Avdel Genesis 4 User manual

Genesis®
4
G4
Hydro-Pneumatic Power Tool
Instruction Manual

3
Safety Instructions 4
Specifications
Tool Specification 5
Tool Dimensions 5
Intent of Use
Range of Fasteners 6
Part Numbering 6
Putting into Service
Air Supply 7
Operating Procedure - All fasteners except
Avtainer® and Maxlok®7
Operating Procedure - Avtainer® and Maxlok®8
Nose Assemblies
Nose Tip Selection 9
Fitting Instructions - All Nose Assemblies except
Avtainer® and Maxlok®9
Servicing Instructions 9
Nose Tips 10 - 13
Type 1 - Standard 10
Type 2 - Limited Access 11
Type 5 - Avtainer®11
Type 6 - Hemlok®- Stavex®11
Type 7 - Avibulb ® - Avinox®12
Maxlok®12
Fitting Instructions for Avtainer® and Maxlok®
Nose Assemblies 13
Servicing Instructions for all Nose Assemblies 13
Accessories
Stem Deflector 14
Preparing the Base Tool for use with Stem Deflector 14
Extension 14
Servicing the Tool
Daily / Weekly 16
Moly Lithium Grease EP 3753 Safety Data 16
Molykote®55m Grease Safety Data 17
Molykote®111 Grease Safety Data 17
Service Kit 18
Maintenance 18
Nose Equipment 18
Dismantling the Tool 19
Head Assembly 19
Pneumatic Piston Assembly 20
Air Valve 20
Rotary Valve 21
Trigger 21
Base Tool
General Assembly of Base Tool 71234-02000 22
Parts List for 71234-02000 23
Priming
Oil Details 24
Hyspin®VG32 Oil Safety Data 24
Priming Kit 24
Priming Procedure 25
Fault Diagnosis
Symptom, Possible Cause and Remedy 26
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
Safety Instructions
1Do not use outside the design intent.
2Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.
3Any 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.
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 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.
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 UK Limited.
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) or the operator.
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 deflector, it should be rotated until the aperture is facing away from the operator and other person(s)
working in the vicinity.
15 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.
16 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.
17 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
18 Excessive contact with hydraulic fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
19 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 person
installing, operating, or servicing this tool.

Tool Specification
Specifications
5
Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cu ft)
Stroke Minimum 17 mm
Pull Force @ 5.5 bar 18.68 kN (4200 lbf)
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
22.9
12•30'
140
128
156
150
320
145
116
70
4
n
61
Dimensions in millimetres
Tool Dimensions

6
Intent of Use
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.
A complete tool is made up of three
separate elements which will be supplied
individually. See diagram below.
NOSE EQUIPMENT MUST BE FITTED AS
DESCRIBED ON PAGE 9.
FASTENER
NAME
MM
IN
FASTENER SIZE ( )
AVEX®
STAVEX®
AVINOX II
®
AVIBULB®
BULBEX®
T-L OK ®
AVDEL®SR
HEMLOK®
MAXLOK®
AVTAINER®
**AVSEAL®
II
QRIVET
T RIVET
AVDELMATE®
KLAMP-TITE®
KLAMPTITE KTR®
LOCKBOLT
4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10 11 12
–3/16 – – –
1/4– – – – 3/8– – –
*
COMPLETE TOOL
71234-00 . . . *
BASE TOOL
NOSE ASSEMBLY
NOSE TIP
71234-02000
71210-15000
see note 3 ++=
1
1 2 3
1
2
2
3
3
*ADD 3 DIGITS FROM THE
LAST COLUMN OF A NOSE
TIP TABLE ON PAGES 10-12.
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 22 and 23.
The nose tip part number relates to a specific fastener. If access to the application is
restricted, some extended nose tips are available. See table page 12.
This single nose assembly will allow placing of 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 and special fasteners see table page 12.
Range of Fasteners
Part Numbering
*For 3/16” and 1/4” Lockbolt®equipment refer to separate Data Sheet 07900-00795.
** 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 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 1/4inch.
8
6
4
2
0
10
12
14
16
TAKE OFF POINT
FROM
MAIN SUPPLY
STOP COCK
(USED DURING MAINTENANCE
OF FILTER/REGULATOR OR LUBRICATION UNITS)
MAIN SUPPLY
DRAIN POINT
AIR LUBRICATION
PERMISSABLE
PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)
3 METRES MAXIMUM
•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.
•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.
Putting into Service
Air Supply
Operating Procedure -All fasteners except Avtainer®and Maxlok®
Lift Trigger to
cut-off the
vacuum air
supply.

