Genesis ng3

Instruction Manual
G3
Genesis ®
H y d ro - P n e u m a t i c P o w e r To o l
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Contents
Safety Instructions 4 Base Tool

General Assembly of Base Tool - 71223-0200 24
Specifications Parts List for 71223-02000 25
Tool Specification 5
Tool Dimensions 5 Priming
Oil Details 26
Intent of Use Hyspin® VG32 Oil Safety Data 26
Range of Fasteners 6 Priming Kit - 07900-00688 26
Part Numbering 6 Priming Procedure 27
Putting into Service Fault Diagnosis

Air Supply 7 Symptom, Possible Cause and Remedy 28
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
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.

Safety Instructions
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
1 Do not use outside the design intent.
2 Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.
3 Any 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.
4 The 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.
5 The 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.
6 The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
7 Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8 Do not operate a tool/machine that is directed towards any person(s) or the operator.
9 Always 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.

Specifications
To o l S p e c i f i c a t i o n
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 )
To o l D i m e n s i o n s
61
22.9
145
12°
30'
116
70
140
320
3
n
156
150
128
Dimensions in millimetres

Intent of Use
Range of Fasteners
nG3 is a hydro-pneumatic tool designed

to place Avdel® breakstem fasteners at
high speed making it ideal for batch or MM
flow-line assembly in a wide variety of FASTENER SIZE ( IN )
FASTENER
applications throughout all industries. It 3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10
NAME
can place all fasteners listed opposite. – 1/8 5/32 – 3
/16 – – – 1/4 – – – – 3/8 –
AVEX ®
The tool features a vacuum system for
STAVEX ®
fastener retention and trouble free
collection of the spent stems AVINOX ® II
regardless of tool orientation. AVIBULB ®
ETR
A complete tool is made up of BULBEX ®
three separate elements which will T- LOK ®
be supplied individually. See AVDEL ® SR
diagram below.
MONOBOLT ®
INTERLOCK ®
AVTAINER ®
* AVSEAL ® II
Q RIVET
T RIVET
AVDELMATE ®
KLAMP-TITE ®
NOSE EQUIPMENT MUST BE
KLAMPTITE KTR ®
FITTED AS DESCRIBED ON PAGE 8.
* For Avseal® equipment refer to separate data sheet 07900-00840
Part Numbering
The part number of the base tool remains the same whichever nose assembly, or nose tip is fitted. See the General Assembly
1 pages 24 and 25. If a swivel head is fitted, the same base tool must be adapted. See details pages 14-15.
This single nose assembly will allow placing of fasteners by simply selecting the appropriate nose tip from
2 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.
The nose tip part number relates to a specific fastener. If access to the application is
3 restricted, some extended nose tips are available. See table pages 11 and 12.
NOSE TIP
3
see note 3 1 + 2 + 3 = COMPLETE TOOL
71224-00 . . .
2 NOSE ASSEMBLY *
71210-15000
BASE TOOL
1
71224-02000
* 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.

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 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.
STOP COCK
(USED DURING MAINTENANCE TAKE OFF POINT
OF FILTER/REGULATOR OR LUBRICATION UNITS) FROM
MAIN SUPPLY
3 METRES MAXIMUM
6 8 10
12
0 2 4
1416
MAIN SUPPLY
DRAIN POINT
AIR LUBRICATION PRESSURE REGULATOR

PERMISSABLE AND FILTER (DRAIN DAILY)
O p e r a t i n g P ro c e d u r e
• 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
Lift Trigger to
protruding fastener enters squarely into the hole of the cut-off the
application. vacuum air
supply.
• 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.

Nose Assemblies
Fitting Instructions
I M P O R TA N T
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 1/4 in 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.
I M P O R TA N T
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 4 with Moly Lithium grease*.
• Drop Jaws 4 into Jaw Housing 3 or Chuck Collet 9 depending on which nose assembly you are using.
• Insert Jaw Spreader 5 into Jaw Housing 3 or insert Front Spring Guide 10 into Chuck Collet 9.
• Locate Buffer 6 on Jaw Spreader 5.
• Locate Spring 7 onto Jaw Spreader 5 or onto Front Spring Guide 10.
• Screw Rear Spring Guide 11 into Chuck Collet 9.
• Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool.
• 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 1 and tighten with spanner*.
• Place Nose Casing 1 over Jaw Housing 3 or Chuck Collet 9 and screw onto the tool, tightening with spanner*.
Servicing Instructions
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 7 is not distorted.
• Assemble according to fitting instructions above.
* Item included in the nG3 Service Kit. For complete list see page 20.

