Home

Greenlee G3 User's Manual

1. peseq jo 4 1611 SLUWd 00020 2Z 1 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 CO 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 an
2. 17 Monobolt in applications with restricted TLR access See type 4 NOSE TIP table 4 16 4 Al Alloy 71220 16080 12 z 7 7 7 GO Gd 00 CO 00 CO I O ojooooocoooooo No CO 00 Go TO 4 0 Ae r AINW 0 1 8 gt AVINOX ll 1 8 3 2 Stainless Steel 71210 16070 12 3 5 32 14 0 Stainless Steel 07381 04701 12 8 lee 3 16 14 8 Stainless Steel 07498 01401 12 8 3 16 4 8 Steel 07340 06201 12 7 3 3 2 teel Gd 00 OO 05 AVIBULB 71210 16070 7 07381 04701 7 3 16 4 8 Steel 07498 01401 7 ani 07612 02001 12 7 71210 05002 12 7 7 7 7 7 Od E NO Gop Go Go Gd 00 00 CO 71210 16070 3716 48 Any 07348 07001 3 16 4 8 Any 71210 16050 oo C1 00 uu mw CORN 9 OG O O m WwW NO 71220 60001 12 07381 04701 1210 16070 12 3 3 3 16 48 Steel NOSE ASSEMBLY y 32 Stainless Steel part n 71210 15000 ITEM DESCRIPTION PART N 1 NOSE CASING 07340 00306 316 48 Any O RING 07003 00067 164 An 07612 02001 12 1 4 16 CHERRYMATE 07340 06201 JAW HOUSING 07340 00304 1 4 64 An 07612 02001 i KLAMPTITE 3 16 4 8 Any 71220 16060 4 JAWS 71210 15001 KLAMPTITE 3 8 48 2 2 3 4 5 JAW SPREADER 07498 04502 RIVET 3 16 4 8 Al All
3. IB gs I 90 128 10 4 2 1 F 98 5 TYPE 6 COMPLETE TOOL NOSE ASSEMBLY PART NUMBER PRECEDED WITH part n 71230 15800 NOSE TIPS 7122300 DESCRIPTION PART NOSE CASING 07340 00306 O RING 07003 00067 ASE ER NOSE TIP see CHUCK COLLET 07612 02003 NAME l MATERIAL A B above MONOBOLT 71220 16021 14 3 4 1 201 JAWS 07612 02002 INTERLOCK 1 4 6 4 An 07612 02001 114 3 3 61 261 JAW SPREADER 07498 04502 BUFFER 07498 03003 SPRING 07500 00418 LOCKING RING 07340 00327 12 TEXTRON Fastening Systems Inc 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 e 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 O e Fit Stem Deflector 07340 00342 into Adaptor 71213 20101 e Push the assembled Stem Deflector and Adaptor over Bottle SEALED NUT Adaptor 32 and align with the cut out feature 6 71213 02200 ADAPTOR 71213 20101 STEM DEFLECTOR 71213 20100 Preparing the Base Tool for use with Stem Deflector Sealed Nut 71213 02200 replaces Locknut 40 to cut off air supply to Vacuum System as follows e Loosen Locknut
4. 49 511 7288 133 Email info avdel de ITALY Textron Sistemi di Fissaggio SRL Via Manin 350 21 It 20099 Sesto San Giovanni Milano Tel 39 02 262 9171 Fax 39 02 242 4956 Email tfsQtfsitalia com JAPAN Avdel Kabushiki Kaisha 7F New Erimo Building 2 2 1 Senba Nishi Mino Osaka 562 0036 Tel 81 727 30 0838 Fax 81 727 30 0837 Email webadm avdel co jp SOUTH KOREA Textron Fastening Systems Korea 583 1 Munhyung Ri Opo Eup Kwangju City Kyunggi Do Korea 464 890 Tel 82 31 767 4667 9 Fax 82 2 3471 8917 Email paul tfskorea com Change Note No 05 370 05 519 06 536 Inc SPAIN Textron Sistemas de Fijaci n S A C Puerto de la Morcuera s n Poligono Industrial Prado Overa Autovia Madrid Toledo Km 7 8 Es 28916 Leganes Madrid Tel 349 134 16767 Fax 349 134 16740 Email ventas tfs textron com UNITED KINGDOM Textron Fastening Systems Ltd Pacific House 2 Swiftfields Watchmead Industrial Esate Welwyn Garden City Hertfordshire AL7 1LY Tel 44 1707 292000 Fax 44 1707 292199 Email enquiries tfs textron com USA Avdel Cherry Textron Inc 614 NC Highway 200 South Stanfield North Carolina 28163 Tel 1 704 888 7100 Fax 1 704 888 0258 Email info tfsi textron com Textron Fastening Systems HQ 840 West Long Lake Road Suit 450 Troy MI 48098 Tel 1 800 544 6117 Fax 1 815 961 5345 TEXTRON FASTENING SYSTEMS 2001 PRINTED DEC 2005 Textron Fasteni
5. 99 I JA IVA 4399141 88000 80040 I AT8aW3SSV JIQNVH ETOCOETCIZ v9 I ONIY STVOO EOOZLO 02 I AIAWASSY WAS YAISISNALNI OO8EO OTCIZ 9 I ONIH 0 00 lt 00 0 61 1 XIAWASSYV JAVA 330 NO OOLEO OIZIZ c9 ONY O cvE00 00 0 81 I AIAWASSY 38011 YSSSNVUL OO9E0DEZIZ T9 C ONIH 88200 00 0 71 I AT8aW3SSV 10045 JAVA OOVEO OTCIZ 6G I ONIY 8600 00 0 9I I AIAWASSY QV3H OCEEOETCIZ 89 1 ONY v0c00 00 0 SI I AMIAWASSY NOLSId OLLVINNANd OTCEO TECIZ Z8 E ONIY T8200 00 0 VI do 70020120217 96 I ONIH 8 600 00 0 ET C 439N3IIS 00001017 ES I ONIH Z2600 00 0 cI I ONISNOH WAS VOTZODICIZ cS 1 WAS 0 00 0 TI I ONY AGIND GOCEO OTCIZ TS I WAS vZ200 00Z0 60 I LAN NINIYLJY 8cOCOETCIZ OG 1 WAS 600 00 0 80 I 6060 1 6Y I ONIH 600 00 0 70 I 1008 4388fJ 00c0 lec TZ 8v I 1745 040 04 SW v6100 00 0 90 I Nid 4399141 72002001217 9v C ONIH 68100 00 0 S0 I ONIY NOISNAdSNS CcOCOOTCIZ Gv C ONIH 6100 00 0 70 1 55 31V ld dOL OTOCOETCIZ vv I WAS 00 00 0 cO I HJNIVL3H WAS 6TOZO OTCTZ I 4495 ddd 18 GH 134905 SXSIN 60 00 00 0 TO TEXTRON Fastening Systems Inc 27 Parts List for 71223 02000 NOLLdIVISIA v oN LYWd ALO NOR RE TEN Sui9IAJes