8
Putting into Service
Operating Procedure
AVTAINER®and MAXLOK®
•Ensure that the correct nose assembly is fitted see pages 12 and 13.
•Connect the tool to the air supply.
•Push the Maxlok®or Avtainer®stem through the application hole.
•Place the collar on the stem (orientation as shown below).
•Keeping the head of the stem against the application, push the tool onto the protruding stem.
•Fully depress the trigger. One cycle will ensure that the collar is swaged into the lock grooves of the stem and that the
stem breaks at the breaker groove.
•Release the trigger. The tool completes its cycle by pushing itself off the collar and the spent stem will be pushed to
the rear of the tool on insertion of the next fastener.
Placing AVTAINER®Placing MAXLOK®

9
Nose Tip Selection
Nose Assemblies
IMPORTANT
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. Maxlok®requires a special nose assembly which does not make use of any nose tip, see pages
10 to 13.
Dimensions ‘A’ and ‘B’ 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 with extra reach, are available for some fasteners. Refer to the table on page 12.
It is essential that a fastener-compatible nose assembly and nose tip are fitted prior to operating the tool (no nose tip with Maxlok®).
Fitting Instructions - All Nose Assemblies except Avtainer® and Maxlok®
IMPORTANT
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 4with Moly Lithium grease*.
•Drop Jaws 4into Jaw Housing 3or Chuck Collet 9depending on which nose assembly you are using.
•Insert Jaw Spreader 5into Jaw Housing 3or insert Front Spring Guide 10 into Chuck Collet 9.
•Locate Buffer 6on Jaw Spreader 5.
•Locate Spring 7onto Jaw Spreader 5or onto Front Spring Guide 10.
•Screw Rear Spring Guide 11 into Chuck Collet 9.
•Fit Locking Ring 8onto the Jaw Spreader Housing of the tool.
•Holding tool pointing down, screw the assembled Jaw Housing 3or Chuck Collet 9onto 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 3or Chuck Collet 9and screw onto the tool, tightening with spanner*.
* Item included in the nG4 Service Kit. For complete list see page 18.
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 tool) to assist when servicing nose equipment.
•Remove the nose equipment using the reverse procedure to the ‘Fitting instructions’.
•Any worn or damaged part should be replaced.
•Clean and check wear on Jaws.
•Ensure that neither the Jaw Spreader nor the Front Spring Guide is distorted.
•Check Spring 7is not distorted.
•Assemble according to fitting instructions above.
Servicing Instructions

