Avdel GenesisG2-s User manual

Instruction Manual
Instruktionshandbok
Genesis®G2-s
Hydro-Pneumatic Power Tool
Hydropneumatiskt verktyg

3
Contents
Safety Rules 4
Tool Specifications
Tool Dimensions 5
Intent of Use
Range of Fasteners 6
Part Numbering 6
Putting into Service
Air Supply 7
Operating Procedure 7
Adjusting the Vacuum Extraction 7
Nose Assemblies
Fitting & Servicing Instructions 8
Selection of Nose Tips 9&10
Accessories
Stem Deflector 11
Extension 11
Side Ejector 11
Stem Collector 11
Swivel Heads 12-15
Preparing the Base Tool 13
Fitting Instructions 14
Swivel Head Servicing Instructions 15
Servicing the Tool
Daily / Weekly 16
Moly Lithium Grease EP 3753 Safety Data 16
MolyKote 55m & MolyKote 111 Safety Data 17
Annually 18
Service Kit 18
Head Assembly 19
Trigger 19
Intensifier 19
General Assembly and Parts List
Pistol 22-23
Intensifier 24-25
Priming
Oil Details 24
Hyspin VG 32 Oil Safety Data 24
Priming Procedure 25
Fault Diagnosis
Symptom, Possible Cause & Remedy 26
Svenska 33
Avdel policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
Warranty
Avdel installation tools carry a 12 month warranty against defects caused by faulty
materials or workmanship, the warranty period commencing from the date of delivery
confirmed by invoice or delivery note.
The warranty applies to the user/purchaser when sold through an authorised outlet,
and only when used for the intended purpose. The warranty is invalidated if the
installation tool is not serviced, maintained and operated according to the instructions
contained in the Instruction and Service Manuals.
In the event of a defect or failure, and at its sole discretion, Avdel undertakes only to
repair or replace faulty components.
English

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.
3Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Avdel
or their representatives, shall be the customer’s entire responsibility. Avdel will be pleased to advise upon any proposed modification.
4The tool/machine must be maintained in a safe working condition at all times and examined at regular intervals for damage and
function by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel
procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel with
your training requirements.
5The tool/machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the U.K. the “Health and
Safety at Work etc. Act 1974” applies. Any question regarding the correct operation of the tool/machine and operator safety should
be directed to Avdel.
6The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
7Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8Do not operate a tool/machine that is directed towards any person(s).
9Always adopt a firm footing or a stable position before operating the tool/machine.
10 Ensure that vent holes do not become blocked or covered.
11 The operating pressure shall not exceed 7 bar.
12 Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise.
13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.
14 If the tool is fitted with a stem collector, it must be emptied when half full.
15 If the tool is fitted with a stem deflector, it should be rotated until the aperture is facing away from the operator and other person(s)
working in the vicinity.
16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against
fastener ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the
application.
17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be
kept dry and clean for best possible grip.
18 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
19 Excessive contact with hydraulic oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.

Tool Specifications
Specifications
5
Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 3.6 litres
Stroke Minimum 17 mm
Pull Force @ 5.5 bar 10.88 kN
Cycle time Approximately 1 second
Noise Level 75 dB(A)
Weight Without nose equipment or intensifier 0.88 kg
Vibration Less than 2.5 m/s2
Intensifier Ratio 44:1
Dimensions in millimetres
200
417
12°30'
145
116
70
30
2150
Tool Dimensions
English

