Avdel Genesis G2LB User manual

Genesis®G2LB
2
Hydro-Pneumatic Power Tool
Instruction Manual

3
Safety Rules 4
Specifications
Tool Specification 5
Tool Dimensions 5
Intent of Use
Part Numbering 6
Putting into Service
Air Supply 7
Operating Procedure 7
Nose Assemblies
Avdelok®and Maxlok®Nose Assemblies 8
Fitting Instructions Avdelok®9
Servicing Instructions 9
Fitting Instructions Maxlok®10
Servicing Instructions 10
Accessories
Stem Deflector 11
Extension 11
Servicing the Tool
Daily / Weekly 12
Moly Lithium Grease EP 3753 Safety Data 12
MolyKote®55m and MolyKote®111 Safety Data 13
Annually 14
Service Kit 14
Head Assembly 14-15
Pneumatic Piston Assembly 15
Valve Spool Assembly 15
Trigger 15
General Assembly of Base Tool
General Assembly and Parts List 16-17
Priming
Oil Details 18
Hyspin®VG 32 Safety Data 18
Priming Kit 18
Priming Procedure 19
Fault Diagnosis
Symptom, Possible Cause and Remedy 20
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 Rules
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 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 way 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 fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
20 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.

5
Dimensions in millimetres.
2
23
121
110
120
150
305
145
116
70
2
12°30'
Air Pressure Minimum - Maximum 5-7 bar (72.5 - 101.5 psi)
Free Air Volume Required @ 5.5 bar 2.1 litres
Stroke Minimum 13mm
Pull Force @ 5.5 bar 12.47 KN
Cycle time Approximately 1 second
Noise Level 75 dB(A)
Weight Without nose equipment 1.35 kg
Vibration Less than 2.5 m/s2 (8.2 ft/s2)
Specifications
Tool Specification
Tool Dimensions

6
G2LB is a hydro-pneumatic tool designed to place Avdel Avdelok®/Maxlok®fasteners at high speed making it ideal for batch or flow-line
assembly in a wide variety of applications throughout all industries.
A complete tool is made up of two separate elements. See diagram below.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGES 8-9-10.
BASE TOOL
AVDELOK®
NOSE ASSEMBLY
71255-02000
71230-05010(3/16)
71230-05020(1/4)
1
1
2
COMPLETE TOOL
+=
12
2
MAXLOK®
NOSE ASSEMBLY
07610-02000(3/16)
07610-02100(1/4)
2
AVDELOK®
71255-00391(3/16)
71255-00392(1/4)
MAXLOK®
71255-00371(3/16)
71255-00372(1/4)
The part number of the base tool remains the same whichever nose assembly is fitted. See the General Assembly and
Parts List pages 16-17.
The nose assembly will allow placing of fasteners by simply selecting the appropriate nose
assembly. See page 8.
Intent of Use
Part Numbering

7
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and
automatic 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 1/4inch.
Read daily servicing details page 12.
8
6
4
2
0
10
12
14
16
TAKE OFF POINT
FROM
MAIN SUPPLY
STOP COCK
(USED DURING MAINTENANCE
OF FILTER/REGULATOR)
MAIN SUPPLY
DRAIN POINT
PRESSURE REGULATOR
AND FILTER (DRAIN DAILY)
3 METRES MAXIMUM
•Ensure that the correct nose assembly is fitted.
•Connect the tool to the air supply.
•Disable the vacuum extraction system by turning Rotary Valve
65 until you feel or hear no air flow out of the front of the
nose assembly.
•Push the fastener stem through the application hole.
•Place the collar on the stem (orientation as shown).
•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.
•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.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.
Placing AVDELOK®/MAXLOK®
Putting into Service
Air Supply
Operating Procedure