10
Nose Tips
Nose Assemblies
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
3
Long nose tip for deep placing.
4
Material of the body then of the stem. 'Al' is the
abbreviation for Aluminium.
5
Domehead.
6
Countersunk.
TYPE 1
NOSE TIPS
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Aluminium
Aluminium
Steel
Aluminium
Aluminium
Steel
Steel
Stainless Steel
Steel
Aluminium
Stainless Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
Any
Any
Any
Al/Al4
Al/Al4
Al/Steel4
Al/Steel4
Al/Al4
Al/Al4
Al/Steel4
Al/Steel4
Al Alloy
3/16
3/16
3/16
3/16
1/4
3/16
3/16
3/16
3/16
3/16
3/16
–
3/16
3/16
–
3/16
1/4
3/16
3/16
1/4
3/16
1/4
3/16
3/16
3/16
3/16
1/4
1/4
1/4
1/4
3/16
1/4
3/16
1/4
2.8
3.3
3.3
4.1
3.3
3.3
2.8
2.8
2.8
2.8
4.8
3.3
3.3
4.8
3.3
5.7
3.3
5.7
3.3
3.3
3.3
3.3
9.5
8.0
9.5
9.0
11.2
8.0
10.2
8.3
4.8
4.8
2.8
2.8
12.7
19.0
12.7
12.7
12.7
19.0
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
15.9
12.7
15.9
12.7
17.5
12.7
16.7
12.7
12.7
12.7
12.7
12.7
07381-04701
07340-04800
07490-04401
07340-066012
07612-02001
07381-04701
07381-04701
07381-04701
07340-04800
71220-16080
07498-01401
07340-06201
07340-06201
07498-01401
07612-02001
07348-070015
71220-60001
71210-160506
07340-06201
07612-02001
07340-06201
07612-02001
703-A-25-6TA
703-B-21
703-A-25-6T
703-B-26
743-A-25-8TA
743-B-21
743-A-25-8T
743-B-26
71220-16060
71220-16061
07381-04701
07162-02001
4.8
4.8
4.8
4.8
6.4
4.8
4.8
4.8
4.8
4.8
4.8
4.3
4.8
4.8
6.0
4.8
6.4
4.8
4.8
6.4
4.8
6.4
4.8
4.8
4.8
4.8
6.4
6.4
6.4
6.4
4.8
6.4
4.8
6.4
AVEX®
Large flange
STAVEX®
Countersunk
Large flange
BULBEX®
AVINOX®II
T-LOK ®
AVIBULB®
AVDEL®SR
Countersunk
Q RIVET
AVDELMATE®
T RIVET
Large flange
Large flange
Large flange
Large flange
KLAMPTITE KTR
®
KLAMP-TITE
®
…010
…016
…017
…015
…021
…016
…010
…010
…010
…010
…082
…120
…120
…082
…021
…062
…063
…064
…120
…021
…120
…021
…380
…381
…383
…384
…385
…386
…387
…388
…500
…501
…010
…021
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 TOOL
PART NUMBER :
precede with
71234-00
8 7 6 5 4 23 1 61
22.9
NOSE ASSEMBLY
part nº 71210-15000
Al Alloy
Al Alloy
Al Alloy

11
Nose Tips
Nose Assemblies
1
In inches then in millimetres.
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Aluminium
Steel
Aluminium
Steel
Steel
3/16
3/16
3/16
–
3/16
10.0
11.8
10.0
10.0
10.0
12.7
12.7
12.7
12.7
12.7
07340-02807
07340-07301
07340-02807
07241-07101
07241-07101
4.8
4.8
4.8
4.3
4.8
AVEX®
BULBEX®
T-LOK®
…014
…018
…014
…121
…121
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
17 JAW SPREADER HOUSING 71210-02101
18 'O' RING 07003-00277
COMPLETE TOOL
PART NUMBER :
precede with
71234-00
NOSE ASSEMBLY
part nº 71210-15200
A
B
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 423158.3
22.9
17 18
1
In inches then in millimetres.
TYPE 6
NOSE TIPS
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
A
B
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07612-02003
4 JAWS 07612-02002
5 JAW SPREADER 07498-04502
6 BUFFER 07498-03003
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
COMPLETE TOOL
PART NUMBER :
precede with
71234-00
NOSE ASSEMBLY
part nº 71230-15800
8 7 6 5 423
161
22.9
HEMLOK®
STAVEX®
Any
Any
1/4
1/4
3.6
3.6
14.3
14.3
07612-02001
07612-02001
6.4
6.4
…261
…261
TYPE 5
NOSE TIP
COMPLETE TOOL
PART NUMBER :
precede with
71234-00
1
1
In inches then in millimetres
NOSE ASSEMBLY part nº 71230-15600
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07498-00501
2 'O' RING 07003-00067
9 CHUCK COLLET 07498-00801
4 JAWS 07220-02302
ITEM DESCRIPTION PART Nº
10 FRONT SPRING GUIDE 07498-00803
7 SPRING 07500-02005
11 REAR SPRING GUIDE 07498-00503
8 LOCKING RING 07340-00327
13 STOP NUT ASSY 71233-20200
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Steel
3/8
4.119.107498-00802 9.6 …243
98.5
20.6
11 7 10 4298
A
B
AVTAINER®
13