6
Intent of Use
7
-
AVEX®
STAVEX®
AVINOX®
AVIBULB®
ETR
BULBEX®
T-LOK®
AVDEL®SR
MONOBOLT®
INTERLOCK®
TLR®
AVDEL®
MBC
MBC/LC
AVSEAL®
ll
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
ll
COMPLETE TOOL
71400-00 . . .
*
BASE TOOL
1
1
2
3
1
NOSE ASSEMBLY
NOSE TIP
2
71400-01000
71210-15000
see note 3
2
3
++=
3
G2-s is a hydro-pneumatic tool designed to place Avdel®
breakstem fasteners at high speed making it ideal for batch or
flow-line assembly in a wide variety of applications throughout all
industries. It can place all fasteners listed opposite.
The tool features an adjustable vacuum system for fastener
retention and trouble free collection of the spent stems
regardless of tool orientation.
See the ‘Operating Procedure’, page 7, for adjustment
instructions.
A complete tool, except the 71400-00039, is made up of three
separate elements which must be ordered individually.
See diagram below.
If you wish to place most of the fasteners in the table
opposite, you can order the 71400-00039 complete tool
comprising:
•71400-01000 base tool.
•71210-15000 nose assembly.
•Nose tips 71210-05002, 71210-16070 and 07381-
04701.
Two of the nose tips will be stored in the intensifier body.
Fit nose tips as indicated on pages 8-10.
FASTENER
NAME
FASTENER SIZE ( )
3
-
3.2
1/8
4.0
5/32
4.3
-
4.8
3/16
5
-
5.2
-
6
-
6.5
-
MM
IN
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. For details of the pistol, see
page 20. If a swivel head is fitted, the same base tool must be adapted. See details page 13.
This single nose assembly will allow placing of non-aerospace fasteners by simply selecting the appropriate
nose tip from the range of type 1 nose tips. Other nose assemblies are available for applications with
restricted access, for aerospace and special fasteners. See tables pages 8 and 10. A nose assembly can
be substituted by a swivel head (see pages 12-15). In this case the nose tip is part of the swivel head.
The nose tip part number relates to a specific fastener. If access to the application is
restricted, some extended nose tips are available. See page 10 for selection table.
* ADD 3 DIGITS FROM THE
LAST COLUMN OF A NOSE
TIP TABLE ON PAGE 8 OR 10.
FOR TOOLS WITH SWIVEL
HEADS USE TABLE PAGES
12-13.
l
You can order the above three nose tips and nose assembly as a nose assembly kit part number 71210-15100. For some
fasteners, the base tool, nose assembly and nose tip must be ordered separately.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON PAGE 9.

Air Supply
Putting into Service
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 working effective pressure rating of 150% of the maximum pressure produced in the system
or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where
operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres or 1/4
inch.
Read servicing daily details page 16.
•Before you use the tool, remove screw 57 on top of the oil reservoir of the intensifier to allow venting. Replace screw when transporting
the intensifier.
•Ensure that either a nose assembly or a swivel head suitable for the fastener is fitted (see pages 8-10 and 12-15).
•Connect the tool to the intensifier and the intensifier to the air supply.
•Insert the fastener stem into the nose of the tool. If using a nose assembly, the fastener should remain held in by the vacuum system. If
not, adjust the vacuum extraction rotary valve 46.
•If using a swivel head, the vacuum extraction is disabled but the jaws themselves will grip the fastener.
•Bring the tool with the fastener to the application so that the protruding fastener enters squarely the hole of the application.
•Fully actuate the trigger. The tool cycle will broach the fastener and with standard nose assemblies the broken stem will be projected to the
rear of the tool, when the trigger is released.
ADJUSTING THE VACUUM EXTRACTION
•Using a screwdriver, turn rotary valve 46 until the air flow at the rear of the tool ceases.
•With the nose of the tool pointing downwards, insert a fastener into the nose and hold it into position.
•Turn the rotary valve either way until there is sufficient suction to retain the fastener.
Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.
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
PRESSURE REGULATOR
AND FILTER
(DRAIN DAILY)
3 METRES MAXIMUM
Operating Procedure
English