8
AVDELOK
®
NOSE ASSEMBLY 1
In inches then in millimetres
NOSE ASSEMBLY part nº
71230-05010 for 4.8 (
3
/
16
") Avdelok
®
NOSE ASSEMBLY part nº
71230-05020 for 6.4 (
1
/
4
") Avdelok
®
ITEM DESCRIPTION PART Nº
1 ANVIL CASING 71230-05012
2 BUFFER 71230-05014
3 ANVIL 71230-05011
4 SHROUD 71230-05013
5 CHUCK COLLET 07200-02101
6 CHUCK JAWS 07220-02102
7 SPRING GUIDE 07220-02104
8 SPRING 07220-02103
9 FRICTION RING 07610-02004
10 nG4 CHUCK COLLET ADAPTOR
(nG4) (nG4)
07610-00501
11 nG4 LOCKNUT 71233-20200
ITEM DESCRIPTION PART Nº
1 ANVIL CASING 71230-05012
2 BUFFER 71230-05014
3 ANVIL 71230-05021
4 SHROUD 71230-05013
5 CHUCK COLLET 07200-02201
6 CHUCK JAWS 07220-02302
7 SPRING GUIDE 07220-02104
8 SPRING 07220-02103
9 FRICTION RING 07610-02004
10 nG4 CHUCK COLLET ADAPTOR 07610-00501
11 nG4 LOCKNUT 71233-20200
FASTENER
MATERIAL
Ø1
NOSE ASSEMBLY see
below
PART NºNAME
All
All
3/16
1/4
71230-05010
71230-05020
4.8
6.4
AVDELOK®…391
…392
COMPLETE TOOL PART NUMBER :
precede with 71255-00
21
1
3
65
4
8
7
9
7
11 10
Avdelok®and Maxlok®Nose Assemblies
MAXLOK®-
NOSE ASSEMBLY
1
In inches then in millimetres
READ MAXLOK®'FITTING INSTRUCTIONS' PAGE 10.
FASTENER
MATERIAL
Ø1
NOSE ASSEMBLY see
below
PART NºNAME
All
Al Alloy
3/16
1/4
07610-02000
07610-02100
4.8
6.4
MAXLOK®…371
…372
COMPLETE TOOL PART NUMBER :
precede with 71255-00
52
19
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
13
14 nG4 CHUCK COLLET ADAPTOR
15 ANVIL ADAPTOR
16 ANVIL NUT
nG4 STOP NUT ASSY 71233-20200
07610-00501
71230-02063
07610-00307
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 nG4 CHUCK COLLET ADAPTOR 07610-00501
nG4 STOP NUT ASSY 71233-20200
15 7 10 9410
13 14 (nG4) 12
8
(nG4)
Nose Assemblies

9
Fitting Instructions Avdelok®
•Assemble Chuck Jaws 6, Spring Guides 7and Spring 8into Chuck Collet 5. (Lightly coat Chuck Jaws and Chuck Collet internal
bores with Molylithium grease).
•Screw chuck collet (assembled as above) onto Chuck Collet Adaptor of tool assembly (item 1page 16). Lock in position with
Friction Ring 9.
•Screw Anvil 3into front of placing tool.
•Assemble Buffer 2over Anvil 3followed by Anvil Casing 1.
•Fit rubber Shroud 4over Anvil Casing 1and Buffer 2and locate over flange of Anvil 3to hold components in position.
Servicing Instructions
•Remove nose assembly from tool using the reverse procedure to the fitting instructions above.
•Clean parts. Worn or damaged parts should be replaced.
•Check Anvil 3for wear and/or damage to the swaging bore.
•Lightly coat Chuck Jaws 6and Chuck Collet 5internal bores with Molylithium grease.
•Assemble as above instructions.
•For ease of fitting the rubber shroud, liquid soap can be smeared on its internal surface prior to assembly.
IMPORTANT
Air supply must be disconnected when fitting or removing nose assemblies
21
1
3
65
4
8
7
97
Nose Assemblies
Item numbers in bold refer to the Avdelok®Nose Assembly on page 8.

10
Nose Assemblies
IMPORTANT
Air supply must be disconnected when fitting or removing nose assemblies
•Fit Locking Ring 8onto the Chuck Collet Adaptor.
•Lightly coat Jaws 4with Moly Lithium grease.
•Drop Jaws 4into Chuck Collet 9.
•Insert one Spring Guide 10 into Chuck Collet 9.
•Locate Spring 7onto the Spring Guide 10 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 9and lock into place with Anvil Nut 16.
Fitting Instructions Maxlok®
16
15 7 10 9410 12
8
Servicing Instructions
•Remove nose assembly from tool using the reverse procedure to the fitting instructions above.
•Clean parts. Worn or damaged parts should be replaced.
•Check the Anvil 12 for wear and/or damage to the swaging bore.
•Lightly coat Chuck Jaws 4and Chuck Collet 9internal bores with Molylithium grease.
•Assemble as above instructions.
Item numbers in bold refer to the Maxlok®Nose Assembly on page 8.