12
Nose Assemblies
Nose Tips
1
In inches then in millimetres.
TYPE 7
NOSE TIPS
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
A
B
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07340-00306
2 'O' RING 07003-00067
3 JAW HOUSING 07612-02003
4 JAWS 71230-16101
5 JAW SPREADER 71233-15003
6 BUFFER 07498-03003
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
COMPLETE TOOL
PART NUMBER :
precede with
71234-00
NOSE ASSEMBLY
part nº 71233-15000
8 7 6 5 423
161
22.9
AVIBULB®
AVINOX®
Any
Any
1/4
1/4
3.0
3.0
14.3
14.3
71233-15001
71233-15002
6.4
6.4
…084
…083
MAXLOK®-
NOSE ASSEMBLY
1
In inches then in millimetres
READ MAXLOK®'FITTING INSTRUCTIONS' PAGE 14.
FASTENER
MATERIAL
Ø1
NOSE ASSEMBLY see
below
PART NºNAME
All
All
3/16
1/4
07610-02000
07610-02100
4.8
6.4
MAXLOK®…371
…372
COMPLETE TOOL PART NUMBER :
precede with 71234-00
16
NOSE ASSEMBLY NOSE ASSEMBLY
part nº 07610-02000 for
3
/
16
" ø part nº 07610-02100 for
1
/
4
" ø
ITEM DESCRIPTION PART Nº
9 CHUCK COLLET 07610-02002
4 JAWS 07610-02003
10 SPRING GUIDE 07220-02104
7 SPRING 07610-02107
8 LOCKING RING 07610-02004
12 ANVIL 07610-02001
15 ANVIL ADAPTOR
16 ANVIL NUT
71230-02063
07610-00307
ITEM DESCRIPTION PART Nº
9 CHUCK COLLET 07610-02102
4 JAWS 07610-02103
10 SPRING GUIDE 07220-02104
7 SPRING 07610-02107
8 LOCKING RING 07610-02004
12 ANVIL 07610-02101
13
14 CHUCK COLLET ADAPTOR 07610-00501
STOP NUT ASSY 71233-20200
15 7 10 9410
13 14 12
8
52
19
ADAPTOR KIT
3
/
16
" øpart nº 71234-03400 for and
1
/
4
" ø

