Textron Genesis G2 User manual

Instruction Manual
Genesis G2 model
Hydro-Pneumatic Power Tool
2

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
Selection of Nose Tips 8&10
Fitting and Servicing Instructions 9
Accessories
Stem Deflector 11
Extension 11
Side Ejector 11
Stem Collector 11
Swivel Heads 12
Preparing the Base Tool 13
Swivel Head Fitting Instructions 14
Swivel Head Servicing Instructions 15
Servicing the Tool
Daily / Weekly 16
Moly Lithium Grease EP 3753 Safety Data 16
Service Kit 17
Annually 18
Head Assembly 18
Pneumatic Piston Assembly 19
Valve Spool Assembly 19
Trigger 19
General Assembly of Base Tool
General Assembly and Parts List 20-21
Priming
Oil Details 22
Hyspin VG 32 Oil Safety Data 22
Priming Kit 22
Priming Procedure 23
Fault Diagnosis
Symptom, Possible Cause & Remedy 24
Textron Fastening Systems 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
Textron Fastening Systems 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, Textron Fastening Systems
undertakes only to repair or replace faulty components.
CONTENTS

4
1Do not use outside the design intent.
2Do not use equipment with this tool/machine other than that recommended and supplied by Textron Fastening Systems.
3Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Textron
Fastening Systems or their representatives, shall be the customer’s entire responsibility. Textron Fastening Systems 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 Textron Fastening Systems
procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Textron Fastening
Systems 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 Textron Fastening Systems.
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 collector,it must be emptied when half full.
15 If the G2 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.
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
Safety Rules

5
Specifications
TOOL SPECIFICATION
Air Pressure Minimum - Maximum 5-7 bar
Free Air Volume Required @ 5.5 bar 2.1 litres
Stroke Minimum 17 mm
Pull Force @ 5.5 bar 9.34 kN
Cycle Time Approximately 0.9 seconds
Noise Level 75 dB(A)
Weight Without nose equipment 1.35 kg
Vibration Less than 2.5 m/s2
30
121
150
104
120
284
2
12°30'
126
116
70
TOOL DIMENSIONS
Dimensions in millimetres

6
Intent of Use
G2 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’ on page 7 for
adjustment instructions.
A complete tool, except the 71210-00039, is made up of three
separate elements which will be supplied individually. See diagram
below.
If you wish to place most of the fasteners in the table opposite, you
can order the 71210-00039 complete tool comprising of:
• 71210-02000 base tool
• 71210-15000 nose assembly
• Nose tips 71210-05002, 71210-16070 and 07381-04701,
two screwed into the base cover. Fit nose tip as indicated page
9 or 11.
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 and nose assembly and
nose tip must be ordered separately.
NOSE EQUIPMENT MUST BE FITTED AS DESCRIBED ON
PAGE 9.
FASTENER
NAME
MM
IN
FASTENER SIZE ( )
AVEX®
STAVEX®
AVINOX®
AVIBULB®
ETR
BULBEX®
T-LOK®
AVDEL®SR
MONOBOLT®
INTERLOCK®
TLR®
AVDEL®
MBC
MBC/LC
AVSEAL®
3 3.2 4.0 4.3 4.8 5 5.2 6 6.5 7
–1/85/32 –3/16 –––––
●●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●●●●
COMPLETE TOOL
71210-00 . . . *
BASE TOOL
1
1
2
3
1
NOSE ASSEMBLY
NOSE TIP 2
71210-02000
71210-15000
see note 3
2
3++=
3
2 2
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
pages 20-21. If a swivel head is fitted, the same base tool must be adapted. See details page 13.
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.
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 & 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.
* 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.

7
Putting into Service
AIR SUPPLY
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and automatic
oiling/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 servicing daily details page 16.
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)
LUBRICATOR
3 METRES MAXIMUM
2
OPERATING PROCEDURE
•Ensure that either the correct nose assembly or swivel head
suitable for the fastener is fitted (see pages 8-10 and 12-15).
•Connect the tool 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 60.
•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 .
ADJUSTING THE VACUUM EXTRACTION
•Using a screwdriver, turn rotary valve 60 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 drawing and parts list on pages 20-21.