11
Stem Deflector
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
07340-00342
KIT PART NUMBER: 71210-20100
The stem deflector is a very simple alternative to the standard
stem collector and allows access in restricted areas. It is easy
to fit to the tool 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.
•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.
Accessories
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16 and 17.
INNER OUTER
EXTENSION PART NUMBER: 71210-20300
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 Chuck Collet Adaptor 1.
•Screw the outer onto Head Assembly 4.
•Fit the nose assembly onto the extension.
Extension

12
•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 is correct for the fastener to be placed.
•Check that the stroke of the tool meets the minimum specification (page 5). The last step of the Priming Procedure on page 19
explains how to measure the stroke.
•Either a stem collector or a stem deflector must be fitted to the tool.
•Ensure that Rotary Valve 65 is turned OFF.
•Dismantle and clean nose assembly, with special attention to the jaws. Lubricate with Moly Lithium grease EP 3753 before
assembling.
•Check for air leaks.
Grease can be ordered as a single item, the part number is shown in the Service Kit page 13.
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 16-17.
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.
Servicing the Tool
Daily
Weekly
Moly Lithium Grease EP 3753 Safety Data

13
Servicing the Tool
Molykote®55m Grease Safety Data
Molykote®111 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.

14
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 19.
Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the Nose Assemblies section, pages 8,
9 and 10.
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.
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 should be examined regularly for damage and malfunction.
* Item included in the Service Kit.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.
•Unscrew Retaining Nut 26 and pull off stem collector assembly, items 18, 20, 21, 22, 23, 24 and 25.
•Using the ‘T’ spanner*, remove End Cap Assembly 73 together with Seal 17, ‘O’ Ring 16, Lip Seal 28 and Spring 70.
•Loosen Locknut 3with a spanner* then unscrew Chuck Collet Adaptor 1.
•Remove Locknut 3together with ‘O’ rings 49 and 50.
•Remove screw 9and Bonded Seal 10.
•Push Head Piston 7to the rear and out of Head Assembly 4taking care not to damage the cylinder bore.
•Remove Seal Retainer 30. Push Lip Seal 8to the rear and out of Head Assembly 4taking care again not to damage the cylinder
bore.
•Remove Seal Housing 5and Lip Seal 67.
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 STOP NUT - MAXLOK
07900-00164 CIRCLIP PLIERS
07900-00008 7/16 x 1/2SPANNER
07900-00012 9/16 x 5/8SPANNER
07900-00015 5/8x 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
®
®
®
®
(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.
For an easy complete service, Avdel®is offering a complete service kit.
Servicing the Tool
Annually
Head Assembly

15
Assemble in reverse order to dismantling noting the following points:
•Place Lip Seal 8onto the insertion rod* ensuring correct orientation. Push the guide tube* into the head of the tool and push the
insertion rod* with the seal into place through the guide tube*. Pull the insertion rod* out then the guide tube.
•Drop Seal Retainer 30 against Lip Seal 8large flange first.
•Fit Lip Seal 11 and ‘O’ Ring 13 (2 off) onto the head piston 7.
•Lubricate the cylinder bore and place the piston sleeve* into the back of Head Assembly 4. Slide the bullet* onto the threaded part of
Head Piston 7and push the piston with the seals through the piston sleeve* as far as it will go. Slide the bullet* off the piston and
remove the piston sleeve.
•Fit Seal Housing 5and Lip Seal 67.
•Tighten Chuck Collet Adaptor 1fully tightened onto Head Piston 7BEFORE tightening Locknut 3against it.
•Use Loctite®932 when reassembling Retaining Nut 26.
•Remove ‘ON/OFF’ Valve Assembly 60.
•Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice fitted with soft jaws.
•Pull off Rubber Boot 80.
•Using the peg spanner* unscrew Base Cover 40.
•Unscrew Locknuts 76 (2 off) and remove Base Plate 77.
•Remove Cylinder Liner 45 together with Sealing Washers 75 (2 off) and 'O' Rings 78 (2 off).
•Remove Pneumatic Piston Assembly 42 together with ‘O’ Ring 39, Lip Seals 41 (3 off) and Guide Ring 35.
•Engage the Seal Extractor* into Seal Assembly 34 and withdraw Seal Assembly from intensifier tube of the Head Assembly 4.
Assemble in reverse order.
•Remove Pneumatic Piston Assembly 42 and Intensifier Seal Assembly 34 as described above.
•Using the ‘T’ spanner* and ‘T’ spanner spigot* undo Clamp Nut 36 and remove it together with Top Plate 63, Transfer Tube Assembly
44, ‘O’ ring 6and Silencers 62.
•Release the tool from the vice and separate Body 38 with ‘O’ Ring 31 from Handle Assembly 32.
•Remove ‘O’ Ring 33 from the intensifier tube and pull off Head Assembly 4from Handle Assembly 32.
•Push out Valve Seat 64 with ‘O’ Ring 6.
•Pull out all the components of Valve Spool Assembly 54.
•Finally remove ‘O’ Ring 59 out of the handle counterbore.
Assemble in reverse order noting the following points -
•Ensure that the central port in Valve Seat 64 faces upwards.
•Use Loctite®243 when reassembling Clamp Nut 36, torque to 11ft lb (14.91 Nm).
•Using the 2 millimetre diameter pin punch*, drive Trigger Pin 48 out and lift off Trigger 47.
•Unscrew Trigger Valve 46 using the trigger valve extractor*.
Assemble in reverse order to dismantling.
IMPORTANT
Check the tool against daily and weekly servicing
Priming is ALWAYS necessary after the too has been dismantled and prior to operating.
* Item included in the Service Kit. For complete list see page 14.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.
Servicing the Tool
Head Assembly
Pneumatic Piston Assembly
Valve Spool Assembly
Trigger