Nose Assemblies
Nose Tips
FA S T E N E R NOSE TIP (mm) s ee

TYPE 1 NAME
AVEX ® 1/8
Ø1 MATERIAL
3.2 Al Alloy
PART Nº 'A'
71 21 0 -05 00 2 1 2 .7 4. 8
'B' be lo w
…001
1/8 3.2 Steel 71 21 0 -16 07 0 1 2 .7 3. 3 …004
NOSE TIPS 1/8
–
3.2 Al Alloy
3.0 Al Alloy
0 7 34 0-0 64 0 1 2 1 2 .7 2. 9
71 21 0 -05 00 2 1 2 .7 4. 8
…003
…001
5 / 32 4.0 Al Alloy 71 21 0 -16 07 0 1 2 .7 3. 3 …004
1 5 / 32 4.0 Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
In inches then in millimetres.
2 Head forming nose tips for use with countersunk heads 5 / 32 4.0 Al Alloy 0 7 34 0-0 65 0 1 2 1 2 .7 3. 3 …009
ONLY.
3 / 16 4.8 Al Alloy 07 38 1 -04 70 1 1 2 .7 2. 8 …010
Large flange 3 / 16 4.8 Al Alloy 07 34 0 -04 80 0 1 9 .0 3. 3 …016
3 / 16 4.8 Steel 07 49 0 -04 40 1 1 2 .7 3. 3 …017
3 / 16 4.8 Al Alloy 0 7 34 0-0 66 0 1 2 1 2 .7 4. 1 …015
1/4 6.4 Al Alloy 07 61 2 -02 00 1 1 2 .7 3. 3 …021
* In ADDITION to the nose assembly shown below, MONOBOLT ® /16 4.8 Any
3 71 21 0 -16 02 0 1 2 .7 4. 1 …200
an extra long nose assembly is available to place BULBEX ® 5 / 32 4.0 Al Alloy 71 21 0 -16 07 0 1 2 .7 3. 3 …004
1/ " Monobolt® in applications with restricted
3 / 16 4.8 Al Alloy 07 38 1 -04 70 1 1 2 .7 2. 8 …010
4 AVINOX ® II 1/8 3.2 Stainless Steel 71 21 0 -16 07 0 1 2 .7 3. 3 …004
access. See type 4 NOSE TIP table. 5 / 32 4.0 Stainless Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
3 / 16 4.8 Stainless Steel 07 49 8 -01 40 1 1 2 .7 4. 8 …082
T-LOK ® – 4.3 Steel 07 34 0 -06 20 1 1 2 .7 3. 3 …120
3/ 4.8 Steel 07 34 0 -06 20 1 1 2 .7 3. 3 …120
16
AVIBULB ® 1/8 3.2 Steel 71 21 0 -16 07 0 1 2 .7 3. 3 …004
5 / 32 4.0 Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
3 / 16 4.8 Steel 07 49 8 -01 40 1 1 2 .7 4. 8 …082
– 6 Steel 07 61 2 -02 00 1 1 2 .7 3. 3 …021
AVDEL ® SR 1/8 3.2 Any 71 21 0 -05 00 2 1 2 .7 4. 8 …001
5 / 32 4.0 Any 71 21 0 -16 07 0 1 2 .7 3. 3 …004
3 / 16 4.8 Any 07 34 8 -07 00 1 1 2 .7 5. 7 …062
Countersunk 3 / 16 4.8 Any 71 21 0 -16 05 0 1 2 .7 5. 7 …064
1/4 6.4 Any 71 22 0 -60 00 1 1 2 .7 3. 3 …063
INTERLOCK ® 3/16 4.8 Any 07 38 1 -04 70 1 1 2 .7 2. 8 …010
STAVEX ® 1/8 3.2 Steel 71 21 0 -16 07 0 1 2 .7 3. 3 …004
5 / 32 4.0 Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
3 / 16 4.8 Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
Large flange 3 / 16 4.8 Steel 07 34 0 -04 80 0 1 9 .0 3. 3 …016
Countersunk 3 / 16 4.8 Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
1/8 3.2 Stainless Steel 71 21 0 -16 07 0 1 2 .7 3. 3 …004
5 / 32 4.0 Stainless Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
N O S E A S S E M B LY 3 / 16 4.8 Stainless Steel 07 38 1 -04 70 1 1 2 .7 2. 8 …010
part nº 71210-15000 Q RIVET 1/8 3.2 Any 71 21 0 -05 00 2 1 2 .7 4. 8 …001
5 / 32 4.0 Any 07 34 0 -06 20 1 1 2 .7 3. 3 …120
ITEM DESCRIPTION PART Nº 3 / 16 4.8 Any 07 34 0 -06 20 1 1 2 .7 3. 3 …120
1 NOSE CASING 07340-00306
1/4 6.4 Any 07 61 2 -02 00 1 1 2 .7 3. 3 …021
AVDELMATE® 3 / 16 4.8 Any 07 34 0 -06 20 1 1 2 .7 3. 3 …120
2 'O' RING 07003-00067 1/4 6.4 Any 07 61 2 -02 00 1 1 2 .7 3. 3 …021
KLAMPTITE 3 / 16 4.8 Any 71 22 0 -16 06 0 1 2 .7 4. 8 …430
3 JAW HOUSING 07340-00304
KTR ® 1/4 6.4 Any 71 22 0 -16 06 1 1 2 .7 4. 8 …435
4 JAWS 71210-15001 KLAM-PTITE ® 3 / 16 4.8 Any 07 38 1 -04 70 1 1 2 .7 2. 8 …010
1/4 6.4 Any 07 61 2 -02 00 1 1 2 .7 3. 3 …021
5 JAW SPREADER 07498-04502 T RIVET 3 / 16 4.8 Al Alloy 7 03 -A-2 5- 6TA 1 2 .7 6 .3 5 …380
6 BUFFER 71210-05001 Large flange 3 / 16 4.8 Al Alloy 70 3-B -21 1 2 .7 6 .3 5 …381
3 / 16 4.8 Al Alloy/Steel 70 3- A-2 5-6 T 1 2 .7 6 .3 5 …383
7 SPRING 07500-00418 Large flange 3 / 16 4.8 Al Alloy/Steel 70 3-B -26 1 2 .7 6 .3 5 …384
8 LOCKING RING 07340-00327
1/4 6.4 Al Alloy 7 43 -A-2 5- 8TA 1 2 .7 6 .6 5 …385
Large flange 1/4 6.4 Al Alloy 70 3-B -21 1 2 .7 6 .6 5 …386
1/4 6.4 Al Alloy/Steel 74 3- A-2 5-8 T 1 2 .7 6 .6 5 …387
Large flange 1 /4 6.4 Al Alloy/Steel 74 3-B -26 1 2 .7 6 .6 5 …388
COMPLETE TOOL
22.9 A PART NUMBER :
precede with
61 B 71224-00
8 7 6 5 4 3 2 1

Nose Assemblies
Nose Tips
FA S T E N E R NOSE TIP (mm) s ee

TYPE 2 NAME
AVEX ® 1/8
Ø1 MATERIAL
3.2 Aluminium Alloy
PART Nº 'A' 'B'
07 34 0-0 2 80 5 9 .5 1 2 .9 5
be lo w
…002
1/8 3.2 Steel 07 34 0-0 2 80 6 9 .5 1 1. 4 …008
NOSE TIPS 5 / 32 4.0
5 / 32 4.0
Aluminium Alloy
Steel
07 34 0-0 2 80 6 9 .5 1 1. 4
07 34 0-0 2 80 7 1 2. 7 1 0. 0
…008
…014
3 / 16 4.8 Aluminium Alloy 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
3 / 16 4.8 Steel 07 34 0-0 7 30 1 1 2. 7 1 1. 8 …018
BULBEX ® 5/32 4.0 Aluminium Alloy 07 34 0-0 2 80 6 9 .5 1 1. 4 …008
3 / 16 4.8 Aluminium Alloy 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
T-LOK ® – 4.3 Steel 07 24 1-0 7 10 1 1 2. 7 1 0. 0 …121
N O S E A S S E M B LY 3 / 16 4.8 Steel 07 24 1-0 7 10 1 1 2. 7 1 0. 0 …121
part nº 71210-15200 STAVEX ® 1/8 3.2 Steel 07 34 0-0 2 80 6 9 .5 1 1. 4 …008
5 / 32 4.0 Steel 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
ITEM DESCRIPTION PART Nº 3 / 16 4.8 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
Steel
1 NOSE CASING 07340-02804 1/8 3.2 Stainless Steel 07 34 0-0 2 80 6 9 .5 1 1. 4 …008
2 'O' RING 07003-00067 5 / 32 4.0 Stainless Steel 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
3 JAW HOUSING 07340-00304 3 / 16 4.8 Stainless Steel 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
AVIBULB ® 1/8 3.2 Steel 07 34 0-0 2 80 6 9 .5 1 1. 4 …008
4 JAWS 71210-15001 5 / 32 4.0 Steel 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
5 JAW SPREADER 07498-04502 E.T.R – 5.2 Steel/Brass 07 34 0-0 2 80 7 1 2. 7 1 0. 0 …014
6 BUFFER 71210-05001 1 In inches then in millimetres.
7 SPRING 07500-00418
8 LOCKING RING 07340-00327 TYPE 2 NOSE TIPS ARE EXTENDED COMPLETE TOOL
14 JAW SPREADER HOUSING 71210-02101 TO ALLOW ACCESS INTO A PART NUMBER :
15 'O' RING 07003-00277 APPLICATIONS WHERE TYPE 1 precede with
B 71224-00
NOSE TIPS WILL NOT REACH.
22.9
14 15 8 7 6 5 4 3 2 1 58.3
Note: Items 14 and 15 are not required when assembling a Type 2 Nose Tip to the Base Tool nG3 (71224-02000).
10