6. 07498 03003 07500 00418 07340 00327 1 2 3 4 5 JAW SPREADER 6 7 8 10 TEXTRON Fastening Systems Inc Nose Assemblies Nose Tips FASTENER TYPE 2 l MATERIAL NOSE TIPS NOSE TIP mm PART N E 2 08 08 14 14 16 4 18 3 16 4 8 Aluminium Alloy 07340 02807 12 7 10 0 014 OR Ds 48 steel 10724107101 12711001121 3 16 4 8 Steel 07241 07101 12 7 10 07340 02807 NOSE ASSEMBLY part n 71210 15200 DESCRIPTION 5 32 1 4 0 Steel ITEM PART N I COND 0 NOSE CASING O RING JAW HOUSING JAWS JAW SPREADER BUFFER SPRING LOCKING RING JAW SPREADER HOUSING O RING 07340 02804 07003 00067 07340 00304 71210 15001 07498 04502 71210 05001 07500 00418 07340 00327 71210 02101 07003 00277 3 16 4 8 Steel 07340 02807 1 4 3 2 Stainless Steel 07340 02806 5 321 4 0 Stainless Steel 07340 02807 3 16 4 8 Stainless Steel 07340 02807 14 5 32 4 0 Steel 07340 02807 12 7 10 0 0 15 2 Steel Brass 07340 02807 12 7 10 01 014 1 In inches then in millimetres TYPE 2 NOSE TIPS ARE EXTENDED TO ALLOW ACCESS INTO APPLICATIONS WHERE TYPE 1 NOSE TIPS WILL NOT REACH o omnoomnpoolo n o o o A AR O PO OPOO 0 0 0 0 0 0 0 0 1 1 0 1 1 0 1 8 4 4 8 4 4 8 4 COMPLETE TOOL PART NUMBER precede with 71223 00 Note
7. Items 9 and 10 are not required when assembling Type 2 or Type 3 Nose Tip to the Base Tool nG3 71223 02000 1 2 3 4 5 6 7 8 9 1 TYPE 3 NOSE TIPS NOSE ASSEMBLY part n 71210 15300 DESCRIPTION NOSE CASING O RING JAW HOUSING JAWS JAW SPREADER BUFFER SPRING LOCKING RING JAW SPREADER HOUSING O RING PART N 07344 02001 07003 00067 07340 00304 71210 15001 07498 04502 71210 05001 07500 00418 07340 00327 71210 02101 07003 00277 TYPE 3 NOSE TIPS ARE SPECIFICALLY FOR THE AEROSPACE FASTENERS LISTED BELOW FASTENER 01 MATERIAL 1 8 3 2 Al Alloy 32 Al Alloy O 1 8 3 2 Stainless Steel NOSE TIP mm see PART N below 71210 16030 12 7 71210 16031 12 TIZ OTG OIZA N 00 5 32 4 0 Al Alloy 71210 16033 12 5 32 4 0 Al Alloy O 71210 16034 12 71210 16035 12 71210 16036 1 7 7 7 5 32 4 0 Stainless Steel 7 2 7 71210 16037 12 7 257 2 7 7 7 7 Oo BS NI RO GO NO IRI O9 O1 O1 Co 01101 Gd C9 IN IN NNN 07340 06701 12 07340 06801 12 07340 06901 12 07344 04701 12 07344 04701 12 07344 04701 12 7 4 COMPLETE TOOL PART NUMBER precede with 71223 00 N NP Ko o o 00 00 O COJO O ww N Note Items 9 and 10 are not required when assembling Type 2 or Type 3 Nose Tip to the Base Tool
8. nose tip or nose casing fastener not properly seated Tighten nose assembly 9to12 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 28 and 29 Cannot feed next Broken stems jammed inside tool Empty stem collector 7 fastener Check jaw spreader is correct 9to 12 Adjust air pressure to within specification 5 Slow cycle Low air pressure Adjust air pressure to within specification 9 Build up of dirt inside the nose assembly Service nose assembly 81 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 Textron Fastening Systems Low oil level or air present in oil Prime tool 28 and 29 T Page 17 if a swivel head is used instead of a nose assembly Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 Other symptoms or failures should be reported to your local TFS authorised distributor or repair centre 30 TEXTRON Fastening Systems Inc Declaration of Conformity We Textron Fastening Systems Inc 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 rel
9. 20 Nose Equipment 20 Dismantling the Tool 21 Head Assembly 21 Pneumatic Piston Assembly 22 Air Valve 22 Rotary Valve 23 LIMITED WARRANTY TFS makes the limited warranty that it s 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 TFS of such defect upon inspection and testing TFS makes the foregoing limited warranty for a period of twelve 12 months following TFS delivery of the product to the direct purchaser from TFS 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 TFS 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 TFS Textron Fastening Systems Inc policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice TEXTRON Fastening Systems Inc 3 Safety Instructions This instruction manual must be read with particular attention to the following safety rules by any person installing operating or serv
10. 4 5 8 9 3 4 0 5 0 0 0 7 7 0 1 6 8 6 8 0 1 0 1 8 8 8 8 8 9 9 0 0 1 2 2 2 2 07498 04401 2 03 07498 04401 COMPLETE TOOL PART NUMBER precede with 71213 40 the stop nut and safety cap are included IMPORTANT in contrast to complete tools with nose assemblies those fitted with swivel heads include the nose tip as a part of the head O Oversize TEXTRON Fastening Systems Inc 15 Accessories The fitting and servicing procedures for both types of head are almost identical Differences are clearly indicated IMPORTANT PRIOR to fitting a swivel head the base tool must be adapted See Preparing the base tool opposite The air supply must be disconnected when fitting or removing swivel heads 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 23 o x RIGHT ANGLE HEAD 16 TEXTRON Fastening Systems Inc Fit Locking Ring 10 over Jaw Spreader Housing 41 71210 02101 See pages 26 and 27 Coat Screw 13 with thread locking adhesive and u
11. 40 using 16mm AF Spanner e Unscrew and remove both Jaw Spreader Housing 41 and Pe Locknut 40 Replace Locknut 40 with Sealed Nut 71213 02200 screw Sealed Nut onto Piston 36 to disable Vacuum System e Spreader Housing 41 must be tightened onto Piston 36 finally tightening Sealed Nut against it 07340 00342 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 71210 20302 EXTENSION PART NUMBER 71210 20300 Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 TEXTRON Fastening Systems Inc 13 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 IMPORTANT PRIOR to fitting a swivel head the