Nose Assemblies
8
Fitting Instructions
IMPORTANT
The air supply must be disconnected when fitting or removing nose assemblies.
Item numbers in bold refer to nose assembly components in all 3 nose tip tables.
•Lightly coat jaws 4with Moly lithium grease*.
•Drop jaws 4into jaw housing 3.
•Insert jaw spreader 5into jaw housing 3.
•Locate buffer 6on jaw spreader 5.
•Locate spring 7onto jaw spreader 5.
•Fit locking ring 8onto the jaw spreader housing of the tool.
•Holding tool pointing down, screw the assembled jaw housing onto the jaw spreader housing and tighten with spanner.
•Screw the nose tip into nose casing 1and tighten with spanner*.
•Place nose casing 1over jaw housing 3and screw onto the tool, tightening with spanner*
Nose assemblies should be serviced at weekly intervals. You should hold some stock of all internal components of the nose assembly
and nose tips as they will need regular replacement.
•Remove the nose equipment using the reverse procedure to the ‘Fitting Instructions’.
•Any worn or damaged part should be replaced.
•Clean and check wear on jaws.
•Ensure that the jaw spreader is not distorted.
•Check spring 7is not distorted.
•Assemble according to fitting instructions above.
* Item included in the G2-s service kit. For complete list see page 18.
Item numbers in bold refer to the illustrations on pages 8 and 10.
Servicing Instructions

Nose Assemblies
9
A tool (except part number 71400-00039) must always be fitted with the correct nose assembly and nose tip for your fastener and
must be ordered separately, refer to the ‘NOSE TIPS’ tables below and page 10.
If your application presents no access restriction use a type ‘1’ nose tip unless you are placing aerospace fasteners which requires a
type ‘3’ nose tip.
Dimensions ‘A’ and ‘B’ below will help you assess the suitability of a particular nose tip.
You should also check that the dimensions of the nose casing will not restrict access to your application. If access is restricted type
‘2’ nose tips are available for some fasteners. Refer to the table on page 10.
It is essential that nose assembly and nose tip are compatible with the fastener prior to operating the tool. If you have ordered a
71400-00039 complete tool, it is important that you check that the nose tip already fitted to the nose assembly is the correct one to
place your fastener by sliding the fastener stem into the nose tip. No force should be required and play should be minimal. The two
alternative nose tips are screwed into the side of the intensifier.
Swivel heads are available as an alternative to nose assemblies when further reach is required. See pages 12-15 in the ‘Accessories’
section.
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
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
Domed Head.
5
Countersunk.
TYPE 1
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15000
(+ 3 nose tips above = 71210-15100)
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 71400-00039
does not only include the 71210-15000 nose
assembly below but also the following three
nose tips: 71210-05002, 71210-16070 and
07381-04701 making up a nose assembly kit
part number 71210-15100. Use the nose tip
listed in the table.
COMPLETE TOOL
PART NUMBER :
precede with 71400-00.
* See top left
8 7 6 5 4 23 1
61
22.9
FASTENER
MATERIAL
Ø
1
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
Any
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Stainless Steel
Stainless Steel
Stainless Steel
Steel
Steel
Steel
Steel
Steel
Any
Any
Any
Any
Any
Steel
Steel
Steel
Steel
Steel
Stainless Steel
Stainless Steel
Stainless Steel
Any
Any
Any
1/8
1/8
1/8
–
5/32
5/32
5/32
3/16
3/16
3/16
3/16
3/16
5/32
3/16
–
–
–
–
–
–
–
–
–
–
3/16
1/8
5/32
3/16
–
3/16
1/8
5/32
3/16
1/8
5/32
3/16
3/16
3/16
1/8
5/32
3/16
3/16
3/16
1/8
5/32
3/16
1/8
5/32
3/16
6.35
3.3
2.9
6.35
3.3
2.8
3.3
2.8
3.3
3.3
4.1
4.1
3.3
2.8
4.9
6.9
4.7
6.9
5.3
7.2
5.4
7.3
5.4
7.3
4.1
3.3
2.8
4.8
3.3
3.3
3.3
2.8
4.8
6.35
3.3
5.7
5.7
2.8
3.3
2.8
2.8
3.3
2.8
3.3
2.8
2.8
6.35
3.3
3.3
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
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
71210-05002
71210-16070
07340-06401
2
71210-05002
71210-16070
07381-04701
07340-06501
2
07381-04701
07340-04800
07490-04401
07340-06601
2
71210-16020
71210-16070
07381-04701
71210-16001
71210-16006
3
71210-16002
71210-16007
3
71210-16003
71210-16008
3
71210-16004
71210-16009
3
71210-16005
71210-16010
3
07605-00220
71210-16070
07381-04701
07498-01401
07340-06201
07340-06201
71210-16070
07381-04701
07498-01401
71210-05002
71210-16070
07348-07001
4
71210-16050
5
07381-04701
71210-16070
07381-04701
07381-04701
07340-04800
07381-04701
71210-16070
07381-04701
07381-04701
71210-05002
07340-06201
07340-06201
3.2
3.2
3.2
3
4.0
4.0
4.0
4.8
4.8
4.8
4.8
4.8
4.0
4.8
4
4
5
5
6
6
6.5
6.5
7
7
4.8
3.2
4.0
4.8
4.3
4.8
3.2
4.0
4.8
3.2
4.0
4.8
1.8
4.8
3.2
4.0
4.8
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.8
AVEX
®
Large flange
MONOBOLT
®
BULBEX
®
AVSEAL
®
TLR
®
AVINOX
®
II
T-LOK
®
AVIBULB
®
AVDEL®SR
INTERLOCK
®
STAVEX
®
Large flange
Countersunk
Q™RIVET
…039*
…039*
…003
…039
…039*
…039*
…009
…039
…016
…017
…015
…200
…039*
…039*
…160
…180
…161
…181
…162
…182
…163
…183
…164
…184
…140
…039*
…039*
…082
…120
…120
…039*
…039*
…082
…039*
…039*
…062
…064
…039
…039
…039
…039
…016
…039
…039
…039
…039
…039
…120
…120
English