Nose Assemblies
Nose Tips
FASTENER NOSE TIP (mm) se e

TYPE 4 NAME Ø1 MATERIAL PART Nº 'A' 'B' b el o w
MONOBOLT® 1/4 6.4 Any 7 12 20 -1 60 21 1 4. 3 4 .1 … 2 0 2
NOSE TIP 1 In inches then in millimetres
COMPLETE TOOL
A PART NUMBER :
N O S E A S S E M B L Y part nº 71220-15400
precede with
ITEM DESCRIPTION PART Nº ITEM DESCRIPTION PART Nº B 71224-00
1 NOSE CASING 07498-00501 10 FRONT SPRING GUIDE 07498-00507
2 'O' RING 07003-00067 7 SPRING 07500-02005
FITTED TO THIS LONG NOSE
9 CHUCK COLLET 07498-00502 11 REAR SPRING GUIDE 07498-00503
ASSEMBLY, THE TYPE 4 NOSE TIP
4 JAWS 07497-03002 8 LOCKING RING 07340-00327
WILL ALLOW THE PLACING OF
1 /4 " MONOBOLT ® FASTENERS
IN APPLICATIONS REQUIRING
20.6
VERY DEEP ACCESS.
8 11 7 10 4 9 2 1 98.5
FA S T E N E R NOSE TIP (mm) se e

TYPE 5 NAME Ø1 MATERIAL PART Nº 'A' 'B' b el o w
AVTAINER ® 3/8 9.6 Steel 0 74 98 -0 08 02 1 9. 1 4 .1 … 2 4 3
NOSE TIP 1 In inches then in millimetres
COMPLETE TOOL
A PART NUMBER :
N O S E A S S E M B LY part nº 71220-15500
precede with
ITEM DESCRIPTION PART Nº ITEM DESCRIPTION PART Nº B 71224-00
1 NOSE CASING 07498-00501 7 SPRING 07500-02005
2 'O' RING 07003-00067 11 REAR SPRING GUIDE 07498-00503 THERE IS ONLY ONE TYPE 5 NOSE
9 CHUCK COLLET 07498-00801 8 LOCKING RING 07340-00327 TIP, SPECIFICALLY DESIGNED TO
4 JAWS 07220-02302 12 SIDE EJECTION ADAPTOR 07498-00900 PLACE AVTAINER ® FASTENERS WITH
10 FRONT SPRING GUIDE 07498-00803 13 VAC SHUT-OFF STOP NUT ASSY 71233-20200 THIS SPECIAL NOSE ASSEMBLY.
20.6
28.6
13 90 12 8 11 7 10 4 9 2 1 98.5
COMPLETE TOOL
TYPE 6 A PART NUMBER
N O S E A S S E M B LY
part nº 71230-15800
PRECEDED WITH:
B
NOSE TIPS 71224-00 ITEM
1
DESCRIPTION
NOSE CASING
PART Nº
07340-00306
2 'O' RING 07003-00067
FA S T E N E R NOSE TIP (mm) see 3 JAW HOUSING 07612-02003
NAME Ø1 MATERIAL PART Nº 'A' 'B' a b o v e
4 JAWS 07612-02002
MONOBOLT ® 1/4 6.4 Any 71220 -16 0 21 1 4. 3 4 .1 ... 201
5 JAW SPREADER 07498-04502
INTERLOCK® 1/4 6.4 Any 07612 -02 0 01 1 4. 3 3 .6 ... 261
STAVEX ® 1/4 6.4 Any 07612 -02 0 01 1 4. 3 3 .6 ... 261 6 BUFFER 07498-03003
7 SPRING 07500-00418
8 LOCKING RING 07340-00327
22.9
1 In inches then in millimetres
8 7 6 5 4 3 2 1 61
11

Accessories
Stem Deflector
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:
Preparing the Base Tool for use with Stem Deflector

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:
• Loosen Locknut 40 using

41 40
16mm AF Spanner.
• Unscrew and remove both Jaw
Spreader Housing 41 and
71210-20101
Locknut 40. ADAPTOR NUT
• Replace Locknut 40 with
‘Sealed’ Nut 71213-02200, 36
07340-00342
screw ‘Sealed’ Nut onto Head STEM DEFLECTOR
Piston 36 to disable Vacuum
System.
• Jaw Spreader Housing 41
must be tightened onto Head
Piston 36, finally tightening
‘Sealed’ Nut against it.
STEM DEFLECTOR
07340-00342
• 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. SEALED NUT
• Push the bossend of the stem deflector into the internal groove 71213-02200
of the adaptor nut.
• Rotate the stem deflector until the aperture faces away from the
operator and any other person(s) in the vicinity.
ADAPTOR NUT
71210-20101
STEM DEFLECTOR
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 41.
INNER
• Screw the outer onto Head Assembly 58.
71210-20301
• Fit the nose assembly onto the extension.
OUTER
71210-20302
EXTENSION PART NUMBER: 71210-20300
Item numbers in bold refer to the General Assembly drawing and Parts List on pages 24 and 25.
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 16 and 17 for detail.
I M P O R TA N T
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.
STRAIGHT SWIVEL HEAD capability