12. 6 On 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 Snap Guard 1 over the assembly align screw holes in guard with tapped holes in body assembly Insert Pivot Pin 15 through slots in guard and hole in body Fit Circlip 2 onto pivot pin so that the circlip seats in groove provided Coat the thread of Screws 23 4 off with thread locking adhesive and screw into body assembly securing guard to body assembly Accessories Swivel Head Servicing Instructions Swivel heads should be serviced at weekly intervals e Remove the complete head using the reverse procedure to the Fitting instructions omitting step L e lf Guard 1 is at all damaged it must be replaced by a new one e Any worn or damaged parts should be replaced e 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 e Check that spring clip 7 is not distorted When removing Spring Clip 7 use two screwdrivers as shown in the lower illustration opposite e Check for excessive wear on slots of Body 5 e Assemble according to fitting instructions Item numbers in bold refer to Swivel Head illustrations on this page Guard 1 refers to ill
13. Collector Bottle Assembly 25 See illustration on page 7 Remove Stop Plate Assembly 104 by unscrewing Screws 89 2 off Unscrew Retaining Nut 50 Pull off Bottle Adaptor Assembly 32 together with O Rings 20 and 28 Remove End Cap Assembly 35 together with O Ring 97 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 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 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
14. 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 MAIN SUPPLY DRAIN POINT AIR LUBRICATION B PRESSURE REGULATOR PERMISSABLE AND FILTER DRAIN DAILY Operating Procedure Ensure that the correct nose assembly suitable for the fastener is fitted e Connect the tool to the air supply e Insert the fastener stem into the nose of the tool If using a standard nose assembly the fastener should remain held in by the vacuum system Bring the tool with the fastener to the application so that the protruding fastener enters squarely into the hole of the application e Fully actuate the trigger The tool cycle will broach the fastener and with standard nose assemb
15. nG3 71223 02000 TEXTRON Fastening Systems Inc 11 Nose Assemblies Nose Tips FASTENER NOSE TIP mm see T Y E 4 NAME MATERIAL PART N B below MONOBOLTe 1 4 6 4 Steel 71220 16021 14 314 1 202 N O S E T P 1 n inches then in millimetres CU COMPLETE TOOL NOSE ASSEMBLY part n 71220 15400 PART NUMBER precede with DESCRIPTION PART N DESCRIPTION PART N 71223 00 NOSE CASING 07498 00501 FRONT SPRING GUIDE 07498 00507 O RING 07003 00067 SPRING 07500 02005 FITTED To THIS LONG NOSE CHUCK COLLET 07498 00502 REAR SPRING GUIDE 07498 00503 ASSEMBLY THE TYPE 4 NOSE TIP JAWS 07497 03002 LOCKING RING 07340 00327 WILL ALLOW THE PLACING OF 1 4 MONOBOLT FASTENERS IN APPLICATIONS REQUIRING VERY DEEP ACCESS FASTENER NOSE TIP mm see NAME MATERIAL PART N below AVTAINER 3 8 9 6 Steel 07498 00802 19 1 4 1 243 N O S E T P 1 n inches then in millimetres COMPLETE TOOL NOSE ASSEMBLY part n 71220 15500 PART NUMBER precede with DESCRIPTION PART N ITEM DESCRIPTION PART N 71223 00 NOSE CASING 07498 00501 7 SPRING 07500 02005 O RING 07003 00067 11 REAR SPRING GUIDE 07498 00503 THERE IS ONLY ONE TYPE 5 NOSE CHUCK COLLET 07498 00801 8 LOCKING RING 07340 00327 TIP SPECIFICALLY DESIGNED TO JAWS 07220 02302 12 SIDE EJECTION ADAPTOR 07498 00900 PLACE AVTAINER FASTENERS WITH FRONT SPRING GUIDE 07498 00803 THIS SPECIAL NOSE ASSEMBLY
16. 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 14 to 17 in the Accessories section IMPORTANT The air supply must be disconnected when fitting or removing nose assemblies Item numbers in bold refer to nose assembly components in all 5 nose tip tables ightly coat Jaws 4 with Moly Lithium grease e Drop Jaws 4 into Jaw Housing or Chuck Collet 9 depending on which nose assembly you are using e Insert Jaw Spreader 5 into Jaw Housing or insert Front Spring Guide 10 into Chuck Collet 9 e Locate Buffer 6 on Jaw Spreader 5 e Locate Spring 7 onto Jaw Spreader 5 or onto Front Spring Guide 10 e Screw Rear Spring Guide 11 into Chuck Collet 9 e Fit Locking Ring 8 onto the Jaw Spreader Housing of the tool e Holding tool pointing down screw the assembled Jaw Housing or Chuck Collet onto the Jaw Spreader Housing and tighten with spanner e Screw the nose tip into Nose Casing 1 and tighten with spanner e Place Nose Casing 1 over Jaw Housing 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 an
17. 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 29 Item included in the nG3 Service Kit For complete list see page 20 Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 TEXTRON Fastening Systems Inc 21 servicing the Tool 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 90 3 off and Guide Ring 51 Engage the Seal Extractor into Seal Assembly 63 and withdraw 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 Air Valve Dismantling Remove Pneumatic Piston Assembly 57 as described above in Pneumatic Pist