10
Nose Assemblies
1
In inches then in millimetres.
FASTENER
MATERIAL
Ø
1
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
COMPLETE TOOL
PART NUMBER :
precede with
71400-00
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 4231
58.3
22.9
TYPE 3
NOSE TIPS
COMPLETE TOOL
PART NUMBER :
precede with
71400-00
1
56.3
22.9
1
In inches then in millimetres. O Oversize
NOSE ASSEMBLY
part nº 71210-15300
ITEM DESCRIPTION PART Nº
1 NOSE CASING 07344-02001
2 'O' RING 07003-00067
3 JAW HOUSING 07340-00304
4 JAWS 71210-15001
5 JAW SPREADER 07498-04502
6 BUFFER 71210-05001
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE
FASTENERS LISTED BELOW.
FASTENER
MATERIAL
Ø
1
NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME
Aluminium Alloy
Aluminium Alloy
O
Stainless Steel
Aluminium Alloy
Aluminium Alloy
O
Stainless Steel
Aluminium Alloy
Aluminium Alloy
O
Any
Any
Aluminium Alloy
Any
Any
Aluminium Alloy
1/8
1/8
1/8
5/32
5/32
5/32
3/16
3/16
1/8
5/32
3/16
1/8
5/32
3/16
2.5
2.5
3.3
2.5
2.5
3.3
2.5
2.5
4.8
5.0
5.1
4.6
4.6
4.6
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
71210-16030
71210-16031
71210-16032
71210-16033
71210-16034
71210-16035
71210-16036
71210-16037
07340-06701
07340-06801
07340-06901
07344-04701
07344-04701
07344-04701
3.2
3.2
3.2
4.0
4.0
4.0
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.8
AVDEL
®
MBC
MBC L/C
…283
…284
…285
…288
…289
…290
…293
…294
…300
…305
…310
…320
…320
…320
A
B
8 7 6 5 423

