Inc. Instruction Manual G3 Genesis ® model H y d ro - P n e u m a t i c P o w e r To o l Textron Fastening Systems Inc. is a wholly owned subsidary of Textron Inc.
Contents Safety Instructions 4 Trigger Stop Plate Assembly (71213-03900) 23 24 Specifications Tool Specification Tool Dimensions 5 5 General Assembly of Base Tool General Assembly Parts List 26 27 Intent of Use Range of Fasteners Part Numbering 6 6 Putting into Service Air Supply Operating Procedure 7 7 Priming Oil Details Hyspin® VG 32 Oil Safety Data Priming Kit Priming Procedure 28 28 28 29 Fault Diagnosis Symptom, Possible Cause and Remedy 30 Nose Assemblies Fitting Instructions Servicin
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.
Specifications To o l S p e c i f i c a t i o n Air Pressure Minimum - Maximum 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 Noise Level 5-7 bar (72.5 - 101.5 psi) 1.2 seconds 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 Note: Stem Collector Short Version Bottle is an accessory part number 71213-03810.
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 flow-line assembly in a wide variety of applications throughout all industries. It can place all fasteners listed opposite. FASTENER SIZE ( FASTENER NAME 3 3.2 4.0 4.3 4.8 – 1/8 5/32 AVEX ® ● AVINOX ® AVIBULB ® ETR BULBEX ® A complete tool is made up of three separate elements which will be supplied individually. See diagram below.
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.
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 unless you are placing aerospace fasteners which requires a Type ‘3’ Nose Tip or Avtainer® fasteners a Type 5 Nose Tip.
Nose Assemblies Nose Tips FASTENER MATERIAL Ø1 1/8 3.2 Al Alloy 1/8 3.2 Steel 1/8 3.2 Al Alloy – 3.0 Al Alloy 5 / 32 4.0 Al Alloy 5 / 32 4.0 Steel 5 / 32 4.0 Al Alloy 3 / 16 4.8 Al Alloy 3 / 16 4.8 Al Alloy Large flange 3 / 16 4.8 Steel 3 / 16 4.8 Al Alloy 1/4 6.4 Al Alloy MONOBOLT® 3/16 4.8 Any 5 / 32 BULBEX ® 4.0 Al Alloy 3 / 16 4.8 Al Alloy 3 / 16 4.8 Al Alloy TLR ® 1/4 6.4 Al Alloy 1 /8 AVINOX ® II 3.2 Stainless Steel 5 / 32 4.0 Stainless Steel 3 / 16 4.8 Stainless Steel – T-LOK ® 4.3 Steel 3/ 16 4.
Nose Assemblies Nose Tips A V S E A L ®I I NOSE TIPS NAME AVSEAL ®II FASTENER MATERIAL Ø – 6.0 Standard Al. Alloy - Flush Nose Tip – 6.0 Standard Al. Alloy - 2mm Extended Nose Tip – 6.0 Standard Al. Alloy - 8mm Extended Nose Tip – 6.5 Standard Al. Alloy - Flush Nose Tip – 6.5 Standard Al. Alloy - 2mm Extended Nose Tip – 6.5 Standard Al. Alloy - 8mm Extended Nose Tip – 7.0 Standard Al. Alloy - Flush Nose Tip – 7.0 Standard Al. Alloy - 2mm Extended Nose Tip – 7.0 Standard Al.
Nose Assemblies Nose Tips FASTENER MATERIAL Ø1 1/8 3.2 Aluminium Alloy 1/8 3.2 Steel 5 / 32 4.0 Aluminium Alloy 5 / 32 4.0 Steel 3 / 16 4.8 Aluminium Alloy 3 / 16 4.8 Steel 5 / 32 BULBEX ® 4.0 Aluminium Alloy 3 / 16 4.8 Aluminium Alloy – T-LOK ® 4.3 Steel 3 / 16 4.8 Steel 1/8 STAVEX ® 3.2 Steel 5 / 32 4.0 Steel 3 / 16 4.8 Steel 1/8 3.2 Stainless Steel 5 / 32 4.0 Stainless Steel 3 / 16 4.8 Stainless Steel AVIBULB ® 1/8 3.2 Steel 5 / 32 4.0 Steel – E.T.R 5.