18. 00 00684 GUIDE TUBE 07900 00677 SEAL EXTRACTOR 07900 00685 INSERTION ROD 07900 00698 STOP NUT 07900 00351 3 MM ALLEN KEY 07900 00700 PRIMING PUMP 07900 00469 2 5 MM ALLEN KEY 07992 00020 GREASE MOLY LITHIUM E P 3753 07900 00158 2 MM PIN PUNCH 07992 00075 GREASE MOLYKOTE 55M 07900 00755 GREASE MOLYKOTE 111 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 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 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 in
19. 1210 16100 71210 16113 Standard amp Low Pressure Flush Nose Tip 71220 16100 71220 16102 NININININININININ Standard amp Low Pressure 2mm Ext Nose Tip 71220 16100 71220 16103 OIN Standard amp Low Pressure 8mm Ext Nose Tip 71220 16100 71220 16104 Low Pressure Al Alloy Flush Nose Tip 71230 15800 71220 16105 Low Pressure Al Alloy 2mm Ext Nose 71230 15800 71220 16106 9 99 o o oo oo oo 11 A o o oo CO Low pressure Al Alloy 8mm Ext Nose Tip 71230 15800 71220 16107 O jan m m NOSE ASSEMBLY part n 71210 16100 ITEM DESCRIPTION PART N COMPLETE TOOL PART NUMBER 1 2 B 4 5 6 7 8 NOSE CASING O RING JAW HOUSING JAWS JAW SPREADER BUFFER SPRING LOCKING RING 07340 00306 07003 00067 07340 00304 71210 16001 07498 04502 71210 05001 07500 00418 07340 00327 NOSE ASSEMBLY part n 71220 16100 precede with 71223 00 ITEM DESCRIPTION PART NOSE CASING O RING JAW HOUSING JAWS 07340 00306 07003 00067 07612 02003 71220 16120 07498 04502 NOSE ASSEMBLY part n 71230 15800 ITEM DESCRIPTION NOSE CASING 0 RING PART N 07340 00306 07003 00067 BUFFER SPRING LOCKING RING 07498 03003 07500 00418 07340 00327 JAW HOUSING JAWS JAW SPREADER BUFFER SPRING LOCKING RING 07612 02003 07612 02002 07498 04502
20. 1213 06600 3 81 07490 04602 220 71213 16402 07340 00213 71213 06100 71213 16403 07340 00213 71213 06700 1 8 3 2 Al Alloy 07345 03300 07340 00213 07340 00229 71213 164042 07345 03301 1 g 13 2 Al Alloy O 07494 03600 07494 03601 l s 13 2 Stainless Steel 07494 03000 07494 03011 07340 00213 5 32 4 0 Al Alloy 07345 03400 07345 03401 07340 00229 5 32 4 0 AI Alloy O 07494 03700 07494 03701 07340 00229 3 16 4 8 Al Alloy 07345 03500 07345 03501 07498 04401 3 16 4 8 Al Alloy 07494 03800 07340 00229 07498 04401 07340 00229 07494 03801 07165 00701 8 13 4 75 2 36 6 35 07165 00702 07340 00229 1 8 13 2 Al Alloy 5 32 4 0 Al Alloy 3 16 4 8 Al Alloy 01 Gy 01 A NA O C O PIO RARO O gt gt 0 0 1 1 1 1 2 2 2 2 2 2 2 3 3 3 0 165 00703 07345 04701 7 92 2 46 07498 04401 0 340 00229 07345 04700 07345 04701 07340 00229 07345 04800 07345 04701 07498 04401 07345 04800 56 __92 a 360 rotation _ 20 1 In inches then millimetres 2 Long nose tip for deep placing 14 TEXTRON Fastening Systems Inc 07345 04701 07498 04401 COMPLETE TOOL PART NUMBER precede with 71213 30 the stop nut and safety cap are included IMPORTANT in contrast to complete tools with nose assemblies those fitted with swivel heads include t
21. E TOTCOOTCIZ Tv I TOAWAS 40098 138V1 0410 700 0 OOT I 1NNY001 EOTCOOTCIZ OV I AdO8 JAVA 66 1 LAN dAVIO 71000012174 6 I ONIY cv000 00 0 86 I JA WA CLOCO ETCTIZ 8 ONIY 86 00 00 0 76 I YANIT YSCNIIAD 80002016017 LE I 89200 00 0 96 I NOLSId QV3H 10210062217 9 I ONIYdS 20060076 0 16 1 55 AVI ANd GCOCOETCIZ GE WAS dil 7 200500 0 06 I 1V3S ANWA 600c001c1Z ve MAHOS 44900 10040 68 I AIAWASSY 4399141 80002061217 EE I LAN 90 IAN SIN 86000 20020 08 I AT8IN3SSV YOldYAY 411108 OOOEO ETCTIZ cE I MAHOS MNNSYALNNOD 6T X GN 70100162017 6L 1 4 ASV c00cO Tec TZ TE I L3NOVIN 31Od 3H1N39 6610 0040 ZZ I Q3NIHOVIN AGO 10004062217 OE 43HSVM 9100 200 0 9Z C YAHSVM 9NITV3S 90000122147 6c I 08600 00 0 SZ I ONIY 91700 lt 00 0 MAYOS TIN 1519345 20100122124 YL I NOLSId ddVL 9NINSV38 22002061217 Le C LAN ONINIVLSY ONITINOW 0T0c TeclZ El I OY NOLSId 34 1 9 TCOCOETCIZ 9c I ONIGINOW YSALNNOO TOTOC TCCIL eZ 1 455 311108 801941109 WALS OO8EO ETCTZ Sc I YALNNOO GAISIGOW 40102 1221 TZ 10 45 uuo rxvig WWE 72200700 0 vc LAN OTAN 9N 8010070070 Z9 1 25 318IX314 9 01000 800 0 C ONIY 720000070 99 I Ofrld dSd 8 T 7 210500 0 22 I AIAWASSY 31V ld 3SV8 71040120217
22. Head Piston 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 reaches specification If not repeat above procedure Switch OFF air supply and refit nose equipment see page 8 Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 TEXTRON Fastening Systems Inc 29 Fault Diagnosis Symptom Possible Cause Remedy Page Ref 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 28 and 29 Build up of dirt inside the nose assembly Service nose assembly 81 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 81 broken stem of Jaw housing