13
* Item included in the nG4 service kit. For complete list see page 18
Item numbers in bold refer to the general assembly drawing and parts list on pages 22 and 23.
Nose Assemblies
IMPORTANT
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 a nG4 tool with a Maxlok®or Avtainer®nose assembly.
Refer to the ‘Operating Procedure’ for Avtainer®and Maxlok®, page 8.
AVTAINER®
Item numbers in bold refer to the general assembly and parts
list pages 22 and 23. Other items numbers refer to the ‘Type 5
Nose Tip’ table page 12.
•Remove Jaw Spreader Housing 41, ‘O’ ring 12, Locknut
40, Vacuum Sleeve 42 and Seal Housing 52.
•Screw Vacuum ‘Shut-off’ Stop Nut Assy 13 onto Head Piston
36. (Items 40, 42 and 52 are not refitted).
•Replace Jaw Spreader Housing 41 and ‘O’ Ring 12.
•Lightly coat jaws 4 with Moly Lithium grease*.
•Drop jaws 4 into Chuck Collet 9.
•Insert Front Spring Guide 10 into Chuck Collet 9.
•Locate Spring 7 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.
•Screw the assembled 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 with ‘O’ Ring 2 over Chuck Collet 9
and screw onto the tool, tightening with spanner*
MAXLOK®
Item numbers in bold refer to the general assembly and parts
list pages 22-23. Other items numbers refer to the ‘Maxlok®
Nose Tip’ table page 13.
•Remove Jaw Spreader Housing 41, ‘O’ Ring 12, and
Vacuum Sleeve 42. Seal housing 52 and Locknut 40.
(None of the above parts are refitted).
•Screw Stop Nut Assy 13 onto Head Piston 36.
•Substitute Jaw Spreader Housing 1 with Chuck Collet
Adaptor 14. Tighten fully onto piston before tightening the
Stop Nut Assy 13 against it.
•Fit Locking Ring 8 onto the Chuck Collet Adaptor.
•Lightly coat Jaws 4 with Moly Lithium grease.
•Drop Jaws 4 into Chuck Collet 9.
•Insert one Spring Guide 10 into Chuck Collet 9.
•Locate Spring 7 onto the Spring Guide already in place.
•Drop the other Spring Guide 10 into Spring 7.
•Holding tool pointing down, screw the assembled Chuck
Collet onto the Chuck Collet Adaptor and tighten with
spanner.
•Screw Anvil Adaptor 15 into the Head Assembly.
•Place Anvil 12 over Chuck Collet 9 and lock into place with
Anvil Nut 16.
Fitting instruction for Avtainer® and Maxlok® Nose Assemblies
Servicing Instructions for all Nose Assemblies
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 assembly 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 that the spring is not distorted.
•On nose assemblies for Maxlok®and Avtainer®check that the spring guides are not distorted.
•On nose assemblies for Maxlok®check that the anvil is neither cracked nor has any scoring or corrosion marks on the inside face
of the concave shape at the front end.
•Assemble according to fitting instructions.

14
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
07340-00342
SEALED NUT
71213-02200
STEM DEFLECTOR
Stem Deflector
Accessories
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 22 and 23.
INNER OUTER
EXTENSION PART NUMBER: 71210-20300
MAXLOK®EXTENSION 71230-20300
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.
•Loosen Locknut 40 using
16mm A Spanner.
•Unscrew and remove both Jaw
Spreader Housing 41 and
Locknut 40.
•Replace Locknut 40 with
‘Sealed’ Nut 71213-02200,
screw ‘Sealed” Nut onto Head
Piston 36.
•Jaw Spreader Housing 41
must be tightened onto Head
Piston 36, finally tightening
‘Sealed’ Nut against it.
Extension
Preparing the Base Tool for use with Stem Deflector
07340-00342
STEM DEFLECTOR
71210-20101
ADAPTOR NUT
41
40
36
The air line 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:
Note: If Pintail Deflector is used with Maxlok®equipment then Seal Housing 52 will need to be removed and Stop Nut 71233-20200
fitted instead of ‘Sealed’ Nut 71213-02200.
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:
•Remove Retaining Nut 35 and the Stem Collector Bottle
Assembly, items 25, 28, 30, 32, 97 and 98.
•Screw the Adaptor Nut 71210-20101 onto End Cap Assembly
50.
•Push the bossend 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 any other person(s) in the vicinity.

