ASSEMBLY 62. REMOVE NOSE ASSEMBLY . All operations should be carried out on a clean bench, with clean hands in a clean area. Ensure that the new oil is perfectly clean and free from air bubbles. Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result. • Switch OFF air supply at ON/OFF Valve Assembly 62.
Fault Diagnosis M PpTtO SSyYm oM m 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 9 place fastener Low oil level or air in oil Prime tool 25, 26 Build up of dirt inside the nose assembly Service nose assembly 9 5 Tool will not grip Worn or broken jaws Fit new jaws 9,
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 nG4 Serial No. ................................................
Notes 29
Since 1936 2010 AUSTRALIA Infastec (Australia) Pty Ltd. 891 Wellington Road Rowville Victoria 3178 Tel: +61 3 9765 6400 Fax: +61 3 9765 6445 info@infastech.com.au GERMAN Avdel Deutschland GmbH Rotenburger Str. 28 30659 Hannover Tel: +49 (0) 511 7288 0 Fax: +49 (0) 511 7288 133 AvdelDeutschland@infastech.com CANADA Avdel Canada Limited 1030 Lorimar Drive Mississauga Ontario L5S 1R8 Tel: +1 905 364 0664 +800 268 9947 Fax: +1 905 364 0678 +800 594 7661 infoAvdel-Canada@infastech.