23. TEXTRON Fastening Systems Inc Instruction Manual Genesis G3 model Hydro Pneumatic Power Tool Textron Fastening Systems Inc is a wholly owned subsidary of Textron Inc 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 2 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 Instructions 8 Nose Tips 9 12 Type 1 Standard 9 Avseal Nose Tips 10 Type 2 Limited Access 11 Type 3 Aerospace 11 Type 4 Monobolt Extended 12 Type 5 Avtainer 12 Type 6 Monobolt Interlock 12 Accessories Stem Deflector 13 Preparing the Base Tool for use with Stem Deflector 13 Extension 13 Swivel Heads 14 Straight Swivel Head capability 14 Preparing the Base Tool for Right Angle and Straight L5 Swivel Head Attachment Right Angle Swivel Head capability 15 Swivel Head Fitting Instructions 16 Swivel Head Servicing Instructions 17 Constant Components 17 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
24. ates is in conformity with the following standards EN ISO 12100 parts 1 amp 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 89 392 EC as amended by Directive 91 368 EC 93 44 EC as superceded by 98 37 EC and 93 68 EC Seewraj Product Engineering Manager Automation Tools Date of issue This box contains a power tool which is in C 4 conformity with Machines Directive 89 392 EC The Declaration of Conformity is contained within TEXTRON Fastening Systems Inc 31 TEXTRON Fastening Systems AUSTRALIA Textron Fastening Systems Pty Ltd 891 Wellington Road Rowville Victoria 3178 Tel 613 9765 6400 Fax 613 9765 6445 Email custserv textronfast com au CANADA Avdel Division of Textron Canada Ltd 87 Disco Road Rexdale Ontario M9W 1M3 Tel 1 416 679 0622 Fax 1 416 679 0678 Email info tfs textron com CHINA Textron Fastening Systems China Ltd Room 1708 Nanyang Plaza 57 Hung To Road Kwun Tong Kowloon Hong Kong Tel 852 2950 0630 Fax 852 2950 0022 Email tfschinaQtfschina com FRANCE Avdel s a 33 bis rue des Ardennes BP4 75921 Paris C dex 19 Tel 33 1 4040 8000 Fax 33 1 4040 8040 Email avpcomQtfs textron com Manual No 07900 00842 GERMANY Textron Verbindungstechnik GmbH Klusriede 24 D 30851 Langenhagen Tel 49 511 7288 0 Fax
25. 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 FASTENER MATERIAL 3 2 Al Alloy SWIVEL HEAD PART N 07345 03000 NAME 1 8 NOSE TIP mm PART N 07345 03600 7 87 JAWS see B PART N below 1 ae 07340 00213 o o 1 8 3 2 Steel 07345 03100 07345 03700 07340 00213 9 32 4 0 AI Alloy 07345 03100 07345 03700 3 32 4 0 Steel 07345 03200 07340 00213 07345 03800 07490 04602 3 16 4 8 Al Allo 07345 03200 07345 03800 07490 04602 AVINOX Il 0 0 1 i 1 ETE 07345 03100 07345 03700 07340 00213 3 16 4 8 Al Allo 07345 03200 07345 03800 7 87 3 81 07490 04602 01 0 1 0 0 0 0 0 0 AVSEAL Il 71213 06000 Stainless Steel 07345 03100 07345 03700 5 32 4 0 Stainless Steel 07345 03200 07345 03800 3 16401 71213 07340 00213 7
26. ble 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 No first aid should be needed INGESTION No first aid should be needed EYES No first aid should be needed INHALATION No first aid should be needed Fire FLASH POINT Above 101 1 C closed cup Explosive Properties No Suitable Extinguishing Media Carbon Dioxide Foam Dry Powder or fine water spray Water can be used to cool fire exposed containers Environment No adverse effects are predicted Handling General ventilation is recommended Avoid eye contact Storage Do not store with oxidizing agents Keep container closed and store away from water or moisture TEXTRON Fastening Systems Inc 19 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 N DESCRIPTION PART N DESCRIPTION 07900 00667 PISTON SLEEVE 07900 00164 CIRCLIP PLIERS 07900 00692 TRIGGER VALVE EXTRACTOR 07900 00008 7 16 x 1 2 SPANNER 07900 00670 BULLET 07900 00012 16 x 8 SPANNER 07900 00672 T SPANNER 07900 00015 3 8 x 11 16 SPANNER 07900 00706 T SPANNER SPIGOT 07900 00686 PEG SPANNER 079
27. d nose tips as they will need regular replacement e Remove the nose equipment using the reverse procedure to the Fitting instructions e Any worn or damaged part should be replaced e Clean and check wear on Jaws e Ensure that neither the Jaw Spreader nor the Front Spring Guide is distorted e Check Spring 7 is not distorted e Assemble according to fitting instructions above Item included in the nG3 Service Kit For complete list see page 20 8 TEXTRON Fastening Systems Inc Nose Assemblies Nose Tips TYPE 1 ee gi MATERIAL PART N eee AVEX Al Alloy 71210 05002 NOSE TIPS Steel 71210 16070 1 n inches then in millimetres o o w O00 Al Alloy 71210 16070 Steel 07381 04701 Al Alloy 07340 065012 Al Alloy 07381 04701 Al Alloy 07340 04800 Steel 07490 04401 Al Alloy 07340 066012 Al Alloy 07340 064012 Al Alloy 71210 05002 2 Head forming nose tips for use with countersunk heads ONLY NIN NI NI NI NIJ NI Bm T bw 00 l O OD O O h5 Co BS Gol Go nm no O m e Ol O O Go E 1 4 16 4 Al Allo 07612 02001 12 7 3 MONOBOLTe 3 16 4 8 Any 71210 16020 112 714 1 200 In ADDITION to the nose assembly shown below BULBEX 5 32 4 0 Al Alloy 71210 16070 112 71 3 3 an extra long nose assembly is available to place BULBEXe orga TOL 12 7 2387
28. d 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 DESCRIPTION 07900 00351 3mm ALLEN KEY 07900 00700 PRIMING PUMP 07900 00224 4mm ALLEN KEY 28 TEXTRON Fastening Systems Inc Priming Priming Procedure IMPORTANT DISCONNECT THE TOOL FROM THE AIR SUPPLY OR SWITCH OFF AT VALVE 55 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