15
Notes

Servicing the Tool
•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 25 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 Machined 55.
•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.
Grease can be ordered as a single item, the part number is shown in the Service Kit page 18.
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 22 and 23.
IMPORTANT
Read Safety Instructions on page 4.
The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.
The operator should not be involved in maintenance or repair of the tool unless properly trained.
The tool shall be examined regularly for damage and malfunction.
Daily
Weekly
Moly Lithium Grease EP 3753 Safety Data
16

17
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.
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
Servicing the Tool

Service Kit
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 SLEEVE
07900-00692 TRIGGER VALVE EXTRACTOR
07900-00670 BULLET
07900-00672 'T' SPANNER
07900-00706 'T' SPANNER SPIGOT
07900-00684 GUIDE TUBE
07900-00685 INSERTION ROD
07900-00351 3 MM ALLEN KEY
07900-00469 2.5 MM ALLEN KEY
07900-00158 2 MM PIN PUNCH
07900-00224 4 MM A/F ALLEN KEY
07900-00734
07900-00164
STOP NUT - MAXLOK
CIRCLIP PLIERS
07900-00008 7/16" x
1/2" SPANNER
07900-00012 9/16" x
5/8" SPANNER
07900-00015 5/8" x
11/16" SPANNER
07900-00686 PEG SPANNER
07900-00677 SEAL EXTRACTOR
07900-00698 STOP NUT
07900-00700 PRIMING PUMP
07992-00020 GREASE - MOLY LITHIUM E.P.3753
07992-00075 GREASE - MOLYKOTE 55M
07900-00755 GREASE - MOLYKOTE 111
07900-00850 PIN SPANNER
07900-00898 ROTARY VALVE HOOK
®
®
®
®
Servicing the Tool
Maintenance
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 25.
Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 9 to
14.
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 see page 25 and to fit an appropriate nose assembly see pages 9 to 14.
(Annually or every 500,000 cycles whichever is the soonest)
Annually or every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged
or recommended. All ‘O’ rings and seals should be renewed and lubricated with Molykote®55m grease for pneumatic sealing or
Molykote®111 for hydraulic sealing.
IMPORTANT
Read Safety Instructions on page 4.
The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.
The operator should not be involved in maintenance or repair of the tool unless properly trained.
The tool shall be examined regularly for damage and malfunction.
Nose Equipment
•Unscrew Nose Casing 1 and Nose Tip.
•Unscrew Jaw Housing 3and remove Jaws 4, Jaw Spreader 5, Spring 7and 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 3.
•Insert Jaws 4, Jaw Spreader 5, Spring 7and Buffer 6into Jaw Housing 3and 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 10 to 13.
41* refers to illustration on page 22.
18

19
Dismantling the Tool
Servicing the Tool
Before dismantling the tool the oil must be emptied from it.
•With the air supply switched OFF at ON/OFF Valve Assembly 62 remove Bleed Screw 1and 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.
•Unscrew Retaining Nut 35 and remove Stem Collector Bottle Assembly 71210-20400.
•Pull off Bottle Adaptor Assembly 10.
•Remove End Cap Assembly 50 together with ‘O’ Ring 47 and Lip Seal 9.
•Remove Spring 91.
•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
•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 8onto 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*.
•After fitting Lip Seals 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 25.
* Item included in the nG4 Service Kit. For complete list see page 18.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 22 and 23.
Head Assembly

•Remove ‘ON/OFF’ Valve Assembly 62.
•Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice fitted with soft jaws.
•Pull off Rubber Boot 48.
•Using the peg spanner* unscrew Base Cover 31.
•Unscrew Nyloc Nuts 67 (2 off) and remove Base Plate Assembly 65.
•Remove Cylinder Liner 37 together with Sealing Washers 29 (2 off) and ‘O’ Rings 66 (2 off).
•Remove Pneumatic Piston Assembly 57 together with ‘O’ Ring 75, Lip Seal 9(3 off) and Guide Ring 51.
•Engage the Seal Extractor* into Intensifier 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.
Dismantling
•Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Piston Assembly.
•Using Spanner (07900-00672), and Location Spigot (07900-00706). 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 Machined 55 from Handle Assembly 64. Remove ‘O’ ring 17.
•Push out the Valve Seat 34, from the Body Machined 55, 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)
IMPORTANT
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 nG4 Service Kit. For complete list see page 18.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 22 and 23.
Pneumatic Piston Assembly
Servicing the Tool
Air Valve
20