Nose Assemblies Nose Tips TYPE 4 NOSE TIP NAME MONOBOLT® FASTENER MATERIAL Ø1 1/4 6.4 Steel NOSE TIP (mm) see PART Nº 'A' 'B' b e l o w 7 1 2 2 0 -1 6 0 2 1 1 4 .3 4 .
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: • • • STEM DEFLECTOR 07340-00342 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).
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.
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. 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* and 15*, and Seal Housing 52*. Do not refit these items (*).
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.
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’. 17 • If Guard 1 is at all damaged it must be replaced by a new one. • Any worn or damaged parts should be replaced. • Pay particular attention to jaw carrier items in the upper illustration opposite as follows: Check wear on Jaws 17. Check that Jaw Spreader Tube 18 is not distorted.
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.
S e r v i c i n g t h e To o l 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.
S e r v i c i n g t h e To o l Service Kit For an easy complete service, Textron Fastening Systems Inc offers the complete service kit below. SERVICE KIT : 71210-99990 PART Nº 07900-00667 07900-00692 07900-00670 07900-00672 07900-00706 07900-00684 07900-00685 07900-00351 07900-00469 07900-00158 Spanners are specified in inches and across flats unless otherwise stated DESCRIPTION PISTON SLEEVE TRIGGER VALVE EXTRACTOR BULLET 'T' SPANNER 'T' SPANNER SPIGOT GUIDE TUBE INSERTION ROD 3 MM ALLEN KEY 2.
S e r v i c i n g t h e To o l 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.
S e r v i c i n g t h e To o l 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).
S e r v i c i n g t h e To o l 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 (07900-00671), unscrew Clamp Nut 39 and remove together with Top Plate Assembly 44 together with Tie Rods 56, Transfer Tube Assembly 61, Seperate Body 30 from Handle Assembly 64.
S e r v i c i n g t h e To o l Stop Plate Assembly (71213-03900) Assembly (see illustration below) • Place ‘O’ Ring 2 into the recess in Housing 5 retain in position using grease Molykote® 55. • 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 slot in Piston 1 parallel to the step face in Housing 5. • Slide Plate Shut Off 3 into the assembled parts 1, 2, 4, and 5. Retain parts in place using grease Molykote® 55.
Notes Inc.
19 15 42 Inc.
07003-00341 07003-00277 07003-00278 07003-00281 07003-00204 07003-00287 07003-00288 07003-00342 07003-00310 07003-00415 07005-00088 07005-01274 07008-00010 07007-00224 71213-03800 71213-02021 71213-02022 07003-00416 71221-02006 71223-02001 71221-02002 71213-03000 71213-02008 71210-02009 71213-02025 71223-02121 71221-02008 71213-02012 71210-02014 71210-02103 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 71210-02101 71220-02102 07001-00405 0
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.
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 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.
Fault Diagnosis M PpTtO SSyYm oM m P oP sO sS iSbI Bl eL ECCaAuUsSeE M EeDdYy RReEm 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 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 8† 5 Tool will not grip Worn or broken jaws Fit new jaws
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. ................................................
GERMANY SPAIN Textron Fastening Systems Pty Ltd Textron Verbindungstechnik GmbH Textron Sistemas de Fijación S.A. 891 Wellington Road Klusriede 24 c/ Puerto de la Morcuera, s/n Rowville D - 30851 Langenhagen Poligono Industrial Prado Overa Victoria 3178 Tel: Autovia Madrid Toledo Km 7.8 Tel: Fax: +49 511 7288 133 Es - 28916 Leganes (Madrid) Email: info@avdel.de Tel: +613 9765 6400 Fax: +613 9765 6445 +49 511 7288 0 Email: custserv@textronfast.com.