29. ean 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 e 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 e Check that the nose assembly or swivel head is correct for the fastener to be placed e Check the stroke of the tool meets the minimum specification page 5 The last step of the Priming Procedure on page 29 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 e Check that Base Cover 31 is fully tightened onto Body 30 e Stem Collector Bottle O Rings 20 and 28 to be cleaned and lubricated with Molykote 55m Weekly e 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 19 First Aid SKIN As the grease is completely water resistant it is best removed with an approved emulsify
30. he airline from the tool machine inlet before attempting to adjust fit or remove a nose assembly Do not operate a tool machine that is directed towards any person s or the operator Always adopt a firm footing or a stable position before operating the tool machine Ensure that vent holes do not become blocked or covered The operating pressure shall not exceed bar Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise Care shall be taken to ensure that spent stems are not allowed to create a hazard Vacuum Air MUST be turned off using the Trigger before removing the Stem Collector Bottle which Must be emptied when half full The Tool MUST NOT be operated with the Stem Collector Bottle removed 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 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 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 When carrying the tool from place to place keep hands away from the t
31. he nose tip as a part of the head O Oversize Accessories Disconnect the air supply Remove any nose assembly items Remove Stem Collector Bottle Assembly 25 71213 03800 Replace assembly 25 with Safety Cap 71213 20201 Unscrew Jaw Spreader Housing 41 and remove with O Ring 12 Locknut 40 O Rings 19 15 and Seal Housing 52 Do not refit these items Screw Stop Nut 71213 20200 onto the front of Head Piston 36 as far as it will go by hand Fit Jaw Spreader Housing 41 and O Ring 12 tighten onto Head Piston 36 finally tighten Stop Nut against Jaw Spreader Housing 41 The tool is now ready to be fitted with a swivel head see page below Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 Base tool to receive a nose assembly RIGHT ANGLE FASTENER MATERIAL 07346 03000 NOSE TIP mm PART N 07345 03600 17 8 Preparing the Base Tool for Right Angle and Straight Swivel Head Attachment View with 25 removed and stop nut replacing removed items 19 15 52 40 JAWS see B PART below 3 81 m 07340 00213 0 346 03100 07345 03700 07340 00213 07346 03100 07345 03700 07340 00213 07346 03200 07345 03800 07490 04602 07346 03200 4 6 0 07345 03800 07490 04602 07346 03200 0737503700 3 3 07340 00 007 07345 03800 07490 04602 EIR AVSEAL Il 1 In inches then in mi
32. icing this tool 1 2 3 10 11 12 13 14 15 16 17 18 19 20 Do not use outside the design intent Do not use equipment with this tool machine other than that recommended and supplied by Textron Fastening Systems Inc Any modification undertaken by the customer to the tool machine nose assemblies accessories or any equipment supplied by Textron Fastening Systems Inc or their representatives shall be the customer s entire responsibility Textron Fastening Systems Inc will be pleased to advise upon any proposed modification 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 Textron Fastening Systems Inc procedures Do not dismantle this tool machine without prior reference to the maintenance instructions Please contact Textron Fastening Systems Inc with your training requirements 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 Textron Fastening Systems The precautions to be observed when using this tool machine must be explained by the customer to all operators Always disconnect t
33. ing 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 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 26 and 27 18 TEXTRON Fastening Systems Inc 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 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 negligi
34. lies the broken stem will be projected to the rear of the tool into the collector bottle Do not use tool when Stem Collector Bottle is removed e 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 e 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 Lift Trigger to cut off the vacuum air supply TEXTRON Fastening Systems Inc Nose Assemblies Fitting Instructions IMPORTANT Nose assemblies do NOT include nose tips Nose tips must be ordered separately A complete tool must always be fitted with the correct nose assembly and nose tip for your fastener and must be ordered separately refer to the NOSE TIPS tables on pages 9 to 12 If your application presents no access restriction use a Type 1 Nose Tip unless you are placing aerospace fasteners which requires a Type 3 Nose Tip or Avtainer fasteners a Type 5 Nose Tip 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