Stem Deflector
Accessories
11
Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.
Fitted between the tool and the nose assembly, the side ejector
forces fastener stems to eject at the front of the tool and
reaches into deep channels.
It cannot be used in conjunction to a swivel head. Select the
correct part number (below right) according to the stem diame-
ter of the fastener.
For greater ease of use, it is recommended that the stem
collector or deflector is replaced with safety cap part number
71210-20201 as used with swivel heads. See page 13 for fitting
instructions, but note that the stop nut is not fitted in this case.
•To fit the side ejector, remove any nose assembly compo-
nents.
•Remove the socket cap screw from the side ejector.
•Screw the inner extension onto jaw spreader housing 1.
•Screw the outer casing onto head assembly 4.
•Replace the socket cap screw securing with Loctite
Screwlock 222, part number 07900-00371.
•Screw the nose assembly onto the side ejector.
The stem deflector is a very simple alternative to the standard
stem collector and allows access in restricted areas. To replace
the stem collector with the stem deflector proceed as follows:
•Unscrew retaining nut 26 by inserting a 3 millimetre diameter
rod into one of the holes.
•Remove retaining nut 26 and the stem collector assembly,
items 18, 20, 21, 22, 23, 24, and 25.
•Screw the adaptor nut onto end cap 27.
•Push the boss end of the stem deflector into the internal
groove of the adaptor nut.
•Rotate the stem deflector until the aperture faces away from
the operator and other person(s) in the vicinity.
Fitted between the tool and the nose assembly the extension
allows access into deep channels.
•To fit the extension, remove any nose assembly components.
•Screw the inner extension to jaw spreader housing 1.
•Screw the outer onto head assembly 4.
•Fit the nose assembly onto the extension.
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
07340-00342
INNER
71210-20301
OUTER
71210-20302
STEM DEFLECTOR: 71210-20100
EXTENSION: 71210-20300
INNER
EXTENSION
OUTER CASING
8-32 x
1
/ 4 " SOCKET
CAP HEAD SCREW
Part number: 07498-00900
for fasteners with a stem larger than 3.1 mm (1/8") Ø
Extension
Side Ejector
English

Swivel Heads
Accessories
12
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 and page 13 for dimensions and page 14 for details.
FASTENER
MATERIAL
Ø
1
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
Aluminium Alloy
Aluminium Alloy
O
Stainless Steel
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
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
1/8
1/8
1/8
5/32
5/32
3/16
3/16
1/8
5/32
3/16
1/8
5/32
5/32
3/16
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
1.17
1.17
3.81
0.84
0.84
0.25
0.25
1.9
2.36
2.46
2.03
2.03
2.03
2.03
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
5.08
5.08
5.08
6.6
6.6
8.13
8.13
4.75
6.35
7.92
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
07494-06000
07494-06600
07494-06100
07494-06700
07345-03100
07345-03200
07345-03100
07345-03200
07345-03300
07494-03600
07494-03000
07345-03400
07494-03700
07345-03500
07494-03800
07345-04000
07345-04100
07345-04200
07345-04700
07345-04700
07345-04800
07345-04800
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
07340-04602
07340-00213
07340-04602
07340-00229
07340-00229
07340-00213
07340-00229
07340-00229
07498-04401
07498-04401
07340-00229
07340-00229
07498-04401
07340-00229
07340-00229
07498-04401
07498-04401
PART Nº
07345-03600
07345-03700
07345-03700
07345-03800
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
07494-06001
07494-06601
2
07494-06101
07494-06701
2
07345-03700
07345-03800
07345-03700
07345-03800
07345-03301
07494-03601
07494-03011
07345-03401
07494-03701
07345-03501
07494-03801
07165-00701
07165-00702
07165-00703
07345-04701
07345-04701
07345-04701
07345-04701
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
3.2
3.2
3.2
4.0
4.0
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.0
4.8
AVEX
®
BULBEX
®
AVINOX
®
AVSEAL
®
STAVEX
®
AVDEL
®
MBC
MBC L/C
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010
…283
…284
…285
…288
…289
…293
…294
…300
…305
…310
…320
…320
…327
…327
STRAIGHT SWIVEL HEAD capability
1
In inches then in millimetres.
2
Long nose tip for deep placing. O Oversize
COMPLETE TOOL PART NUMBER :
precede with 71400-30
(the stop nut and safety cap are included)
IMPORTANT: by opposition to complete tools
with nose assemblies, those fitted with swivel
heads include the nose tip as a part of the head.
A
B
360°rotation
56 92
6
20
IMPORTANT
PRIOR to fitting a swivel head, the base tool must be adapted. See Preparing the base tool page 13.
In contrast to nose assemblies part numbers of swivel heads do INCLUDE a nose tip as shown below.
Swivel heads can be ordered on their own or supplied with a base 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 13, ‘constant component table’ page 15.
'A’ and ‘B’ dimensions will help you assess the accessibility of your application.