FA S T E N E R SWIVEL HEAD NOSE TIP (mm) JAWS s ee
NAME Ø1 MATERIAL PART Nº PART Nº 'A' 'B' PART Nº be lo w
AVEX ® 1 / 8 3.2 Al Alloy 07345- 03 00 0 0 7 34 5-0 36 0 0 7. 87 3 .8 1 0 73 40 -0 02 13 …001
1 / 8 3.2 Steel 07345- 03 10 0 0 7 34 5-0 37 0 0 7. 87 3 .8 1 0 73 40 -0 02 13 …004
5 / 32 4.0 Al Alloy 07345- 03 10 0 0 7 34 5-0 37 0 0 7. 87 3 .8 1 0 73 40 -0 02 13 …004
5 / 32 4.0 Steel 07345- 03 20 0 0 7 34 5-0 38 0 0 7. 87 3 .8 1 0 74 90 -0 46 02 …010
3 / 16 4.8 Al Alloy 07345- 03 20 0 0 7 34 5-0 38 0 0 7. 87 3 .8 1 0 74 90 -0 46 02 …010
BULBEX ® 5 / 32 4.0 Al Alloy 07345- 03 10 0 0 7 34 5-0 37 0 0 7. 87 3 .8 1 0 73 40 -0 02 13 …004
3 / 16 4.8 Al Alloy 07345- 03 20 0 0 7 34 5-0 38 0 0 7. 87 3 .8 1 0 74 90 -0 46 02 …010
®
AVINOX II 1/8 3.2 Stainless Steel 07345- 03 10 0 0 7 34 5-0 37 0 0 7. 87 3 .8 1 0 73 40 -0 02 13 …004
5 / 32 4.0 Stainless Steel 07345- 03 20 0 0 7 34 5-0 38 0 0 7. 87 3 .8 1 0 74 90 -0 46 02 …010
AVSEAL ® II – 4 Al Alloy 71213- 06 00 0 7 1 21 3-1 64 0 1 6. 35 1 .9 5 0 73 40 -0 02 13 …160
– 4 Al Alloy 71213- 06 60 0 7 12 13 -1 64 02 2 6. 35 4 .1 1 0 73 40 -0 02 13 …180
– 5 Al Alloy 71213- 06 10 0 7 12 13 -16 4 03 7. 62 2 .0 0 0 73 40 -0 02 13 …161
– 5 Al Alloy 71213- 06 70 0 71 2 13 -16 40 4 2 7. 62 4 .1 1 0 73 40 -0 02 13 …181
STAVEX ® 1 / 8 3.2 Steel 07345- 03 10 0 0 73 45 -03 7 00 7. 87 3 .8 1 0 73 40 -0 02 13 …004
5 / 32 4.0 Steel 07345- 03 20 0 0 73 45 -03 8 00 7. 87 3 .8 1 0 74 90 -0 46 02 …010
1 / 8 3.2 Stainless Steel 07345- 03 10 0 0 73 45 -03 7 00 7. 87 3 .8 1 0 73 40 -0 02 13 …004
5 / 32 4.0 Stainless Steel 07345- 03 20 0 0 73 45 -03 8 00 7. 87 3 .8 1 0 74 90 -0 46 02 …010
56 92 COMPLETE TOOL PART NUMBER :

20 A
precede with 71224-30
(the stop nut and safety cap are included)
6
IMPORTANT: in contrast to complete tools
360• rotation B with nose assemblies, those fitted with swivel heads
include the nose tip as a part of the head.
1 In inches then in millimetres. 2 Long nose tip for deep placing. O Oversize
13

Accessories
Preparing the Base Tool for Right-Angle and Straight Swivel Head A t t a c h m e n t
• Disconnect the air supply.
• Remove any nose assembly items. Base tool to receive a nose assembly
• Remove Stem Collector Bottle Assembly 41 12 40 52
71210-20400.
• Replace Stem Collector Bottle Assembly with
Safety Cap 71210-20201.
• Unscrew Jaw Spreader Housing 41 and 19
remove with ‘O’ Ring 12, Locknut 40*, ‘O’ 15
Rings 19* and 15*, and Seal Housing 52*.
Do not refit these items (*).
• Screw Stop Nut (71213-20200) onto the 36
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 71213-20202

STOP NUT
swivel head, see page below.
Item numbers in bold refer to the General

Assembly drawing and Parts List on pages 24 71210-20201
Base tool to receive a swivel head SAFETY CAP
and 25.
RIGHT-ANGLE SWIVEL HEAD capability

FASTENER SWIVEL HEAD NOSE TIP (mm) JAWS see
NAME Ø1 MATERIAL PART Nº PART Nº 'A' 'B' PART Nº below
AVEX® 1 / 8 3.2 Aluminium Alloy 0 734 6-0 30 00 07 345 -03 600 7 .8 7 3 .8 1 07 340 -00 213 …001
1 / 8 3.2 Steel 0 734 6-0 31 00 07 345 -03 700 7 .8 7 3 .8 1 07 340 -00 213 …004
5 / 32 4.0 Aluminium Alloy 0 734 6-0 31 00 07 345 -03 700 7 .8 7 3 .8 1 07 340 -00 213 …004
5 / 32 4.0 Steel 0 734 6-0 32 00 07 345 -03 800 7 .8 7 3 .8 1 07 490 -04 602 …010
3 / 16 4.8 Aluminium Alloy 0 734 6-0 32 00 07 345 -03 800 7 .8 7 3 .8 1 07 490 -04 602 …010
BULBEX® 5 / 32 4.0 Aluminium Alloy 0 734 6-0 31 00 07 345 -03 700 7 .8 7 3 .8 1 07 340 -00 213 …004
3 / 16 4.8 Aluminium Alloy 0 734 6-0 32 00 07 345 -03 800 7 .8 7 3 .8 1 07 490 -04 602 …010
AVINOX® II 1 / 8 3.2 Stainless Steel 0 734 6-0 31 00 07 345 -03 700 7 .8 7 3 .8 1 07 340 -00 213 …004
5 / 32 4.0 Stainless Steel 0 734 6-0 32 00 07 345 -03 800 7 .8 7 3 .8 1 07 490 -04 602 …010
AVSEAL ® II – 4 Aluminium Alloy 7 121 3-0 40 00 71 213 -16 401 6 .3 5 1 .9 5 07 340 -00 213 …160
2
– 4 Aluminium Alloy 7 121 3-0 47 00 712 13 -164 02 6 .3 5 4 .1 1 07 340 -00 213 …180
– 5 Aluminium Alloy 7 121 3-0 41 00 7 121 3-1 640 3 7 .6 2 2 .0 0 07 340 -00 213 …161
– 5 Aluminium Alloy 7 121 3-0 48 00 71 213 -16 404 2 7 .6 2 4 .1 1 07 340 -00 213 …181
STAVEX ® 1 / 8 3.2 Steel 07 346-0 31 00 0 734 5-0 370 0 7 .8 7 3 .8 1 07 340 -00 213 …004
5 / 32 4.0 Steel 07 346-0 32 00 0 734 5-0 380 0 7 .8 7 3 .8 1 07 490 -04 602 …010
1 / 8 3.2 Stainless Steel 07 346-0 31 00 0 734 5-0 370 0 7 .8 7 3 .8 1 07 340 -00 213 …004
5 / 32 4.0 Stainless Steel 07 346-0 32 00 0 734 5-0 380 0 7 .8 7 3 .8 1 07 490 -04 602 …010
7.6
COMPLETE TOOL PART NUMBER :
56 52 A
precede with 71224-40
74
32 20
97
(the stop nut and safety cap are included)
IMPORTANT: in contrast to complete tools

B with nose assemblies, those fitted with swivel
360∞ rotation heads include the nose tip as a part of the head.
1 2
In inches then in millimetres. Long nose tip for deep placing. O Oversize
14

Accessories
The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated.
I M P O R TA N T
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.
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.
A Fit Locking Ring 10 over Jaw Spreader Housing 41*

1 (71210-02101). *See pages 24 and 25.
B Coat Screw 13 with thread locking adhesive and use to
secure Nose Tip 14 onto Body 5.
17 18 C Lightly lubricate items 17, 18, 19, 20 and insert into
16
3 Jaw Carrier 3 as shown. Secure with Screws 16.
19 20
D Position Lever 4 into Body 5 and hold in place with pin
16 15 through the hole of Body 5 (not a slot).
E Lubricate the sides of the Jaw Carrier Assembly and
5
14 insert into Body 5.
13 F Lubricate Rollers 8 and ENSURE that they will freely
6
rotate in the holes of Adaptor 9. If necessary ream the
holes.
12
21 10 G Position Spring Clip 7 over Adaptor 9 past the holes for
8
7 the rollers and rotate until the locating peg is aligned
8
22 11 with the corresponding hole in Adaptor 9 (smallest
hole).
H Fit Adaptor 9 over the end of Body 5 and drop Rollers 8
9 into place. Push Spring Clip 7 over Rollers 8.
8
I Insert Spindle 11 through Adaptor 9 into Jaw Carrier 3
STRAIGHT SWIVEL HEAD until the hole lines up with slot in Body 5. Temporarily
hold in place with Pin 6.
J Insert Pin 12 through the front slot of Body 5 into Jaw
Carrier 3.
20 K Hold the assembly vertical to prevent all pins dropping
18 19
23 17 out and slide the jaw carrier assembly back and forth a
15 few times to ensure free movement. Go to M.
L Remove Screws 23 (4 off) and guard 1. On a straight
1 swivel head also remove Screw 21 and Platform 22.
16 2
M Push Pin(s) 6 out 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
16 11 straight swivel. Tighten gently with a tommy bar.
3 4
N Screw the assembly over Spindle 11 onto the tool
14 handle. Replace Pin(s) 6.
7
6 O On straight swivel heads attach Platform 22 onto the
8 top of the Spindle with Screw 21. Deburr the back end
6 8 of Platform 22 so that it cannot catch on Guard 1.
12 P Snap Guard 1 over the assembly, align screw holes in
13
guard with tapped holes in body assembly.
Q Insert Pivot Pin 15 through slots in guard and hole in
5 9 body. Fit Circlip 2 onto pivot pin so that the circlip seats
10 in groove provided.
R Coat the thread of Screws 23 (4 off) with thread locking
RIGHT-ANGLE HEAD
adhesive and screw into body assembly securing guard
to body assembly.
15

Accessories
Swivel Head Servicing Instructions
Swivel heads should be serviced at weekly intervals.
• Remove the complete head using the reverse procedure to

the ‘Fitting instructions’ omitting step ‘L’. 18
17
• If Guard 1 is at all damaged it must be replaced by a new
one.
20
19
• 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. 7 5
• Check that Spring Clip 7 is 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 1 refers 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.
C O N S TA N T C O M P O N E N T S
ITEM DESCRIPTION STRAIGHT SWIVEL RIGHT-ANGLE SWIVEL
1 GUARD 07494-05000 07495-03003
2 CIRCLIP - 07004-00105
3 JAW CARRIER 07494-03026 07494-03026
4 LEVER - 07495-03004
5 BODY 07494-03015 07495-03002
6 PIVOT PIN 07343-02207 07343-02207
7 SPRING CLIP 07495-03900 07495-03900
8 ROLLER 07007-00039 07007-00039
9 ADAPTOR 07345-03001 07345-03001
10 LOCKING RING 07345-03003 07345-03003
11 SPINDLE 07345-03002 07345-03002
12 DOWEL PIN 07007-00038 07007-00038
13 SCREW 07342-02207 07342-02207
15 PIVOT PIN - 07343-02207
16 SCREW 07494-03028 07494-03028
18 JAW SPREADER 07346-03101 07346-03101
19 SPRING 07165-00305 07165-00305
20 SPRING GUIDE 07494-03027 07494-03027
21 SCREW 07001-00368 –
22 PLATFORM 07345-00401 –
23 SCREW - 07210-00804
16

Notes
17

S e r v i c i n g t h e To o l
I M P O R TA N T
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
• 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.
We e k l y
• 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 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.
18

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.
Molykote® 111 Grease Safety Data

First Aid
SKIN:
INGESTION:
EYES:
INHALATION:
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.
19

Service Kit
For an easy complete service, Avdel offers the complete service kit below.
SERVICE KIT : 71210-99990 Spanners are specified in inches and across flats unless otherwise stated
PART Nº DESCRIPTION PART Nº DESCRIPTION ®
07900-00667 PISTON SLEEVE 07900-00008 7/16" x1/2" SPANNER
07900-00692 TRIGGER VALVE EXTRACTOR 07900-00012 9/16" x5/8" SPANNER
07900-00670 BULLET 07900-00015 5/8" x 11/16" SPANNER
07900-00672 'T' SPANNER 07900-00686 PEG SPANNER
07900-00706 'T' SPANNER SPIGOT 07900-00677 SEAL EXTRACTOR
07900-00684 GUIDE TUBE 07900-00698 STOP NUT
07900-00685 INSERTION ROD 07900-00700 PRIMING PUMP
07900-00351 3 MM ALLEN KEY 07992-00020 GREASE - MOLY LITHIUM E.P.3753
07900-00469 2.5 MM ALLEN KEY 07992-00075 GREASE - MOLYKOTE ® 55M
07900-00158 2 MM PIN PUNCH 07900-00755 GREASE - MOLYKOTE ® 111
07900-00224 4 MM A/F ALLEN KEY 07900-00850 PIN SPANNER
07900-00734 STOP NUT - MAXLOK ® 07900-00898 ROTARY VALVE HOOK
07900-00164 CIRCLIP PLIERS
Maintenance
(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.
I M P O R TA N T
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.
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.
Nose Equipment
• Unscrew Nose Casing 1 and Nose Tip.
• Unscrew Jaw Housing 3 and remove Jaws 4, Jaw Spreader 5, Spring 7 and 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 7 and Buffer 6 into Jaw Housing 3 and 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

D i s m a n t l i n g t h e To o l
Before dismantling the tool the oil must be emptied from it.
• With the air supply switched OFF at ON/OFF Valve Assembly 62 remove Bleed Screw 1 and Bonded Seal 6.
• Insert tool over a suitable container, switch air supply ON and actuate tool.
• Oil will expel from bleed screw orifice into container.
• Switch air supply OFF after all oil is expelled.
This operation must have the Bleed Screw orifice facing away from the person performing this operation.
Head Assembly
• Unscrew Retaining Nut 35 and remove stem Collector Bottle Assembly 71210-20400.
• Pull off Bottle Adaptor Assembly 10.
• Remove End Cap Assembly 50 together with ‘O’ Ring 47 and Lip Seal 9.
• Remove Spring 91.
• Loosen Locknut 40 with a spanner* and unscrew Jaw Spreader Housing 41 together with ‘O’ Ring 12.
• Remove Locknut 40 together with ‘O’ Rings 19 and 15, withdraw Vacuum Sleeve 42..
• Push Head Piston 36 to the rear and out of Head Assembly 58 taking care not to damage the cylinder bore
• Using circlip pliers* remove Seal Retainer 43. Push Lip Seal 8 and Bearing Tape 26 to the rear and out of Head Assembly 58 taking
care not to damage the cylinder bore.
• Remove Seal Housing 52 and Lip Seal 2.
Assemble in reverse order noting the following points:
• Place Lip Seal 8 onto the insertion rod* ensuring correct orientation. Locate the guide tube* into the head of the tool and push the
insertion rod* with the seal in place through the guide tube*. Pull the insertion rod* out and then the guide tube*.
• The chamfered edge of Seal Retainer 43 must face forward with the gap at the bottom.
• After fitting Lip Seal 11, ‘O’ Rings 18 and Bearing Tape 27 onto the Head Piston 36 ensuring correct orientation, lubricate the cylinder
bore and place the piston sleeve* into the back of Head Assembly 58. Slide the bullet* onto the threaded part of Head Piston 36 and
push the piston with the seals through the piston sleeve* as far as it will go. Slide the bullet* off the piston and remove piston sleeve*.
• Jaw Spreader Housing 41 must be fully tightened onto Head Piston 36 before tightening Locknut 40 against it.
• Reprime in accordance with the instructions on page 27.
21

Pneumatic Piston Assembly
• Remove ‘ON/OFF’ Valve Assembly 62.
• Clamp the body of the inverted tool ACROSS THE AIR INLET BOSSES in a vice fitted with soft jaws.
• Pull off Rubber Boot 48.
• Using the peg spanner* unscrew Base Cover 31.
• Unscrew Nyloc Nuts 67 (2 off) and remove Base Plate Assembly 65.
• Remove Cylinder Liner 37 together with Sealing Washers 29 (2 off) and ‘O’ Rings 66 (2 off).
• Remove Pneumatic Piston Assembly 57 together with ‘O’ Ring 75, Lip Seal 9 (3 off) and Guide Ring 51.
• Engage the seal extractor* into Intensifier Seal Assembly 63 and withdraw Intensifier Seal Assembly from intensifier tube of the Head
Assembly 58.
Assemble in reverse order to dismantling.
Seals should be checked for damage and replaced as necessary. Lubricate Pneumatic seals with Molykote® 55m Grease and Hydraulic seals
with Molykote® 111 Grease.
A i r Va l v e
Dismantling
• Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Piston Assembly.
• Using Spanner (07900-00672), and Location Spigot (07900-00706). Unscrew Clamp Nut 39 and remove together with Top Plate
Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, ‘O’ Rings 14 and Silencer 53.
• Remove tool from vice and separate Body Machined 55 from Handle Assembly 64. Remove ‘O’ ring 17.
• Push out the Valve Seat 34, from the Body Machined 55, together with ‘O’ Rings 14.
• Pull out Valve Spool Assembly 59 from Handle Assembly 64. Remove ‘O’ Ring 7 from handle counterbore.
Assembly
Assemble in reverse order to Dismantling Instructions.
• Seals should be checked for damage and replaced if necessary, lubricated with Molykote® 55M Grease.
• Apply Loctite® 243 to Clamp Nut 39 and tighten to torque 11ftlb (14.91 Nm)
I M P O R TA N T
Check the tool against daily and weekly servicing.

Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
22

R o t a r y Va l v e
Dismantling
• Using a 4mm pin punch (07900-00158) drive Trigger Pin 46 out and remove Trigger Assembly 33.
• Remove Pneumatic Piston Assembly 57 as described in Pneumatic Piston Assembly, see page 22.
• Using Spanner (07900-00672), and Location Spigot (07900-00706), unscrew Clamp Nut 39 and remove together with Top Plate
Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, Seperate Body Machined 55 from Handle Assembly 64.
Remove ‘O’ Rings 16 and 17.
• Seperate Head Assembly 58 from Handle Assembly 64. NOTE ORIENTATION OF ROTARY VALVE 38
• Push out Rotary Valve 38 together with ‘O’ Rings 5.
Assembly
Assemble in reverse order to Dismantling Instructions noting the following:
• Seals should be checked for damage and replaced if necessary, lubricated with Molykote® 55m grease.
• Ensure Rotary Valve 38 is assembled in correct orientation, align pins with forks on the Trigger Assembly 33.
See illustration below.
Tr i g g e r
Dismantling
• Using a 4mm Pin Punch (07900-00158) drive Trigger Pin 46 out and remove Trigger Assembly 33.
• Unscrew Trigger Valve 21 using Trigger Valve Extractor (0900-00692).
Assembly
Assemble in reverse order to Dismantling Instructions noting the following:
• When assembling Trigger Assembly 33 the trigger forks locate on the pins each side of the Rotary Valve 38.
• Ensure Rotary Valve 38 is orientated correctly. See illustration below.
38
33
23

Assy
41 12 40 52 58 2 26 8 1,6 43 11 'X' 91 10 47 20
24
45
100 74
5 38 73
13
54
25 28
42 19
15 71
B
B
Suspension

46 Section B-B
Ring 72
Assy 33 36 9
21 17 Section C-C
50 35
60 7
64 Assy 32
30 99
A 97 98 14
17 18 27 Assy 59 4
24
63 Assy 22 96 14 62 Assy
4
16
39
44
Detail 'X' 53
37 53 34 14
Assy 61 C C 76
76 23
51
49 56
Assy 57
55
79
80
75
9
31
G e n e r a l A s s e m b l y o f B a s e To o l 7 1 2 2 4 - 0 2 0 0 0
48
A
77 9 67 29 66
65 Assy Section A-A
71 224 - 02 000 PAR TS L I ST * Th es e are m i ni m um re c om men ded lev els o f sp ares b as ed o n regu lar ser v ic ing
ITEM PART Nº DESCRIPTION QTY SPARES ITEM PART Nº DESCRIPTION QTY SPARES
01 07001-00405 M5 x 5 HEX SOCKET BUTTON HD BLEED SCREW* 1 2 43 71210-02019 SEAL RETAINER 1
02 07003-00333 LIP SEAL 1 44 71213-02010 TOP PLATE ASSEMBLY 1
04 07003-00127 'O' RING 2 45 71210-02022 SUSPENSION RING* 1 1
05 07003-00189 'O' RING 2 46 71210-02024 TRIGGER PIN* 1 2
06 07003-00194 M5 BONDED SEAL* 1 2 47 07003-00278 O
ë ’ RING 1
07 07003-00271 'O' RING 1 48 71221-02007 RUBBER BOOT 1
08 07003-00273 LIP SEAL 1 49 71223-02027 LABEL 1
09 07003-00274 LIP SEAL 4 50 71403-02120 END CAP ASSEMBLY 1
10 71403-02110 BOTTLE ADAPTOR ASSEMBLY 1 51 71210-03205 GUIDE RING 1

11 07003-00341 LIP SEAL 52 71210-02104 SEAL HOUSING 1
12 07003-00277 'O' RING 1 53 71210-02031 SILENCER 2
13 07003-00311 'O' RING * # 1 3 54 07003-00067 ‘O’ RING 1
14 07003-00281 'O' RING 3 55 71223-02001 BODY MACHINED 1
15 07003-00204 'O' RING 1 56 71221-02004 TIE ROD 2
16 07003-00287 'O' RING 1 57 71221-03210 PNEUMATIC PISTON ASSEMBLY 1
17 07003-00288 'O' RING 2 58 71213-03320 HEAD ASSEMBLY 1
18 07003-00342 'O' RING 2 59 71210-03400 VALVE SPOOL ASSEMBLY* 1 1
19 07003-00310 'O' RING 1 60 07003-00042 ‘O’ RING 1
20 71212-02029 SEAL* 1 1 61 71230-03600 TRANSFER TUBE ASSEMBLY 1
21 07005-00088 TRIGGER VALVE* 1 1 62 71210-03700 ON/OFF VALVE ASSEMBLY* 1 1
22 07005-01274 1/8" BSP PLUG 1 63 71210-03800 INTENSIFIER SEAL ASSEMBLY 1
23 07008-00010 6" FLEXIBLE HOSE 1 64 71213-02013 HANDLE ASSEMBLY 1
24 07007-00224 3mm DIA x 10mm SPIROL PIN 2 65 71221-02014 BASE PLATE ASSEMBLY 1
Parts List for 71224-02000
25 07640-00239 STEM COLLECTOR BOTTLE OUTER * # 1 1 66 07003-00027 'O' RING 2

26 71213-02021 BEARING TAPE - PISTON ROD 1 67 07002-00108 M6 NYLOC NUT 2
27 71213-02022 BEARING TAPE - PISTON 1 71 71221-20105 MODIFIED COUNTER 1
28 71210-02051 STEM COLLECTOR BODY * # 1 1 72 71221-20101 COUNTER MOULDING 1
29 71221-02006 SEALING WASHER 2 73 71221-20103 MOULDING RETAINING NUT 2
30 07340-00335 STEM COLLECTOR END CAP * # 1 1 74 71221-20102 SPECIAL M4 SCREW 2
31 71221-02002 BASE COVER 1 75 07003-00280 'O' RING 1
32 07640-00244 SILENCER * # 1 1 76 07002-00163 WASHER 2
33 71213-02008 TRIGGER ASSEMBLY* 1 1 77 07007-01993 CENTRE POLE MAGNET 1
34 71210-02009 VALVE SEAT 1 79 71221-20104 M5 X 19 COUNTERSUNK SCREW 1
35 71210-02028 RETAINING NUT * # 1 1 80 07002-00098 M5 NYLOK NUT 1
36 71223-02121 HEAD PISTON 1 91 07490-03002 SPRING 1
37 71221-02008 CYLINDER LINER 1 96 07003-00268 'O' RING 1
38 71213-02012 ROTARY VALVE 1 97 71210-02034 SILENCER CAP * # 2 1
39 71210-02014 CLAMP NUT* 1 1 98 71210-02035 SILENCER * # 1 1
40 71210-02103 LOCKNUT* 1 1 99 71210-03401 VALVE BODY 1
41 71210-02101 JAW SPREADER HOUSING 1 100 07007-01503 LABEL BOOK SYMBOL 1
42 71220-02102 VACUUM SLEEVE 1 103 07900-00930 TOOL INSTRUCTION MANUAL 1
25
# These items are available as a complete kit 71210-20400
Priming
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full stroke
after considerable use, when the stroke may be reduced and fasteners are not fully placed by one operation of the trigger.
Oil Details
The recommended oil for priming is Hyspin® VG32 available in 0.5 litre (part number 07992-00002) or one gallon containers (part number
07992-00006). Please see safety data below.
Hyspin® VG 32 Oil Safety Data

First Aid
SKIN:
Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact requires no
immediate attention.
INGESTION:
Seek medical attention immediately. DO NOT induce vomiting.
EYES:
Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact.
Fire
Flash point 232°C. Not classified as flammable.
Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets.
Environment
WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation.
SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material.
Handling
Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.
Storage
No special precautions.
Priming Kit
To enable you to follow the priming procedure opposite, you will need to obtain a priming kit:
PRIMING KIT : 07900-00688

PART Nº DESCRIPTION
07900-00351 3mm ALLEN KEY
07900-00700 PRIMING PUMP
07900-00224 4mm ALLEN KEY
07900-00698 STOP NUT
07900-00734 STOP NUT - MAXLOK®
26

Priming
P r i m i n g P ro c e d u r e
I M P O R TA N T
DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE ASSEMBLY 62.
REMOVE NOSE ASSEMBLY OR SWIVEL HEAD COMPONENTS.
All operations should be carried out on a clean bench, with clean hands in a clean area.
Ensure that the new oil is perfectly clean and free from air bubbles.
Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result.
• Switch OFF air supply at ON/OFF Valve Assembly 62.
• Remove all nose equipment. (see page 8)
• Remove Bleed Screw 1 and Bonded Seal 6.
• Invert tool over suitable container, switch ON air supply at ON/OFF Valve Assembly 62 and actuate tool.
• Residual oil in the tools hydraulic system will empty through bleed screw orifice.
CARE SHALL BE TAKEN TO ENSURE THAT THE BLEED HOLE IS NOT DIRECTED TOWARDS THE OPERATOR OR OTHER
PERSONNEL.
• Switch air supply OFF at ON/OFF Valve Assembly 62.
• Screw Priming Pump (07900-00700) into bleed screw port, utilising Bonded Seal 6.
• Actuate Priming Pump by pressing down and releasing several times until resistance is evident and the Head Piston 36 starts to move
rearward.
ENSURE PUMP IS KEPT ‘SQUARE’ TO BLEED SCREW PORT DURING PRIMING OPERATION TO PREVENT BREAKAGE OF BLEED
NIPPLE ON PRIMING PUMP.
• Remove the Priming Pump, surplus oil will expel from bleed screw port.
• Replace the Bleed Screw 1 together with Bonded Seal 6.
• Switch ON air supply at ON/OFF Valve Asembly 62.
• Check that the stroke of the Head Piston 36 reaches specification. If not repeat above procedure.
• Switch OFF air supply and refit nose equipment. (see page 8).
27

Fault Diagnosis
SSyYm
M PpTtO
oMm P oP sO sS iSbI Bl eL ECCaAuUsSeE RReEm
M EeDdYy P aPA
g GeE RReEfF
More than one Air leak Tighten joints or replace components

operation of the Insufficient air pressure Adjust air pressure to within specification 5
trigger needed to Worn or broken jaws Fit new jaws 8
place fastener Low oil level or air in oil Prime tool 26 and 27
Build up of dirt inside the nose assembly Service nose assembly 8†
Tool will not grip Worn or broken jaws Fit new jaws 8 to 12
stem of fastener Build up of dirt inside the nose assembly Service nose assembly 8
Loose jaw housing Tighten against locking ring 8
Weak or broken spring in nose assembly Fit new spring 8 to 12
Incorrect component in nose assembly Identify and replace 9 to 12
Jaws will not release Build up of dirt inside the nose assembly Service nose assembly 8†
broken stem of Jaw housing, nose tip or nose casing
fastener not properly seated Tighten nose assembly 9 to 12
Weak or broken spring in nose assembly Fit new spring 9 to 12
Air or oil leak Tighten joints or replace components
Low oil level or air present in oil Prime tool 26 and 27
Cannot feed next Broken stems jammed inside tool Empty stem collector 7
fastener Check jaw spreader is correct 9 to 12
Adjust air pressure to within specification 5
Slow cycle Low air pressure Adjust air pressure to within specification 5
Build up of dirt inside the nose assembly Service nose assembly 8†
Tool fails to operate No air pressure Connect and adjust to within specification 5
Damaged Trigger Valve 21 Replace 23
Fastener fails to break Insufficient air pressure Adjust air pressure to within specification 5
Fastener outside tool capability Use more powerful Genesis tool
Contact Avdel UK Limited.
Low oil level or air present in oil Prime tool 26 and 27
† Page 17 if a swivel head is used instead of a nose assembly.