8
Nose Assemblies
IMPORTANT
Nose assemblies do NOT include nose tips. Nose tips must be ordered separately.
A tool (except part number 71210-00039) must always be fitted with the correct nose assembly and nose tip for your fastener but if you wish
to order a nose assembly or a nose tip 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 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 71210-00039
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 base of the tool.
Swivel heads are available as an alternative to nose assemblies when further reach is required. See page 12-15 in the ‘Accessories’ section.
1
In inches then in millimetres.
2
Head forming nose tips for use with countersunk heads
ONLY.
3
Long nose tip for deep placing.
TYPE 1
NOSE TIPS
NOSE ASSEMBLY
part nº 71210-15000
(+ 3 nose tips above = 71210-15100)
FASTENER
MATERIAL
Ø1NOSE 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
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
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
2.8
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
71210-05002
71210-16070
07340-064012
71210-05002
71210-16070
07381-04701
07340-065012
07381-04701
07340-04800
07490-04401
07340-066012
71210-16020
71210-16070
07381-04701
71210-16001
71210-160063
71210-16002
71210-160073
71210-16003
71210-160083
71210-16004
71210-160093
71210-16005
71210-160103
07605-00220
71210-16070
07381-04701
07498-01401
07340-06201
07340-06201
71210-16070
07381-04701
07498-01401
71210-05002
71210-16070
07348-07001
07381-04701
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
4.8
AVEX®
Large flange
MONOBOLT®
BULBEX®
AVSEAL®
TLR®
AVINOX®II
T-LOK®
AVIBULB®
AVDEL®SR
INTERLOCK®
…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
…039
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 07498-04301
8 LOCKING RING 07340-00327
* Complete tool part number 71210-00039 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 71210-00.
* See top left
8 7 6 5 4 23 1 61
22.9

9
Nose Assemblies
Nose assemblies should be serviced at weekly intervals. You should hold some stock of all internal components of the nose assembly and
nose tips as they will need regular replacement.
•Remove the nose 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 service kit. For complete list see page 17.
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*.
SERVICING INSTRUCTIONS

10
Nose Assemblies
1
In inches then in millimetres.
FASTENER
MATERIAL
Ø1NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME Al Alloy
Steel
Al Alloy
Steel
Al Alloy
Steel
Al Alloy
Al Alloy
Steel
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
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
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
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
3.2
3.2
4.0
4.0
4.8
4.8
4.0
4.8
4.3
4.8
3.2
4.8
5.2
AVEX®
BULBEX®
T-LOK®
AVIBULB®
E.T.R
…002
…008
…008
…014
…014
…018
…008
…014
…121
…121
…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 07498-04301
8 LOCKING RING 07340-00327
COMPLETE TOOL
PART NUMBER :
precede with
71210-00
NOSE ASSEMBLY
part nº 71210-15200
A
B
TYPE 2 NOSE TIPS ARE EXTENDED
TO ALLOW ACCESS INTO
APPLICATIONS WHERE TYPE 1
NOSE TIPS WILL NOT REACH.
TYPE 2
NOSE TIPS
8 7 6 5 423158.3
22.9
TYPE 3
NOSE TIPS
COMPLETE TOOL
PART NUMBER :
precede with
71210-00
156.3
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 07498-04301
8 LOCKING RING 07340-00327
TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE
FASTENERS LISTED BELOW.
FASTENER
MATERIAL
Ø1NOSE TIP (mm) see
below
PART Nº 'A' 'B'NAME Al Alloy
Al Alloy O
Stainless Steel
Al Alloy
Al Alloy O
Stainless Steel
Al Alloy
Al Alloy O
Any
Any
Al Alloy
Any
Any
Al 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

11
Accessories
STEM DEFLECTOR
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
07340-00342
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 21 by inserting a 3 millimetre diameter rod
into one of the holes.
•Remove retaining nut 21 and the stem collector assembly, items
15, 16, 17, 18, 19, and 20.
•Screw the adaptor nut onto end cap 22.
•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.
Item numbers in bold refer to the general assembly drawing and parts list on pages 20-21.
INNER
71210-20301 OUTER
71210-20302
STEM DEFLECTOR: 71210-20100
EXTENSION PART NUMBER: 71210-20300
INNER
EXTENSION
OUTER CASING
8-32 x 1/4" SOCKET
CAP HEAD SCREW
Part number: 07490-04000
for fasteners with a stem up to 3.1 mm (1/8") Ø
Part number: 07498-00900
for fasteners with a stem larger than 3.1 mm (1/8") Ø
EXTENSION
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.
SIDE EJECTOR
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 diameter 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 14 for fitting instructions, but note
that the stop nut is not fitted in this case.
•To fit the side ejector, remove any nose assembly components.
•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.
STEM COLLECTOR: 71210-20400
SEE GENERAL ASSEMBLY AND
PARTS LIST PAGES 20-21
STEM COLLECTOR
The different components which make up a stem collector are
available as an assembly. Part number shown opposite.For details of
the components, see the note below the parts list page 21.
To replace the stem deflector with the stem collector proceed as per
‘Head Assembly’ instructions page 18 after having removed both the
stem deflector and adaptor nut.