Preparing the base tool
Accessories
13
•Disconnect the air supply.
•Remove any nose assembly items.
•Remove retaining nut 26 and all elements
of the stem collector (items 18,20,21,
22,23,24,25. Note that ‘O’ ring 19
remains.
•Replace the above with a safety cap as
shown in drawing opposite.
•Unscrew jaw spreader housing 1and
remove with ‘O’ ring 2, locknut 3, seal
housing 6.
•Screw stop nut 71210-20202 onto the
front of head piston 8as far as it will go
by hand.
•Re-fit jaw spreader housing 1and ‘O’ ring
2.
•Unscrew the stop nut until it locks against
jaw spreader housing 1and tighten with
spanner.
The tool is now ready to be fitted with a swivel
head. Instructions are on page 14.
1
2
3
6
8
19
1818
21 2020
22
24
23
25
26 27
71210-20202
STOP NUT
71210-20201
SAFETY CAP
Base tool to receive a nose assembly
Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.
Base tool to receive a swivel head
FASTENER MATERIAL
Ø
1
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
Aluminium Alloy
Aluminium Alloy
O
Stainless Steel
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
Aluminium Alloy
O
Aluminium Alloy
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
1/8
1/8
1/8
5/32
5/32
3/16
3/16
1/8
5/32
3/16
1/8
5/32
5/32
3/16
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
1.17
1.17
3.81
0.84
0.84
0.25
0.25
1.9
2.36
2.46
2.03
2.03
2.03
2.03
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
5.08
5.08
5.08
6.6
6.6
8.13
8.13
4.75
6.35
7.92
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
07495-04000
07495-04700
07495-04100
07495-04800
07346-03300
07495-03600
07495-03000
07346-03400
07495-03700
07346-03500
07495-03800
07346-04000
07346-04100
07346-04200
07346-04500
07346-04500
07346-04600
07346-04600
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
07340-00229
07340-00229
07340-00213
07340-00229
07340-00229
07498-04401
07498-04401
07340-00229
07340-00229
07498-04401
07340-00229
07340-00229
07498-04401
07498-04401
PART Nº
07345-03600
07345-03700
07345-03700
07345-03800
07345-03800
07345-03700
07345-03800
07345-03700
07345-03800
07494-06001
07494-06601
2
07494-06101
07494-06701
2
07345-03700
07345-03800
07345-03700
07345-03800
07345-03301
07494-03601
07494-03011
07345-03401
07494-03701
07345-03501
07494-03801
07165-00701
07165-00702
07165-00703
07345-04701
07345-04701
07345-04701
07345-04701
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
3.2
3.2
3.2
4.0
4.0
4.8
4.8
3.2
4.0
4.8
3.2
4.0
4.0
4.8
AVEX
®
BULBEX
®
AVINOX
®
AVSEAL
®
STAVEX
®
AVDEL
®
MBC
MBC L/C
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…004
…010
…004
…010
…283
…284
…285
…288
…289
…293
…294
…300
…305
…310
…320
…320
…327
…327
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 71400-40
(the stop nut and safety cap are included)
IMPORTANT: by opposition 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
English