Other symptoms or failures should be reported to your local Avdel® authorised distributor or repair centre.
28

Notes
29

Notes
30

Declaration of Conformity
We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY
declare under our sole responsibility that the product:
Model nG3
Serial No. ................................................
to which this declaration relates is in conformity with the following standards:
EN ISO 12100 - parts 1 & 2

BS EN ISO 8662 - part 6 BS EN ISO 11202
BS EN ISO 3744 BS EN 982
ISO EN 792 part 13 - 2000 BS EN 983
following the provisions of the Machine Directive 98/37/EC.
A. Seewraj - Product Engineering Manager - Automation Tools
Date of issue
This box contains a power tool which is in

conformity with Machines Directive
98/37/EC. The ‘Declaration of Conformity’ is
contained within.
31

© 2009 Acument Intellectual Properties, LLC. Printed January 09
AUSTRALIA GERMANY SOUTH KOREA
Acument Australia Pty Ltd. Avdel Deutschland GmbH Acument Korea Ltd.
891 Wellington Road Klusriede 24 212-4, Suyang-Ri,
Rowville, Victoria 3178 30851 Langenhagen Silchon-Eup, Kwangju-City,
Tel: +61 3 9765 6400 Tel: +49 (0) 511 7288 0 Kyunggi-Do, Korea, 464-874
Fax: +61 3 9765 6445 Fax: +49 (0) 511 7288 133 Tel: +82 31 798 6340
Email: [email protected] Email: [email protected] Fax: +82 31 798 6342
Email: [email protected]
CANADA ITALY
Avdel Canada, a Development of Avdel Italia S.r.l. SPAIN
Acument Canada Limited. Viale Lombardia 51/53 Avdel Spain S.A.
87 Disco Road 20047 Brugherio (MI) C/ Puerto de la Morcuera, 14
Rexdale Tel: +39 039 289911 Poligono Industrial Prado Overa
Ontario M9W 1M3 Fax: +39 039 2873079 Ctra. de Toledo, km 7,8
Tel: +1 416 679 0622 Email: [email protected] 28919 Leganés (Madrid)
Fax: +1 416 679 0678 Tel: +34 (0) 91 3416767
Email: [email protected] JAPAN Fax: +34 (0) 91 3416740
Acument Japan Kabushiki Kaisha Email: [email protected]
CHINA Center Minami SKY,
Acument China Ltd. 3-1 Chigasaki-Chuo, Tsuzuki-ku, UNITED KINGDOM
RM 1708, 17/F., Nanyang Plaza, Yokohama-city, Kanagawa Prefecture Avdel UK Limited
57 Hung To Rd., Kwun Tong Japan 224-0032 Pacific House
Hong Kong Tel: +81 45 947 1200 2 Swiftfields
Tel: +852 2950 0631 Fax: +81 45 947 1205 Watchmead Industrial Estate
Fax: +852 2950 0022 Email: [email protected] Welwyn Garden City
Email: [email protected] Hertfordshire
SINGAPORE AL7 1LY
FRANCE Acument Asia Pacific (Pte) Ltd. Tel: +44 (0) 1707 292000
Avdel France S.A.S. #05-03/06 Techlink Fax: +44 (0) 1707 292199
33 bis, rue des Ardennes 31 Kaki Bukit Road 3 Email: [email protected]
BP4 Singapore, 417818
75921 Paris Cedex 19 Tel: +65 6840 7431 USA
Tel: +33 (0) 1 4040 8000 Fax: +65 6840 7409 Avdel USA LLC
Fax: +33 (0) 1 4208 2450 Email: [email protected] 614 NC Highway 200 South
Email: [email protected] Stanfield,
North Carolina 28163
Tel: +1 704 888-7100
Fax: +1 704 888-0258
Email: [email protected]
Manual No. Issue Change Note No.

A 09/014
07900-00930 A2 09/153
Avdel®, Avdelmate®, Avdel® SR, Avex®, Avinox®, Avseal®, Avtainer®, Bulbex®, Genesis®, Interlock®, Klamptite KTR®, Monobolt®, Stavex®,
T-Lok® are trademarks of Avdel UK Limited.
www.avdel-global.com

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Instruction Manual

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Safety Instructions 4 Base Tool

Putting into Service Fault Diagnosis

Servicing the Tool

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1 Do not use outside the design intent.

10 Ensure that vent holes do not become blocked or covered.

11 The operating pressure shall not exceed 7 bar.

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Air Pressure Minimum - Maximum 5-7 bar (72.5 - 101.5 psi)

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nG3 is a hydro-pneumatic tool designed

* ADD 3 DIGITS FROM THE

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AIR LUBRICATION PRESSURE REGULATOR

• Connect the tool to the air supply.

• To minimise air consumption, the trigger should be ‘lifted” to cut-

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• Lightly coat Jaws 4 with Moly Lithium grease*.

• Locate Buffer 6 on Jaw Spreader 5.

• Screw Rear Spring Guide 11 into Chuck Collet 9.

• Any worn or damaged part should be replaced.

• Clean and check wear on Jaws.

• Check Spring 7 is not distorted.

• Assemble according to fitting instructions above.

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FA S T E N E R NOSE TIP (mm) s ee

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FA S T E N E R NOSE TIP (mm) s ee

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FASTENER NOSE TIP (mm) se e

NOSE TIP 1 In inches then in millimetres

FA S T E N E R NOSE TIP (mm) se e

NOSE TIP 1 In inches then in millimetres

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Preparing the Base Tool for use with Stem Deflector

• Loosen Locknut 40 using

• Remove Retaining Nut 35 and the Stem Collector Bottle

• To fit the extension, remove any nose assembly components.

EXTENSION PART NUMBER: 71210-20300

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STRAIGHT SWIVEL HEAD capability

56 92 COMPLETE TOOL PART NUMBER :

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The tool is now ready to be fitted with a 71213-20202

Item numbers in bold refer to the General

RIGHT-ANGLE SWIVEL HEAD capability

(the stop nut and safety cap are included)

IMPORTANT: in contrast to complete tools

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Swivel Head Fitting Instructions

A Fit Locking Ring 10 over Jaw Spreader Housing 41*

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Swivel heads should be serviced at weekly intervals.

• Remove the complete head using the reverse procedure to

• Pay particular attention to jaw carrier items in the upper

• Check that Spring Clip 7 is not distorted. When removing

• Check for excessive wear on slots of Body 5.