Avdel Genesis nG3 User manual

Genesis®
G3
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 7
Nose Assemblies
Fitting Instructions 8
Servicing Instructions 8
Nose Tips 9 - 12
Type 1 Standard 9
Type 2 Limited Access 10
Type 4 Monobolt® - Extended 11
Type 5 Avtainer®11
Type 6 Monobolt® - Interlock® - Stavex®11
Accessories
Stem Deflector 12
Preparing the Base Tool for use with Stem Deflector 12
Extension 12
Swivel Heads 13
Straight Swivel Head capability 13
Preparing the Base Tool for Right-Angle and Straight 14
Swivel Head Attachment
Right-Angle Swivel Head capability 14
Swivel Head Fitting Instructions 15
Swivel Head Servicing Instructions 16
Constant Components 16
Servicing the Tool
Daily / Weekly 18
Moly Lithium Grease EP 3753 Safety Data 18
Molykote®55m Grease Safety Data 19
Molykote®111 Grease Safety Data 19
Service Kit 20
Maintenance 20
Nose Equipment 20
Dismantling the Tool 21
Head Assembly 21
Pneumatic Piston Assembly 22
Air Valve 22
Rotary Valve 23
Trigger 23
Base Tool
General Assembly of Base Tool - 71223-0200 24
Parts List for 71223-02000 25
Priming
Oil Details 26
Hyspin®VG32 Oil Safety Data 26
Priming Kit - 07900-00688 26
Priming Procedure 27
Fault Diagnosis
Symptom, Possible Cause and Remedy 28
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 (72.5 - 101.5 psi)
Free Air Volume Required @ 5.5 bar 4.3 litres (0.15 cuft)
Stroke Minimum 26 mm (1.02 in)
Pull Force @ 5.5 bar 12.9 kN (2900 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 (8.2 ft/s2 )
22.9
12°30'
140
128
156
150
320
145
116
70
3
n
61
Dimensions in millimetres
Tool Dimensions

6
Intent of Use
nG3 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 8.
FASTENER
NAME
MM
IN
FASTENER SIZE ( )
AVEX
®
STAVEX
®
AVINOX
®
II
AVIBULB
®
ETR
BULBEX
®
T- LOK
®
AVDEL
®
SR
MONOBOLT
®
INTERLOCK
®
AVTAINER
®
*AVSEAL
®
II
Q RIVET
T RIVET
AVDELMATE
®
KLAMP-TITE
®
KLAMPTITE KTR
®
3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10
–1/8 5/32 – 3/16 –––1/4 ––––3/8 –
COMPLETE TOOL
71224-00 . . . *
BASE TOOL
NOSE ASSEMBLY
NOSE TIP
71224-02000
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 9-12.
FOR TOOLS WITH SWIVEL
HEADS USE TABLES ON
PAGES 14-15.
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 24 and 25. If a swivel head is fitted, the same base tool must be adapted. See details pages 14-15.
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 pages 11 and 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,
for special fasteners. See table page 11. A nose assembly can be substituted by a swivel head (see pages
14 and 15). In this case the nose tip is part of the swivel head.
Range of Fasteners
Part Numbering
*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 1/4
inch.
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
Lift Trigger to
cut-off the
vacuum air
supply.

8
Nose Assemblies
* Item included in the nG3 Service Kit. For complete list see page 20.
Fitting Instructions
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A complete tool must always be fitted with the correct nose assembly and nose tip for your fastener and must be ordered separately,
refer to the ‘NOSE TIPS’ tables on pages 9 to 12.
If your application presents no access restriction use a Type ‘1’ Nose Tip. If you are placing Avtainer®fasteners a Type 5 Nose Tip
must be used.
Dimensions ‘A’ and ‘B’ in the following Nose Tip tables will help you assess the suitability of a particular nose tip.
You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted Type
‘2’ Nose Tips are available for some fasteners. Refer to the table on page 11.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool.
The Type 4 Nose Tip is an alternative to place 1/4in Monobolt®. Refer to the table on page 12.
Swivel heads are available as an alternative to nose assemblies as well as an extension when further reach is required.
See pages 13 to 17 in the ‘Accessories’ section.
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.
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 3 or Chuck Collet 9 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 3or Chuck Collet 9and screw onto the tool, tightening with spanner*.
Servicing Instructions