Fitting Instructions
Accessories
14
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 16).
When on grey tint, instructions refer only to the right-angle swivel head. Item numbers in bold refer to illustrations below.
IMPORTANT
PRIOR to fitting a swivel head, the base tool must be adapted. See previous page.
The air supply must be disconnected when fitting or removing swivel heads.
The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.
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
1
3
12
14
13
16
6
5
21
22 11 7
9
8
8
8
10
17 18
19 20
STRAIGHT SWIVEL HEAD
Item numbers in bold refer to illustrations on this page.
AFit locking ring 10 over jaw spreader housing 1.
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 8into
place. Push spring clip 7over rollers 8.
IInsert spindle 11 through adaptor 9into jaw carrier 3until
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 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 Servicing Instructions
Accessories
15
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 il-
lustration opposite as follows:
Check wear on jaws 17.
Check that jaw spreader tube 18 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.
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 jaws part numbers see pages 12-13.
CONSTANT COMPONENTS
ITEM 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
SECURING SCREW (4 off)
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
07346-03102
07494-03028
07346-03101
07165-00305
07494-03027
–
–
07210-00804
Item numbers in bold refer to illustrations on this page.
English

Daily
Weekly
Moly Lithium Grease EP 3753 Safety Data
Servicing the Tool
16
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, 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 is fitted.
•Ensure that rotary valve 46 is correctly adjusted for fastener retention (see ‘Operating Procedure’ page 7).
•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.
•Top up the reservoir of the intensifier with hydraulic oil.
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 drawings and parts lists pages 22-25.

Molykote 111 Grease Safety Data
Molykote 55M Grease Safety Data
Servicing the Tool
17
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.
English

Annually
Servicing the Tool
18
PART N0 -DESCRIPTION PART N0 -DESCRIPTION
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.
(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.
SERVICE KIT : 07900-00716 Spanners are specified in inches and across flats unless otherwise stated.
7/16” x 1/2” SPANNER
9/16” x 5/8” SPANNER
5/8” x 11/16” SPANNER
CIRCLIP PLIERS
2.5 MM ALLEN KEY
PISTON SLEEVE
PISTON BULLET
SPANNER ASSEMBLY
EXTRACTOR
GUIDE TUBE
INSERTION ROD
TRIGGER VALVE EXTRACTOR
2MM PIN PUNCH
GREASE-MOLY LITHIUM EP3753
1/8” ALLEN KEY
NON RETURN VALVE ASSEMBLY
SPANNER FOR INTENSIFIER
4MM ALLEN KEY
5MM ALLEN KEY
1/4” ø ROD
GREASE - MOLYKOTE 55M
GRESDR - MOLYKOTE 111
07900-00008
07900-00012
07900-00015
07900-00164
07900-00469
07900-00667
07900-00670
07900-00672
07900-00677
07900-00684
07900-00685
07900-00692
07900-00158
07992-00020
07900-00013
07900-00714
07900-00717
07900-00224
07900-00225
07900-00521
07992-00075
07900-00775
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.
•Disconnect the hose assembly (3 pipes) from the intensifier.
•Peel back the gator from the handle base.
•Disconnect the hose assembly (3 pipes) from the tool keeping the hose assembly vertical or cap the end to retain the hydraulic oil.
•Remove bleed screw 10 to let the oil flow out of the tool into a suitable container.
Prior to dismantling the tool it is necessary to remove the nose equipment. For instructions see the nose assemblies section, pages 8-10 or if
a swivel head was fitted pages 12-15.
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.
Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.

