Summary of the content on the page No. 1
Inc.
Instruction Manual
®
Genesis model
Hydro-Pneumatic Power Tool
Textron Fastening Systems Inc. is a wholly owned subsidary of Textron Inc.
G3
Summary of the content on the page No. 2
Summary of the content on the page No. 3
Contents Safety Instructions 4 Trigger 23 Stop Plate Assembly (71213-03900) 24 Specifications Tool Specification 5 General Assembly of Base Tool Tool Dimensions 5 General Assembly 26 Parts List 27 Intent of Use Range of Fasteners 6 Priming Part Numbering 6 Oil Details 28 ® Hyspin VG 32 Oil Safety Data 28 Putting into Service Priming Kit 28 Air Supply 7 Priming Procedure 29 Operating Procedure 7 Fault Diagnosis Nose Assemblies Symptom, Possible Cause and Remedy 30 Fitting Instructions 8 Servicing I
Summary of the content on the page No. 4
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 Textron Fastening Systems Inc. 3 Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Textron Fastening Systems Inc. or their
Summary of the content on the page No. 5
Specifications Tool Specification 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 2 2 Vibration Less than 2.5 m/s (8.2 ft/s ) Tool Dimensions Note: Stem Collector Short Version Bottle is an accessory part number 71213-03810. Dimensions in millimetres Inc. 5
Summary of the content on the page No. 6
Intent of Use Range of Fasteners nG3 is a hydro-pneumatic tool designed MM FASTENER SIZE ( ) IN ® to place Avdel breakstem fasteners at FASTENER 3 3.2 4.0 4.3 4.8 5 5.2 6 6.4 6.5 7 8 9 9.5 10 high speed making it ideal for batch or NAME flow-line assembly in a wide variety of 1 5 3 1 3 – /8 /32 – /16–– – /4 –– –– /8 – applications throughout all industries. It ® ● ● ● ● ● AVEX can place all fasteners listed opposite. ® ● ● ● STAVEX The tool features a vacuum system for AVINOX® ● ● ● fast
Summary of the content on the page No. 7
16 14 12 10 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 high
Summary of the content on the page No. 8
Nose Assemblies Fitting Instructions IMPORT ANT 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 unless you are placing aerospace fasteners which requires a ® Type ‘3’ Nose Tip or Avtainer fasteners a Type 5 Nose
Summary of the content on the page No. 9
Nose Assemblies Nose Tips see FASTENER NOSE TIP (mm) 1 NAME Ø MATERIAL PART Nº 'A' 'B' below TYPE 1 ® 1/ AVEX 8 3.2 Al Alloy 71210-05002 12.7 4.8 …001 1 / 3.2 Steel 71210-16070 12.7 3.3 …004 8 2 1/ Al Alloy 8 3.2 07340-06401 12.7 2.9 …003 NOSE TIPS – 3.0 Al Alloy 71210-05002 12.7 6.35 …001 5 / Al Alloy 32 4.0 71210-16070 12.7 3.3 …004 1 5 In inches then in millimetres. / 4.0 Steel 07381-04701 12.7 2.8 …010 32 2 5 2 / Al Alloy 32 4.0 07340-06501 12.7 3.3 …009 Head forming nose tips for use with
Summary of the content on the page No. 10
Nose Assemblies Nose Tips ® AVSEAL II NOSE TIPS see FASTENER NOSE TIP (mm) NOSE below NAME Ø MATERIAL ASSEMBLY PART Nº 'A' 'B' ® – Standard Al. Alloy - Flush Nose Tip AVSEAL II 6.0 71210-16100 71210-16104 12.7 2.5 … 407 – 6.0 Standard Al. Alloy - 2mm Extended Nose Tip 71210-16100 71210-16108 12.7 5.4 … 408 Standard Al. Alloy - 8mm Extended Nose Tip – 6.0 71210-16100 71210-16112 12.7 11.4 … 409 – Standard Al. Alloy - Flush Nose Tip … 413 6.5 71210-16100 71210-16114 12.7 2.5 Standard Al. Alloy - 2
Summary of the content on the page No. 11
Nose Assemblies Nose Tips see FASTENER NOSE TIP (mm) 1 below NAME Ø MATERIAL PART Nº 'A' 'B' TYPE 2 ® 1/ AVEX 8 3.2 Aluminium Alloy 07340-02805 9.5 12.95 …002 1 / 3.2 Steel 07340-02806 9.5 11.4 …008 8 5 / Aluminium Alloy NOSE TIPS 32 4.0 07340-02806 9.5 11.4 …008 5 / 4.0 Steel 07340-02807 12.7 10.0 …014 32 3 / 16 4.8 Aluminium Alloy 07340-02807 12.7 10.0 …014 3 / 4.8 Steel 07340-07301 12.7 11.8 …018 16 5 BULBEX® / 32 4.0 Aluminium Alloy 07340-02806 9.5 11.4 …008 3 /16 4.8 Aluminium Alloy 07340-0
Summary of the content on the page No. 12
Nose Assemblies Nose Tips FASTENER NOSE TIP (mm) see 1 below NAME Ø MATERIAL PART Nº 'A' 'B' TYPE 4 1 ® / 6.4 Steel 71220-16021 14.3 4.1 …202 MONOBOLT 4 1 In inches then in millimetres NOSE TIP COMPLETE TOOL A PART NUMBER : NOSE ASSEMBLY part nº 71220-15400 precede with B 71223-00 ITEM DESCRIPTION PART Nº ITEM DESCRIPTION PART Nº 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 SPR
Summary of the content on the page No. 13
36 Accessories Stem Deflector The stem deflector is a very simple alternative to the standard stem STEM DEFLECTOR collector and allows access in restricted areas. To replace the stem 07340-00342 collector with the stem deflector proceed as follows: • A partial rotation and pull movement removes the collector bottle. The Trigger should be lifted to cut-off the vacuum supply air prior to removing the collector bottle. • Fit Stem Deflector (07340-00342) into Adaptor (71213-20101). SEALED NUT • Push th
Summary of the content on the page No. 14
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 a
Summary of the content on the page No. 15
20 Accessories Preparing the Base Tool for Right-Angle and Straight Swivel Head Attachment • Disconnect the air supply. Base tool to receive a nose assembly • Remove any nose assembly items. • Remove Stem Collector Bottle Assembly 25 41 12 40 52 (71213-03800). • Replace assembly 25 with Safety Cap (71213-20201) • 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)
Summary of the content on the page No. 16
Accessories The fitting and servicing procedures for both types of head are almost identical. Differences are clearly indicated. IMPORT ANT 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 individu
Summary of the content on the page No. 17
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 Tube 18 is not distorted. Che
Summary of the content on the page No. 18
Servicing the Tool IMPORT ANT 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
Summary of the content on the page No. 19
Servicing the Tool ® 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
Summary of the content on the page No. 20
Servicing the Tool Service Kit For an easy complete service, Textron Fastening Systems Inc 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 07900-00164 CIRCLIP PLIERS 7 1 07900-00692 TRIGGER VALVE EXTRACTOR 07900-00008 /16 x /2 SPANNER 9 5 07900-00670 BULLET 07900-00012 /16 x /8 SPANNER 5 11 07900-00672 'T' SPANNER 07900-00015 /8 x /16 SPANNE