Nose Tips
Nose Assemblies
9
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
TYPE 1
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15000
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Steel
Al Alloy
Al Alloy
Any
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
Any
Any
Steel
Steel
Steel
Steel
Steel
Stainless Steel
Stainless Steel
Stainless Steel
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
Al Alloy
Al Alloy
Al Alloy/Steel
Al Alloy/Steel
Al Alloy
Al Alloy
Al Alloy/Steel
Al Alloy/Steel
1/8
1/8
1/8
–
5/32
5/32
5/32
3/16
3/16
3/16
3/16
1/4
3/16
5/32
3/16
1/8
5/32
3/16
–
3/16
1/8
5/32
3/16
–
1/8
5/32
3/16
3/16
1/4
3/16
1/8
5/32
3/16
3/16
3/16
1/8
5/32
3/16
1/8
5/32
3/16
1/4
3/16
1/4
3/16
1/4
3/16
1/4
3/16
3/16
3/16
3/16
1/4
1/4
1/4
1/4
4.8
3.3
2.9
4.8
3.3
2.8
3.3
2.8
3.3
3.3
4.1
3.3
4.1
3.3
2.8
3.3
2.8
4.8
3.3
3.3
3.3
2.8
4.8
3.3
4.8
3.3
5.7
5.7
3.3
2.8
3.3
2.8
2.8
3.3
2.8
3.3
2.8
2.8
4.8
3.3
3.3
3.3
3.3
3.3
4.8
4.8
2.8
3.3
6.35
6.35
6.35
6.35
6.65
6.65
6.65
6.65
12.7
12.7
12.7
12.7
12.7
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
12.7
12.7
12.7
12.7
12.7
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
12.7
12.7
12.7
12.7
12.7
12.7
71210-05002
71210-16070
07340-064012
71210-05002
71210-16070
07381-04701
07340-065012
07381-04701
07340-04800
07490-04401
07340-066012
07612-02001
71210-16020
71210-16070
07381-04701
71210-16070
07381-04701
07498-01401
07340-06201
07340-06201
71210-16070
07381-04701
07498-01401
07612-02001
71210-05002
71210-16070
07348-07001
71210-16050
71220-60001
07381-04701
71210-16070
07381-04701
07381-04701
07340-04800
07381-04701
71210-16070
07381-04701
07381-04701
71210-05002
07340-06201
07340-06201
07612-02001
07340-06201
07612-02001
71220-16060
71220-16061
07381-04701
07612-02001
703-A-25-6TA
703-B-21
703-A-25-6T
703-B-26
743-A-25-8TA
703-B-21
743-A-25-8T
743-B-26
3.2
3.2
3.2
3.0
4.0
4.0
4.0
4.8
4.8
4.8
4.8
6.4
4.8
4.0
4.8
3.2
4.0
4.8
4.3
4.8
3.2
4.0
4.8
6
3.2
4.0
4.8
4.8
6.4
4.8
3.2
4.0
4.8
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.8
6.4
4.8
6.4
4.8
6.4
4.8
6.4
4.8
4.8
4.8
4.8
6.4
6.4
6.4
6.4
AVEX
®
Large flange
MONOBOLT
®
BULBEX
®
AVINOX
®
II
T-LOK
®
AVIBULB
®
AVDEL
®
SR
Countersunk
INTERLOCK
®
STAVEX
®
Large flange
Countersunk
Q RIVET
AVDELMATE
®
KLAMPTITE
KTR
®
KLAM-PTITE
®
T RIVET
Large flange
Large flange
Large flange
Large flange
…001
…004
…003
…001
…004
…010
…009
…010
…016
…017
…015
…021
…200
…004
…010
…004
…010
…082
…120
…120
…004
…010
…082
…021
…001
…004
…062
…064
…063
…010
…004
…010
…010
…016
…010
…004
…010
…010
…001
…120
…120
…021
…120
…021
…430
…435
…010
…021
…380
…381
…383
…384
…385
…386
…387
…388
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
* In ADDITION to the nose assembly shown below,
an extra long nose assembly is available to place
1/4" Monobolt
®
in applications with restricted
access. See type 4 NOSE TIP table.
COMPLETE TOOL
PART NUMBER :
precede with
71224-00
8 7 6 5 4 23 1 61
22.9