16
General Assembly of Base Tool 71255-02000
B - B
6665
37
84 85 86 87
38
40
39
83
31
33
34
A A
44 45
36
35
B B
1 3 4 9105 8
31
30
32
46 48 67 47
50 49
26
73
70 28
72 16
17 18
14
20 21
22
25 24
117
A23
13
88
42 41
80
8281
A - A
6
64
5958
57
54-56
55
52 53 6
61
60
52
69
6
74
80
41 76 7577 78
62 63

17
Parts List for 71255-02000
01 03 04 05 06 07 08 09 10 11 13 14 16 17 18 20 21 22 23 24 25 26 28 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47
07610-00501 71230-02015 71230-03300 71210-02104 07003-00281 71231-02003 07003-00273 71230-02041 07003-00194 07003-00341 07003-00342 71210-02022 07003-00278 71210-02029 07003-00311 07640-00239 71210-02051 07640-00244 71210-02034 07340-00335 71210-02035 71210-02028 07003-00374 71230-02019 07003-00288 71221-02013 07003-00287 71230-03800 71230-03205 71210-02014 71255-02027 71211-02001 07003-00280 71211-02002 07003-00274 71255-03200 71210-03600 71211-02008 07005-00088 71210-02008
CHUCK COLLET ADAPTOR LOCKNUT HEAD ASSEMBLY SEAL HOUSING 'O' RING HEAD PISTON LIP SEAL SCREW BONDED SEAL LIP SEAL 'O' RING SUSPENSION RING 'O' RING SEAL 'O' RING STEM COLLECTOR OUTER # STEM COLLECTOR BODY # SILENCER # SILENCER CAP # STEM COLLECTOR END CAP # SILENCER # RETAINING NUT LIP SEAL SEAL RETAINER 'O' RING HANDLE ASSEMBLY 'O' RING INTENSIFIER SEAL ASSEMBLY GUIDE RING CLAMP NUT LABEL BODY 'O' RING BASE COVER LIP SEAL PNEUMATIC PISTON ASSEMBLY (INCLUDES 41/35/39) TRANSFER TUBE ASSEMBLY CYLINDER LINER TRIGGER VALVE TRIGGER
1 1 1 1 3 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1
-
1
- -
3
-
1 1 2 1 2 1 1 1 1
- -
1
- -
1
- - - -
2 1 1
- -
1
-
1
-
1
- - - - -
48 49 50 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 69 70 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
71210-02024 07003-00310 07003-00204 07003-00127 07005-01274 71210-03400 07003-00268 71210-03402 71210-03401 07003-00042 07003-00271 71210-03700 07008-00010 71210-02031 71221-02003 71210-02009 71210-02013 07003-00189 07003-00333 07007-00224 07490-03002 71403-02110 71231-02001 71211-02004 71221-02006 07002-00108 71221-02005 07003-00027 71221-02003 71210-02055 07007-01993 71221-20104 07002-00098 71221-20105 71221-20101 71221-20102 71221-20103 07007-01503
TRIGGER PIN 'O' RING 'O' RING 'O' RING 1/8" BSP PLUG VALVE SPOOL ASSEMBLY (55 to 58) • 'O' RING • VALVE SPOOL • VALVE BODY • 'O' RING 'O' RING ON/OFF VALVE ASSEMBLY 6" FLEXIBLE HOSE SILENCER TOP PLATE VALVE SEAT ROTARY VALVE 'O' RING LIP SEAL SPIROL PINS SPRING BOTTLE ADAPTOR ASSEMBLY END CAP ASSEMBLY TIE ROD SEALING WASHER M6 NYLOK NUT BASE PLATE 'O' RING TOP PLATE RUBBER BOOT CENTRE POLE MAGNET M5 X 19 COUNTERSUNK SCREW M5 NYLOK NUT COUNTER COUNTER MOULDING SPECIAL M4 SCREW MOULD RETAINING NUT LABEL BOOK SYMBOL
1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 2 1 1 1 2 2 2 1 2 1 1 1 1 1 1 1 2 2 1
-
2 1
- - -
2
- -
2 1
- -
2
-
1
–
2
-
1
- - - - - - - - - - - - - - - - - - -
ITEM PART Nº DESCRIPTION ITEM PART Nº DESCRIPTION
71255-02000 PARTS LIST *These are minimum recommended levels of spares based on regular servicing
QTY SPARES QTY SPARES
# These items are also available as a complete kit. Part Number 71210-20400.