Head Assembly
Trigger
Servicing the Tool
19
•Unscrew retaining nut 26 and pull off stem collector assembly, items 18, 20, 21, 22, 23, 24, 25 and ‘O’ ring 19.
•Pull off stem collector adaptor 15.
•Using the ‘T’ spanner* remove end cap 27 together with seal 17 ‘O’ ring 16 and lip seal 28.
•Remove spring 29 and spring seat 54.
•Loosen locknut 3with a spanner* then unscrew jaw spreader housing 1and ‘O’ ring 2.
•Remove locknut 3together with ‘O’ ring 43 and 7lip seal.
•Push head piston 8to the rear and out of head assembly 4taking care not to damage the cylinder bore.
•Using circlip pliers* remove seal retainer 30. Push lip seal 9to the rear and out of head assembly 4taking care again not to damage
the cylinder bore.
•Remove seal housing 6and lip seal 53.
Assemble in reverse order to dismantling noting the following points:
•Place lip seal 9onto 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.
•The chamfered edge of seal retainer 30 must face forward with the gap at the bottom.
•After fitting seals 12, 52 and 13 onto the piston ensuring correct orientation, lubricate the cylinder bore and place the piston sleeve*
into the back of head assembly 4. Slide the bullet* onto the threaded part of piston 8and 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.
•Jaw spreader housing 1must be fully tightened onto head piston 8before tightening locknut 3against it.
•Use Loctite 932 when reassembling retaining nut 26.
•Using the 2 millimetre diameter pin punch*, drive trigger pin 42 out and lift off trigger 41.
•Unscrew trigger valve 40 using the trigger valve extractor*.
Assemble in reverse order to dismantling.
* Item included in the G2-s service kit. For complete list see page 18.
Item numbers in bold refer to the general assembly drawings and parts lists pages 22-25.
English

Intensifier
Servicing the Tool
20
•Disconnect the air supply.
•Remove cover plate 58 and gasket 83 by removing screws 98 (4 off) and washers 99 (4 off).
•Drain oil into a suitable container.
•Disconnect all air lines and hydraulic hoses.
•Remove screws 92 (2 off).
•Remove protection plate 71 by removing screws 72 (4 off).
•Disconnect timer valve 91.
•Remove valve 89 by removing screws 85 (3 off).
•Remove screw 68, silencer cover 100, foam silencer 64, spacer 67 and retaining plate 66.
•Pull off the 6mm Plastic Tube 104 from Vacuum Connectors 103.
•From the base of the intensifier insert a 3mm Allen Key* through the two holes and unscrew the Vacuum Connectors 103. Note:
•Care must be taken as the vacuum connectors are locked and sealed in place using Loctite 574.
•If difficult to remove, the vacuum connectors can be drilled out using a 3/16 " or 4.7mm diameter drill.
•To reassemble the Vacuum Connectors 103, the following procedure must be followed:
•Soak the vacuum connectors in a suitable primer, i.e. Perma Bond A905.
•Place a drop of Loctite 574 in the intensifier threaded hole.
•From the base of the intensifier insert the Allen Key* through the hole. Ensure that the Allen Key* is free from Loctite 574 before
inserting into the vacuum connector.
•Rotate the Allen Key while applying Loctite 574 to the base of the vacuum connector.
•Screw the Vacuum connector into the intensifier, ensuring that there is sufficient Loctite 574 at the base of the fitting such that the
thread is not visible.
IMPORTANT
Check the tool against daily and weekly servicing.
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
•Remove internal retaining ring 69.
•Using screw 68 as a puller, insert into end cover 63 and withdraw the end cover.
•Remove quick release connector 78.
•Insert the 1/4 " diameter rod* through connector 79 at the front of the intensifier body and push out intensifier rod 78, piston assembly 60,
piston stop 106 and 'O' ring 107.
•Remove seal plug 74 with spanner 07900-00717*.
•Insert the 1/4 " diameter rod* through connector 79 and push out seal housing 77.
•To clean non-return valve 82, blow through orifice in top of valve with a low air pressure gun. Should it be necessary to remove the valve
from the main body, use spanner 07900-00717*. On re-assembly use Loctite 225 on the threads to secure in main body.
Assemble in the reverse order to dismantling.
Item numbers in bold refer to the general views and parts lists pages 22-25.
* Item included in the G2-s service kit. For complete list see page 18.

21
Notes English