12
Accessories
SWIVEL HEADS
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 14-15 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 ‘constant component table’ page 15.
'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
Ø1NOSE 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
Al Alloy
Al Alloy O
Stainless Steel
Al Alloy
Al Alloy O
Al Alloy
Al Alloy O
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy O
Al Alloy
1/8
1/8
5/32
5/32
3/16
5/32
3/16
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
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
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
07345-03300
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
07340-00229
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
07494-066012
07494-06101
07494-067012
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
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®
AVDEL®
MBC
MBC L/C
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…283
…284
…285
…288
…289
…293
…294
…300
…305
…310
…320
…320
…327
…327
COMPLETE TOOL PART NUMBER :
precede with 71210-30
(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.
STRAIGHT SWIVEL HEAD capability
A
B
360°rotation
56 92
6
20

13
Accessories
PREPARING THE BASE TOOL
1
In inches then in millimetres.
2
Long nose tip for deep placing. O Oversize
FASTENER
MATERIAL
Ø1NOSE 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
Al Alloy
Al Alloy O
Stainless Steel
Al Alloy
Al Alloy O
Al Alloy
Al Alloy O
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy
Al Alloy O
Al Alloy
1/8
1/8
5/32
5/32
3/16
5/32
3/16
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
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
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
07340-00229
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
07494-066012
07494-06101
07494-067012
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
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®
AVDEL®
MBC
MBC L/C
…001
…004
…004
…010
…010
…004
…010
…004
…010
…160
…180
…161
…181
…283
…284
…285
…288
…289
…293
…294
…300
…305
…310
…320
…320
…327
…327
COMPLETE TOOL PART NUMBER :
precede with 71210-40
(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.
RIGHT-ANGLE SWIVEL HEAD capability
7.6
32
20
52 56
74
97
A
B
360°rotation
12
7
23
1745 18 19
64
21 20
63
22
6
3
5
67
68
71210-20202
STOP NUT
71210-20201
SAFETY CAP
•Disconnect the air supply.
•Remove any nose assembly items.
•Remove retaining nut 22 and all elements of
the stem collector (items 18, 19, 20, 21,
45, 63, 64). Note that ‘O’ ring 17 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, ‘O’ rings 68 and
67, and seal housing 5.
•Screw stop nut 71210-20202 onto the front
of head piston 7as 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.
Base tool to receive a nose assembly
Base tool to receive a swivel head

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.
14
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.
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
SWIVEL HEAD FITTING INSTRUCTIONS
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.

15
Accessories
SWIVEL HEAD SERVICING INSTRUCTIONS
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 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
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

DAILY
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.
WEEKLY
•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 23 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.
•Check that base cover 36 is fully tightened onto body 34.
•Ensure that rotary valve 60 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.
MOLY LITHIUM GREASE EP 3753 SAFETY DATA
Grease can be ordered as a single item, the part number is shown in the service kit page 17.
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 20-21.
16
Servicing the Tool

17
Servicing the Tool
For an easy complete service, Textron Fastening Systems 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
07900-00164 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
SERVICE KIT

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 23.
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.
18
Servicing the Tool
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 Moly Lithium grease EP 3753 before assembling.
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.
•Unscrew retaining nut 22 and pull off stem collector assembly, items 18, 19, 20, 21, 45, 63, 64 and ‘O’ ring 17.
•Pull off stem collector adaptor 13.
•Using the ‘T’ spanner* remove end cap 23 together with seal 15 ‘O’ ring 14 and lip seal 24.
•Remove buffer 25.
•Loosen locknut 3with a spanner* then unscrew jaw spreader housing 1and ‘O’ ring 2.
•Remove locknut 3together with ‘O’ rings 66 and 67.
•Push head piston 7to the rear and out of head assembly 4taking care not to damage the cylinder bore.
•Using circlip pliers* remove seal retainer 26. 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 6.
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.
•The chamfered edge of retainer 26 must face forward with the gap at the bottom.
•After fitting seals 65, 11 and 12 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 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.
•Jaw spreader housing 1must be fully tightened onto head piston 7before tightening locknut 3against it.
HEAD ASSEMBLY
* Item included in the G2 service kit. For complete list see page 18.
Item numbers in bold refer to the general assembly drawing and parts list on pages 20-21.