18
Priming
Oil Details
Hyspin®VG 32 Oil Safety Data
Priming Kit
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 3mm ALLEN KEY
07900-00698 STOP NUT
07900-00700 PRIMING PUMP
07900-00224 4mm ALLEN KEY
07900-00734 MAXLOK®STOP NUT
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full stroke
after considerable use, when the stroke may be reduced and fasteners are not fully placed by one operation of the trigger.
The recommended oil for priming is Hyspin®VG32 available in 0.5l (part number 07992-00002) or one gallon containers (part number
07992-00006). Please see safety data below.
First Aid
SKIN:
Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact
requires no immediate attention.
INGESTION:
Seek medical attention immediately. DO NOT induce vomiting.
EYES:
Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact.
Fire
Flash point 232°C. Not classified as flammable.
Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets.
Environment
WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation.
SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material.
Handling
Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.
Storage
No special precautions.

19
IMPORTANT
DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 55.
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.
•Remove bleed Screw 9and Bonded Seal 10.
•Connect air supply to tool and switch ON/OFF Valve Assembly 60 to "ON” position.
•Invert tool over suitable container and actuate trigger. Waste oil will be ejected through the bleed screw hole.
CARE SHALL BE TAKEN TO ENSURE THAT THE BLEED HOLE IS NOT DIRECTED TOWARDS THE OPERATOR OR OTHER
PERSONNEL.
•Screw stop nut 07900-00734 onto Chuck Collet Adaptor 1.
•Disconnect air supply to tool or switch ON/OFF Valve Assembly 60 to ‘OFF” position.
•Fill the priming pump with oil.
•Screw priming pump 07900-00700 into the bleed screw hole with Bonded Seal 10 in place.
•Actuate the priming pump by pressing down and releasing several times until resistance is felt.
•Remove the priming pump and the stop nut.
•Replace bleed Screw 9and Bonded Seal 10.
•Connect air supply to tool and switch ON/OFF Valve Assembly 60 to ‘ON” position.
•Check that the stroke of the tool meets the minimum specification of 13 millimetres. To check the stroke, measure the distance
between the front face of Chuck Collet Adaptor 1and the front face of the head, BEFORE pressing the trigger and when the
trigger is fully actuated. The stroke is the difference between the two measurements. If it does not meet the minimum
specification, repeat the priming procedure.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.
Priming
Priming Procedure

20
Fault Diagnosis
Symptom Possible Cause Remedy Page Ref
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 16-17.
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 18-19
Build up of dirt inside the nose assembly Service 9
Tool will not grip Worn or broken jaws Fit new jaws 9
stem of fastener Build up of dirt inside the nose assembly Service 9
Loose jaw housing or chuck collet Tighten against locking ring 9
Weak or broken spring in nose assembly Fit new spring 9
Incorrect component in nose assembly Identify and replace 9
Jaws will not release Build up of dirt inside the nose assembly Service 12
broken stem of chuck collet.
fastener Tighten nose assembly 9
Weak or broken spring in nose assembly Fit new spring 8-9
Air or oil leak Tighten joints or replace components
Low oil level or air present in oil Prime tool 18-19
Cannot feed next Broken stems jammed inside tool Empty stem collector 4 (point 14)
fastener Check correct equipment is fitted 8-9
Adjust air pressure to within specification 5
Slow cycle Low air pressure Adjust air pressure to within the specification 5
Build up of dirt inside the nose assembly Service 12
Tool fails to operate No air pressure Connect and adjust to within the specification 5
Damaged Trigger Valve 46 Replace 15
Loose stem collector Tighten Retaining Nut 26 15
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 18-19
Tool fails to swage Insufficient air pressure Adjust air pressure to within specification 5
collar Worn or damaged anvil Replace 8-9
Low oil level or air present in oil Prime tool 18-19
Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.