10
Nose Assemblies
1
In inches then in millimetres.
COMPLETE TOOL
PART NUMBER :
precede with
71224-00
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 42314 15 158.3
22.9
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Aluminium Alloy
Steel
Aluminium Alloy
Steel
Aluminium Alloy
Steel
Aluminium Alloy
Aluminium Alloy
Steel
Steel
Steel
Steel
Steel
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel/Brass
1/8
1/8
5/32
5/32
3/16
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
11.4
10.0
10.0
11.8
11.4
10.0
10.0
10.0
11.4
10.0
10.0
11.4
10.0
10.0
11.4
10.0
10.0
9.5
9.5
9.5
12.7
12.7
12.7
9.5
12.7
12.7
12.7
9.5
12.7
12.7
9.5
12.7
12.7
9.5
12.7
12.7
07340-02805
07340-02806
07340-02806
07340-02807
07340-02807
07340-07301
07340-02806
07340-02807
07241-07101
07241-07101
07340-02806
07340-02807
07340-02807
07340-02806
07340-02807
07340-02807
07340-02806
07340-02807
07340-02807
3.2
3.2
4.0
4.0
4.8
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
…008
…014
…014
…018
…008
…014
…121
…121
…008
…014
…014
…008
…014
…014
…008
…014
…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
14 JAW SPREADER HOUSING 71210-02101
15 'O' RING 07003-00277
Note: Items 14 and 15 are not required when assembling a Type 2 Nose Tip to the Base Tool nG3 (71224-02000).
Nose Tips

11
Nose Assemblies
Nose Tips
NOSE ASSEMBLY
part nº 71230-15800
A
B
8 7 6 5 4 23 1 61
22.9
... 201
... 261
... 261
1 In inches then in millimetres
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
above
PART Nº 'A' 'B'NAME
1/4
1/4
1/4
MONOBOLT
®
INTERLOCK
®
STAVEX
®
TYPE 6
NOSE TIPS
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
Any
Any
Any
4.1
3.6
3.6
14.3
14.3
14.3
71220-16021
07612-02001
07612-02001
6.4
6.4
6.4
COMPLETE TOOL
PART NUMBER
PRECEDED WITH:
71224-00
TYPE 4
NOSE TIP
COMPLETE TOOL
PART NUMBER :
precede with
71224-00
1
1
In inches then in millimetres
NOSE ASSEMBLY part nº 71220-15400
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07498-00501
2 'O' RING 07003-00067
9 CHUCK COLLET 07498-00502
4 JAWS 07497-03002
ITEM DESCRIPTION PART Nº
10 FRONT SPRING GUIDE 07498-00507
7 SPRING 07500-02005
11 REAR SPRING GUIDE 07498-00503
8 LOCKING RING 07340-00327
FITTED TO THIS LONG NOSE
ASSEMBLY, THE TYPE 4 NOSE TIP
WILL ALLOW THE PLACING OF
1/4 " MONOBOLT
®
FASTENERS
IN APPLICATIONS REQUIRING
VERY DEEP ACCESS.
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Any
1/4
4.114.3
71220-16021
6.4
MONOBOLT
®
…202
11 7 10 4298
A
B
20.6
98.5
13
TYPE 5
NOSE TIP
COMPLETE TOOL
PART NUMBER :
precede with
71224-00
1
1
In inches then in millimetres
NOSE ASSEMBLY part nº 71220-15500
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07498-00501
2 'O' RING 07003-00067
9 CHUCK COLLET 07498-00801
4 JAWS 07220-02302
10 FRONT SPRING GUIDE 07498-00803
ITEM DESCRIPTION PART Nº
7 SPRING 07500-02005
11 REAR SPRING GUIDE 07498-00503
8 LOCKING RING 07340-00327
12 SIDE EJECTION ADAPTOR 07498-00900
THERE IS ONLY ONE TYPE 5 NOSE
TIP, SPECIFICALLY DESIGNED TO
PLACE AVTAINER
®
FASTENERS WITH
THIS SPECIAL NOSE ASSEMBLY.
FASTENER
MATERIAL
Ø1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Steel
3/8
4.119.1
07498-00802
9.6
AVTAINER
®
…243
98.5
20.6
90 12 11 7 10 4298
A
B
28.6
13 71233-20200
VAC SHUT-OFF STOP NUT ASSY

12
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
07340-00342
SEALED NUT
71213-02200
STEM DEFLECTOR
Stem Deflector
Accessories
•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.
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 24 and 25.
INNER
71210-20301
OUTER
71210-20302
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 Jaw Spreader Housing 41.
•Screw the outer onto Head Assembly 58.
•Fit the nose assembly onto the extension.
•Loosen Locknut 40 using
16mm AF 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 to disable Vacuum
System.
•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 airline must be disconnecte before any servicing or dismantling.
‘Sealed’ Nut 71213-02200 replaces Locknut 40 (to cut-off air supply to Vacuum System) as follows:
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:

13
Swivel Heads
Accessories
Instead of a nose assembly, a swivel head can be fitted to a base tool. It allows 360° rotation of the tool about the nose tip and
allows access into many applications otherwise too restrictive. There are two types of swivel heads: the straight swivel head with the
nose tip slightly offset from the centre line of the tool head and the right-angle swivel head with the nose tip on a perpendicular axis to
the head of the tool. See drawings below for dimensions and pages 16 and 17 for detail.
IMPORTANT
PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the base tool opposite.
In contrast to nose assemblies part numbers of swivel heads do INCLUDE a nose tip as shown below.
Swivel heads are supplied separately for fitting to a base tool forming a complete tool. See table below for part numbers. Jaws and
nose tips vary depending on the fastener to be placed but all other components remain the same within each type of swivel head. See
the ‘capability’ tables below and page 15. For the ‘Constant Components’ table see page 17.
'A’ and ‘B’ dimensions will help you assess the accessibility of your application.
1
In inches then in millimetres.
2
Long nose tip for deep placing. O Oversize
FASTENER
MATERIAL
Ø1
NOSE TIP (mm)SWIVEL HEAD
PART Nº
JAWS see
below
'A' 'B'NAME
Al Alloy
Steel
Al Alloy
Steel
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Steel
Steel
Stainless Steel
Stainless Steel
1/8
1/8
5/32
5/32
3/16
5/32
3/16
1/8
5/32
–
–
–
–
1/8
5/32
1/8
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
1.95
4.11
2.00
4.11
3.81
3.81
3.81
3.81
7.87
7.87
7.87
7.87
7.87
7.87
7.87
7.87
7.87
6.35
6.35
7.62
7.62
7.87
7.87
7.87
7.87
07345-03000
07345-03100
07345-03100
07345-03200
07345-03200
07345-03100
07345-03200
07345-03100
07345-03200
71213-06000
71213-06600
71213-06100
71213-06700
07345-03100
07345-03200
07345-03100
07345-03200
PART Nº
07340-00213
07340-00213
07340-00213
07490-04602
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07340-00213
07340-00213
07340-00213
07340-00213
07490-04602
07340-00213
07490-04602
PART Nº
07345-03600
07345-03700
07345-03700
07345-03800
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
71213-16401
71213-164022
71213-16403
71213-164042
07345-03700
07345-03800
07345-03700
07345-03800
3.2
3.2
4.0
4.0
4.8
4.0
4.8
3.2
4.0
4
4
5
5
3.2
4.0
3.2
4.0
AVEX®
BULBEX®
AVINOX® II
AVSEAL®II
STAVEX®
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010
COMPLETE TOOL PART NUMBER :
precede with 71224-30
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete tools
with nose assemblies, those fitted with swivel heads
include the nose tip as a part of the head.
STRAIGHT SWIVEL HEAD capability
A
B
360•rotation
56 92
6
20
5/32

14
FASTENER
MATERIAL
Ø1
NOSE TIP (mm)SWIVEL HEAD
PART Nº
JAWS see
below
'A' 'B'NAME
Aluminium Alloy
Steel
Aluminium Alloy
Steel
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Stainless Steel
Stainless Steel
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Steel
Steel
Stainless Steel
Stainless Steel
1/8
1/8
5/32
5/32
3/16
5/32
3/16
1/8
5/32
–
–
–
–
1/8
5/32
1/8
5/32
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
3.81
1.95
4.11
2.00
4.11
3.81
3.81
3.81
3.81
7.87
7.87
7.87
7.87
7.87
7.87
7.87
7.87
7.87
6.35
6.35
7.62
7.62
7.87
7.87
7.87
7.87
07346-03000
07346-03100
07346-03100
07346-03200
07346-03200
07346-03100
07346-03200
07346-03100
07346-03200
71213-04000
71213-04700
71213-04100
71213-04800
PART Nº
07340-00213
07340-00213
07340-00213
07490-04602
07490-04602
07340-00213
07490-04602
07340-00213
07490-04602
07340-00213
07340-00213
07340-00213
07340-00213
07340-00213
07490-04602
07340-00213
07490-04602
PART Nº
07345-03600
07345-03700
07345-03700
07345-03800
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
71213-16401
71213-164022
71213-16403
71213-164042
07345-03700
07345-03800
07345-03700
07345-03800
3.2
3.2
4.0
4.0
4.8
4.0
4.8
3.2
4.0
4
4
5
5
3.2
4.0
3.2
4.0
AVEX®
BULBEX®
AVINOX® II
AVSEAL®II
STAVEX®
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010
RIGHT-ANGLE SWIVEL HEAD capability
1 In inches then in millimetres. 2 Long nose tip for deep placing.
O
Oversize
COMPLETE TOOL PART NUMBER :
precede with 71224-40
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete tools
with nose assemblies, those fitted with swivel
heads include the nose tip as a part of the head.
7.6
32
20
52 56
74
97
A
B
360∞rotation
07346-03100
07346-03200
07346-03100
07346-03200
41 12 40 52
19
15
36
71213-20202
STOP NUT
71210-20201
SAFETY CAP
•Disconnect the air supply.
•Remove any nose assembly items.
•Remove Stem Collector Bottle Assembly
71210-20400.
•Replace Stem Collector Bottle Assembly with
Safety Cap 71210-20201.
•Unscrew Jaw Spreader Housing 41 and
remove with ‘O’ Ring 12, Locknut 40*, ‘O’
Rings 19* and 15*, and Seal Housing 52*.
Do not refit these items (*).
•Screw Stop Nut (71213-20200) onto the
front of Head Piston 36 as far as it will go by
hand.
•Fit Jaw Spreader Housing 41 and ‘O’ Ring 12,
tighten onto Head Piston 36, finally tighten
Stop Nut against Jaw Spreader Housing 41.
The tool is now ready to be fitted with a
swivel head, see page below.
Item numbers in bold refer to the General
Assembly drawing and Parts List on pages 24
and 25.
Base tool to receive a nose assembly
Base tool to receive a swivel head
Preparing the Base Tool for Right-Angle and Straight Swivel Head Attachment
Accessories

15
Accessories
The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.
IMPORTANT
PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the base tool opposite.
The air supply must be disconnected when fitting or removing swivel heads.
AFit Locking Ring 10 over Jaw Spreader Housing 41*
(71210-02101). *See pages 24 and 25.
BCoat Screw 13 with thread locking adhesive and use to
secure Nose Tip 14 onto Body 5.
CLightly lubricate items 17, 18, 19, 20 and insert into
Jaw Carrier 3 as shown. Secure with Screws 16.
DPosition Lever 4into Body 5and hold in place with pin
15 through the hole of Body 5(not a slot).
ELubricate the sides of the Jaw Carrier Assembly and
insert into Body 5.
FLubricate Rollers 8and ENSURE that they will freely
rotate in the holes of Adaptor 9. If necessary ream the
holes.
GPosition Spring Clip 7over Adaptor 9past the holes for
the rollers and rotate until the locating peg is aligned
with the corresponding hole in Adaptor 9(smallest
hole).
HFit Adaptor 9over the end of Body 5and drop Rollers 8
into place. Push Spring Clip 7over Rollers 8.
IInsert Spindle 11 through Adaptor 9into Jaw Carrier 3
until the hole lines up with slot in Body 5. Temporarily
hold in place with Pin 6.
JInsert Pin 12 through the front slot of Body 5into Jaw
Carrier 3.
KHold the assembly vertical to prevent all pins dropping
out and slide the jaw carrier assembly back and forth a
few times to ensure free movement. Go to M.
LRemove Screws 23 (4 off) and guard 1. On a straight
swivel head also remove Screw 21 and Platform 22.
MPush Pin(s) 6out and let Spindle 11 drop out. Screw
Spindle 11 onto the Jaw Spreader Housing of the tool,
leaving the small screw fixing hole uppermost for
straight swivel. Tighten gently with a tommy bar.
NScrew the assembly over Spindle 11 onto the tool
handle. Replace Pin(s) 6.
OOn straight swivel heads attach Platform 22 onto the
top of the Spindle with Screw 21. Deburr the back end
of Platform 22 so that it cannot catch on Guard 1.
PSnap Guard 1over the assembly, align screw holes in
guard with tapped holes in body assembly.
QInsert Pivot Pin 15 through slots in guard and hole in
body. Fit Circlip 2onto pivot pin so that the circlip seats
in groove provided.
RCoat the thread of Screws 23 (4 off) with thread locking
adhesive and screw into body assembly securing guard
to body assembly.
Swivel Head Fitting Instructions
The following procedure will allow you to assemble and fit either of the swivel heads to the tool. If you order a complete swivel head
rather than individual components, you will only need to start at stage ‘L’.
All moving parts should be lubricated. Unless stated otherwise use Moly Lithium grease (details page 18).
When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.
16
1
3
12
14
13
16
6
5
21
22 11
7
9
8
8
8
10
17 18
19 20
STRAIGHT SWIVEL HEAD
2
1
15
9
8
8
10
7
11
17
23 18 19 20
316
16
4
12
14
13
6
6
5
RIGHT-ANGLE HEAD

16
Swivel Head Servicing Instructions
Accessories
5
7
17 18
19 20
Swivel heads should be serviced at weekly intervals.
•Remove the complete head using the reverse procedure to
the ‘Fitting instructions’ omitting step ‘L’.
•If Guard 1is at all damaged it must be replaced by a new
one.
•Any worn or damaged parts should be replaced.
•Pay particular attention to jaw carrier items in the upper
illustration opposite as follows:
Check wear on Jaws 17.
Check that Jaw Spreader 18 tube is not distorted.
Check that Spring 19 is neither broken or distorted.
Check that Spring Guide 20 is not damaged.
•Check that Spring Clip 7is not distorted. When removing
Spring Clip 7, use two screwdrivers as shown in the lower
illustration opposite.
•Check for excessive wear on slots of Body 5.
•Assemble according to fitting instructions.
Item numbers in bold refer to Swivel Head illustrations on
this page. Guard 1refers to illustration on page 16.
While nose tips and jaws will vary for each swivel head, other components remain constant within each type of head. See table below
for nose tips and for jaws part numbers see within the tables on pages 9 to 12.
CONSTANT COMPONENTS
ITEM DESCRIPTION STRAIGHT SWIVEL RIGHT-ANGLE SWIVEL
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
18
19
20
21
22
23
GUARD
CIRCLIP
JAW CARRIER
LEVER
BODY
PIVOT PIN
SPRING CLIP
ROLLER
ADAPTOR
LOCKING RING
SPINDLE
DOWEL PIN
SCREW
PIVOT PIN
SCREW
JAW SPREADER
SPRING
SPRING GUIDE
SCREW
PLATFORM
SCREW
07494-05000
-
07494-03026
-
07494-03015
07343-02207
07495-03900
07007-00039
07345-03001
07345-03003
07345-03002
07007-00038
07342-02207
-
07494-03028
07346-03101
07165-00305
07494-03027
07001-00368
07345-00401
-
07495-03003
07004-00105
07494-03026
07495-03004
07495-03002
07343-02207
07495-03900
07007-00039
07345-03001
07345-03003
07345-03002
07007-00038
07342-02207
07343-02207
07494-03028
07346-03101
07165-00305
07494-03027
–
–
07210-00804

17
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 27 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 20.
First Aid
SKIN:
As the grease is completely water resistant it is best removed with an approved emulsifying skin cleaner.
INGESTION:
Ensure the individual drinks 30ml Milk of Magnesia, preferably in a cup of milk.
EYES:
Irritant but not harmful. Irrigate with water and seek medical attention.
Fire
FLASH POINT: Above 220°C.
Not classified as flammable.
Suitable extinguishing media: CO2, Halon or water spray if applied by an experienced operator.
Environment
Scrape up for 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 24 and 25.
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
18

19
Molykote®55m Grease Safety Data
First Aid
SKIN:
Flush with water. Wipe off.
INGESTION:
No first aid should be needed.
EYES:
Flush with water.
Fire
FLASH POINT: Above 101.1°C. (closed cup)
Explosive Properties: No
Suitable Extinguishing Media: Carbon Dioxide Foam, Dry Powder or fine water spray.
Water can be used to cool fire exposed containers.
Environment
Do not allow large quantities to enter drains or surface waters.
Methods for cleaning up: Scrape up and place in suitable container fitted with a lid. The spilled product produces an 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 28.
Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 9 to
12 or if a swivel head was fitted pages 14 and 15.
For a complete service of the tool, we advise that you proceed with dismantling of sub-assemblies in the order shown.
After any dismantling REMEMBER to prime the tool and to fit an appropriate nose assembly or swivel head.
(Annually or every 500,000 cycles whichever is the soonest)
Annually or every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, 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.
•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 9 to 12.
41* refers to illustration on page 24.
20