35. llimetres 71213 04000 07340 00213 07346 03100 07345 03700 07340 00213 07346 03200 07345 03800 17 87 3 81 07490 04602 0 1040 6 35 99 71213 04700 71213 16402 07340 00213 71213 04100 71213 16403 07340 00213 71213 04800 71213 164042 07340 00213 1 8 3 2 Steel 07346 03100 07345 03700 07340 00213 5 32 4 0 Steel 07346 03200 07345 03800 07490 04602 07346 03100 1 8 3 07346 03200 07345 03700 07345 03800 07345 03301 1 8 2 07494 03601 07340 00229 07495 03000 07494 03011 07340 00213 07346 03400 07345 03401 07340 00229 07494 03701 07340 00229 Ol O w Co Gd GO Co S n5 A 07346 03500 07345 03501 07498 04401 3 07495 03800 07346 04000 07494 03801 07165 00701 4 75 07340 00213 07490 04602 07498 04401 07340 00229 07346 04100 07165 00702 6 35 07340 00229 1614 ini 1 g 3 2 Aluminium Alloy 5 32 4 0 Aluminium Alloy 3 16 4 8 Aluminium Allo 07346 04200 0 346 04500 07165 00703 22 07345 04701 1 81 07498 04401 07340 00229 5 32 4 0 Aluminium Alloy 07346 04500 07345 04701 07340 00229 07345 04701 7 87 2 03 5 32 14 0 Aluminium Alloy O 07346 04600 3 16 4 8 Aluminium Alloy 360 rotation 07346 04600 2 Long nose tip for deep placing 07345 04701 7 87 4 0 0 0 1 1 4 0 4 0
36. ly 44 together with Tie Rods 56 Transfer Tube Assembly 61 Seperate Body 30 from Handle Assembly 64 Remove O Rings 16 and 17 e Seperate Head Assembly 58 from Handle Assembly 64 NOTE ORIENTATION OF ROTARY VALVE 38 Push out Rotary Valve 38 together with O Rings 5 Assemble in reverse order to Dismantling Instructions noting the following e 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 33 See illustration below Trigger Dismantling Using a 4mm pin punch 07900 00158 drive Trigger Pin 46 out and remove Trigger 33 e Unscrew Trigger Valve 21 using trigger valve extractor 0900 00692 Assemble in reverse order to Dismantling Instructions noting the following e When assembling Trigger 33 the trigger forks locate on the pins each side of the Rotary Valve 38 e Ensure Rotary Valve 38 is orientated correctly See illustration below Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 TEXTRON Fastening Systems Inc 23 servicing the Tool Stop Plate Assembly 71213 03900 Assembly see illustration below e Place O Ring 2 into the recess in Housing 5 retain in position using grease Molykote 55 e Assemble O Ring 4 onto Piston 1 and push assembly into Housing 5 making sure it is in as far as it will go Position the
37. ng Systems Inc is a subsidiary of Textron Inc Avdel Avdel SR Avex Avibulb Avinox Avseal Bulbex Genesis Interlock MBC MBC LC Monobolt Stavex T Lok TLR are trademarks of Textron Inc www avdel textron com TEXTRON Fastening Systems Inc
38. on Assembly Using Spanner 07900 00672 and Location Spigot 07900 00671 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 30 from Handle Assembly 64 Remove O ring 17 Push out the Valve Seat 34 from the Body 30 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 amp 55M Grease Apply Loctite 243 to Clamp Nut 39 and tighten to torque 11ftlb 14 91 Nm 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 nG3 Service Kit For complete list see page 20 Item numbers in bold refer to the general assembly drawing and parts list on pages 26 and 27 22 TEXTRON Fastening Systems Inc servicing the Tool Rotary Valve Dismantling e Using a 4mm pin punch 07900 00158 drive Trigger Pin 46 out and remove Trigger Assembly 33 e Remove Pneumatic Piston Assembly 57 as described in Pneumatic Piston Assembly see page 22 e Using Spanner 07900 00672 and Location Spigot 07900 00671 unscrew Clamp Nut 39 and remove together with Top Plate Assemb
39. oy 6 7 8 O O OOO O NINO eH o H m eO O O 0 OOOO A i 3 16 4 8 Al Alloy CE 48 Al Alloy Steel 703 A 25 6T SPRING 07500 00418 3 16 4 8 Al Alloy Steel 703 B 26 l 4 LOCKING RING 0734000327 EGEL 1 4 6 4 Al Alloy Steel 743 25 8 1 4 16 4 Al Alloy Steel 743 B 26 OY OY OV OF OV OF OY OD OYOY OY OF GO Go GO GO COMPLETE TOOL PART NUMBER precede with 71223 00 TEXTRON Fastening Systems Inc 9 Nose Assemblies Nose Tips AVSEAL II NOSE TIPS FASTENER NAME 0 MATERIAL NOSE TIP mm NOSE ASSEMBLY AVSEALSII Standard Al Alloy Flush Nose Tip 71210 16100 PART N CB 2 71210 16104 below Standard Al Alloy 2mm Extended Nose Tip 71210 16100 71210 16108 Standard Al Alloy 8mm Extended Nose Tip 71210 16100 71210 16112 m Standard Al Alloy Flush Nose Tip 71210 16100 71210 16114 Standard Al Alloy 2mm Extended Nose Tip 71210 16100 71210 16115 Standard Al Alloy 8mm Extended Nose Tip 71210 16100 71210 16116 Standard Al Alloy Flush Nose Tip 71210 16100 71210 16105 Standard Al Alloy 2mm Extended Nose Tip 71210 16100 71210 16109 Standard Al Alloy 8mm Extended Nose Tip 7
40. rigger lever to avoid inadvertent start up Excessive contact with hydraulic fluid oil should be avoided To minimize the possibility of rashes care should be taken to wash thoroughly 21 C O S H H data for all hydraulic oils and lubricants is available on request from your tool supplier 4 TEXTRON Fastening Systems Inc 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 Q 5 5 bar 12 9 kN 2900 Ibf Cycle Time Approximately 1 2 seconds Noise Level 75 dB A Weight Including nose equipment 2 25 Kg Vibration Less than 2 5 m s 8 2 ft s Tool Dimensions 123 30 00 12 2 Y 320 156 xy DN BD Note Stem Collector Short Version Bottle is an accessory part number 71213 03810 Dimensions in millimetres TEXTRON Fastening Systems Inc 9 Intent of Use Range of Fasteners nG3 is a hydro pneumatic tool designed to place Avdel breakstem fasteners at MINE LANA 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 FASTENER SIZE STAVEX The tool features a vacuum system for AVINOX fastener retention and trouble free AVIBULB6 collection of the spent