19
Servicing the Tool
•Remove ‘ON/OFF’ valve assembly 55 and ‘O’ ring 47.
•Clamp the body of the inverted tool across the air inlet bosses in a vice fitted with soft jaws.
•Using the peg spanner* unscrew base cover 36 and pull out cylinder liner 41.
•Remove pneumatic piston assembly 38 from body 34 together with ‘O’ ring 35, lip seal 37 and guide ring 31.
•Screw the seal extractor* into seal assembly 30 and pull it out of the intensifier tube of head assembly 4.
Assemble in reverse order to dismantling.
•Remove pneumatic piston assembly 38 and seal assembly 30 as described immediately above.
•Using the ‘T’ spanner* and ‘T’ spanner spigot* undo clamp nut 32 and remove it together with clamp plate 58, transfer tube assembly 40
and valve rod 39.
•Release the tool from the vice and separate body 34 with ‘O’ ring 27 from handle assembly 28.
•Remove ‘O’ ring 29 from the intensifier tube and pull off head assembly 4from handle assembly 28.
•Push out valve seat 59 with both ‘O’ rings 66.
•Pull out all the components of valve spool assembly 49.
•Finally remove ‘O’ ring 54 out of the handle counterbore.
Assemble in reverse order to dismantling ensuring that the central port in valve seat 59 faces upwards.
•Using the 2 millimetre diameter pin punch*, drive trigger pin 44 out and lift off trigger 43.
•Unscrew trigger valve 42 using the trigger valve extractor*.
Assemble in reverse order to dismantling.
PNEUMATIC PISTON ASSEMBLY
VALVE SPOOL ASSEMBLY
TRIGGER
IMPORTANT
Check the tool against daily and weekly servicing.
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
* Item included in the G2 service kit. For complete list see page 17.
Item numbers in bold refer to the general assembly drawing and parts list on pages 20-21.

20
General Assembly of Base Tool 71210-02000
68 67
B - B
A
A - A
A B B
1234 9 105 68
26 27 28 27
29 30
31
32 33 34 36
38 39 40 41 42 44 43
46
37
35
25 24
13 14 1516
18 66
54
53
52
49-51
50
47 48 66 47
6160
55
56
57586657 59
11 127
17
45
22
23
19
21 64
20
63
65
69

21
Parts List for 71210-02000
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
71210-02101 07003-00277 71210-02103 71210-03320 71210-02104 07003-00333 71210-02121 07003-00273 07001-00405 07003-00194 07003-00341 07003-00275 71210-02007 07003-00278 71210-02029 71210-02022 07003-00067 07640-00239 71210-02051 07340-00335 07640-00244 71210-02028 71210-02010 07003-00274 71220-02025 71210-02019 07003-00288 71210-04000 07003-00287 71210-03800 71210-03205 71210-02014 71210-02027 71210-02003
JAW SPREADER HOUSING 'O' RING LOCKNUT HEAD ASSEMBLY SEAL HOUSING LIP SEAL HEAD PISTON LIP SEAL SCREW SEAL LIP SEAL LIP SEAL STEM COLLECTOR ADAPTOR 'O' RING SEAL SUSPENSION RING 'O' RING STEM COLLECTOR OUTER # STEM COLLECTOR BODY # STEM COLLECTOR END CAP # SILENCER # RETAINING NUT # END CAP LIP SEAL BUFFER SEAL RETAINER 'O' RING HANDLE ASSEMBLY 'O' RING SEAL ASSEMBLY GUIDE RING CLAMP NUT LABEL BODY
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1
-
1 1
--
1
-
1 1 2 1 1
-
1 1
-
1
---
1
--
1
--
2
-
1
--
1
--
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69
07003-00280 71210-02006 07003-00274 71210-03200 71210-03500 71210-03600 71210-02012 07005-00088 71210-02008 71210-02024 07003-00311 71210-02102 07003-00127 07005-01274 71210-03400 07003-00268 71210-03402 71210-03401 07003-00042 07003-00271 71210-03700 07008-00010 71210-02031 71210-02021 71210-02009 71210-02013 07003-00189 07900-00664 71210-02034 71210-02035 07003-00342 07003-00281 07003-00204 07003-00310 07007-00224
'O' RING BASE COVER LIP SEAL PNEUMATIC PISTON ASSEMBLY (INCLUDES 31/35/37) VALVE ROD ASSEMBLY TRANSFER TUBE ASSEMBLY CYLINDER LINER TRIGGER VALVE TRIGGER TRIGGER PIN 'O' RING VACUUM SLEEVE 'O' RING PLUG VALVE SPOOL ASSEMBLY (50 to 53) • 'O' RING • VALVE SPOOL • VALVE BODY • 'O' RING 'O' RING ON/OFF VALVE ASSEMBLY FLEXIBLE HOSE SILENCER CLAMP PLATE VALVE SEAT ROTARY VALVE 'O' RING TOOL INSTRUCTION MANUAL SILENCER CAP # SILENCER # 'O' RING 'O' RING 'O' RING 'O' RING SPIROL PIN
1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 3 1 1 2
1
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1
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2
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2
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2 1
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2
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2 1
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1 2 3 1 1
ITEM PART Nº DESCRIPTION QTY SPARES ITEM PART Nº DESCRIPTION QTY SPARES
71210-02000 PARTS LIST *These are minimum recommended levels of spares based on regular servicing
#These items are also available as a complete kit part number 71210-20400.