41. se to secure Nose Tip 14 onto Body 5 Lightly lubricate items 17 18 19 20 and insert into Jaw Carrier 3 as shown Secure with Screws 16 Position Lever 4 into Body 5 and hold in place with pin 15 through the hole of Body 5 not a slot Lubricate the sides of the Jaw Carrier Assembly and insert into Body 5 Lubricate Rollers 8 and ENSURE that they will freely rotate in the holes of Adaptor 9 If necessary ream the holes Position Spring Clip 7 over Adaptor 9 past the holes for the rollers and rotate until the locating peg is aligned with the corresponding hole in Adaptor 9 smallest hole Fit Adaptor 9 over the end of Body 5 and drop Rollers 8 into place Push Spring Clip 7 over Rollers 8 Insert Spindle 11 through Adaptor 9 into Jaw Carrier 3 until the hole lines up with slot in Body 5 Temporarily hold in place with Pin 6 Insert Pin 12 through the front slot of Body 5 into Jaw Carrier 3 Hold the assembly vertical to prevent all pins dropping out and slide the jaw carrier assembly back and forth a few times to ensure free movement Go to M Remove Screws 23 4 off and guard 1 On a straight swivel head also remove Screw 21 and Platform 22 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 straight swivel Tighten gently with a tommy bar Screw the assembly over Spindle 11 onto the tool handle Replace Pin s
42. slot in Piston 1 parallel to the step face in Housing 5 e Slide Plate Shut Off 3 into the assembled parts 1 2 4 and 5 Retain parts in place using grease Molykote 55 o Place O Ring 4 into the recess of Cover Plate 6 retain in position using grease Molykote 55 Place spring 7 into position locate using the recesses in both Plate Shut Off 3 and Bottle Adaptor Assembly 32 Position the above assembled parts onto Bottle Adaptor Assembly 32 e Secure in position using two Screws 89 see pages 26 and 27 ITEM PART No DESCRIPTION 71213 03901 PISTON 07003 00412 O RING 71213 03902 PLATE SHUT OFF 07003 00411 ORING 71213 03904 HOUSING 71213 03905 COVER PLATE 71213 03906 SPRING Ppoo8 989008 08 peooooooee CLOSED 24 TEXTRON Fastening Systems Inc Notes TEXTRON Fastening Systems Inc 25 9 06 Assy G9 Assy 06 LG Assy T9 Assy LE LL O O O O I N E X 118190 qp AS Assy 9 LT NA SRL a O 44 Assy v9 gt L 96 68 0S 0 ze 6 n IZ E 3uly lt 4 Assy GZ Assy YOT S s CD 8c T 16 X If 91892 88 CS 26 TEXTRON Fastening Systems Inc I AIAWASSY 31V ld 4015 OO6EO ETCTZ VOT I 3A33 1S INANOVA cOTCOOCCTL ev I TWWANVIN NOILONYLSNI TOOL 27800 00670 EOL 1 ONISNOH 430V34dS MV
43. stems regardless of tool orientation ETR BULBEX A complete tool is made up of T LOK Gain ee AVDELS SR pp y MONOBOLT diagram below INTERLOCK TLR AVTAINER AVDEL MBC MBC LC NOSE EQUIPMENT must BE FITTED AS DESCRIBED ON PAGE 8 Q RIVET T RIVET CHERRYMATE KLAMPTITE Part Numbering 1 The part number of the base tool remains the same whichever nose assembly or nose tip is fitted See the General Assembly pages 26 27 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 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 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 restricted some extended nose tips are available See table pages 11 and 12 NOSE TIP see note 3 COMPLETE TOOL 71223 00 ADD 3 DIGITS FROM THE LAST COLUMN OF A NOSE TIP TABLE ON PAGE 9 12 FOR TOOLS WITH SWIVEL HEADS USE TABLE PAGES 14 ne 15 6 TEXTRON Fastening Systems Inc Putting into
44. structions 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 e Unscrew Nose Casing 1 and Nose Tip e Unscrew Jaw Housing 3 and remove Jaws 4 Jaw Spreader 5 Spring 7 and Buffer 6 e 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 e Insert Jaws 4 Jaw Spreader 5 Spring 7 and Buffer 6 into Jaw Housing 3 and assemble onto Jaw Spreader Housing 41 e 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 25 20 TEXTRON Fastening Systems Inc servicing the Tool Dismantling the Tool 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 Twist and pull off Stem
45. ustration 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 jaws part numbers see within the table on pages 9 to 12 CONSTANT COMPONENTS DESCRIPTION STRAIGHT SWIVEL RIGHT ANGLE SWIVEL 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 TEXTRON Fastening Systems Inc 1 servicing the Tool IMPORTANT Read Safety Instructions on page 4 The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel The operator should not be involved in maintenance or repair of the tool unless properly trained The tool shall be examined regularly for damage and malfunction Daily e Daily before use or when first putting the tool into service pour a few drops of cl

Greenlee G3 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents