Genesis nG1 Instruction Manual Download Page 1 | Manualshive

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G1

H y d ro - P n e u m a t i c P o w e r To o l

Genesis

®

I n s t r u c t i o n M a n u a l

O r i g i n a l I n s t r u c t i o n

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Summary of Contents for nG1

Page 1: ...G1 Hydro Pneumatic Power Tool Genesis Instruction Manual Original Instruction 1 ...

Page 2: ......

Page 3: ...27 Priming Oil Details 28 Hyspin VG32 Oil Safety Data 28 Priming Kit 28 Priming Procedure 29 Fault Diagnosis Symptom Possible Cause and Remedy 30 Contents 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 maintai...

Page 4: ...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 Vacuum A...

Page 5: ...mately 0 9 seconds Noise Level 75 dB A Weight Including nose equipment 1 7 kg Vibration Less than 2 5 m s2 30 00 DIA 104 00 282 00 104 00 123 30 120 61 90 61 150 00 5 4 0 0 D IA 82 30 2 2 8 0 D IA 93 00 DIA SCRAP VIEW SHOWING BOTTLE STEM COLLECTOR SHORT VERSION NOTE Stem Collector Short Version Bottle is an accessory part number 71213 03810 Dimensions in millimetres Tool Dimensions ...

Page 6: ...base tool FASTENER NAME MM IN FASTENER SIZE AVEX STAVEX AVINOX II AVIBULB BULBEX T LOK AVDEL SR ETR N RIVET Q RIVET AVSEAL II 3 3 2 4 0 4 3 4 8 5 5 2 6 6 5 7 1 8 2 4 3 5 32 32 3 16 COMPLETE TOOL 71203 00 BASE TOOL 1 1 2 3 1 NOSE ASSEMBLY NOSE TIP 2 71203 02000 71203 15000 or 71213 15000 see note 3 2 3 3 1 n 1 n The part number of the base tool remains the same whichever nose assembly or nose tip i...

Page 7: ...The Trigger should be lifted to cut off the vacuum air supply prior to removing the collector bottle Putting into Service Air Supply Operating Procedure 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 Do not use tool when Stem Collector Bottle is removed All to...

Page 8: ...efer to nose assembly components in all 3 Nose Tip tables pages 9 10 and 12 Lightly coat Jaws 4 with MolyLithium grease Drop Jaws 4 into Jaw Housing 3 Insert Jaw Spreader 5 into Jaw Housing 3 Locate Buffer 6 on Jaw Spreader 5 Locate Spring 7 onto Jaw Spreader 5 Insert Detent Sleeve 10 into Jaw Spreader Housing T 9 Not applicable to Type 2 Nose Assemblies Fit Locking Ring 8 onto the Jaw Spreader Ho...

Page 9: ... PART Nº A B NAME Al Alloy Steel Al Alloy Al Alloy Al Alloy Al Alloy Al Alloy Stainless Steel Steel Any Any Steel Stainless Steel Any Any 1 8 1 8 1 8 5 32 5 32 5 32 1 8 1 8 1 8 5 32 1 8 1 8 1 8 3 32 4 8 3 3 2 9 4 8 3 3 3 3 3 3 3 3 3 3 4 8 3 3 3 3 3 3 4 8 3 3 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 12 7 71210 05002 71210 16070 07340 064012 71210 05002 71210 16070 07340...

Page 10: ...340 06201 07381 04701 07381 04701 07381 04701 07340 06201 4 0 4 8 4 8 4 8 4 8 4 3 4 0 4 0 4 0 4 0 AVEX Large flange BULBEX T LOK AVIBULB STAVEX Q RIVET 0 2 0 0 2 0 0 1 6 0 1 5 0 2 0 1 2 0 0 2 0 0 2 0 0 2 0 1 2 0 A B Items 3 11 available as cartridge assembly 71213 20320 COMPLETE TOOL PART NUMBER precede with 71203 00 N O S E A S S E M B LY part nº 71213 15000 ITEM DESCRIPTION PART Nº 1 TAPERED NOS...

Page 11: ...cuum Sleeve 41 finally tighten Locknut 39 against Jaw Spreader Housing 9 For other items refer to the general assembly drawing and parts list on pages 26 and 27 To fit Nose Tip Type 2 or Nose Extension the Male T Adaptor 40 must be replaced with Jaw Spreader Housing 9 Loosen Locknut 39 using 16mm AF Spanner Unscrew and remove Male T Adaptor 40 together with O Ring 11 Items 9 and 10 or 11 refer to ...

Page 12: ...2 7 12 7 07340 02805 07340 02806 07340 02806 07340 02807 07340 02807 07340 02806 07340 02807 07241 07101 07340 02806 07340 02807 07340 02806 07340 02807 07340 02806 07340 02807 07340 02807 3 2 3 2 4 0 4 0 4 8 4 0 4 8 4 3 3 2 4 0 3 2 4 0 3 2 4 0 4 0 AVEX BULBEX T LOK STAVEX AVIBULB ETR 0 0 2 0 0 8 0 0 8 0 1 4 0 1 4 0 0 8 0 1 4 1 2 1 0 0 8 0 1 4 0 0 8 0 1 4 0 0 8 0 1 4 0 1 4 ITEM DESCRIPTION PART Nº...

Page 13: ... to Jaw Spreader Housing 9 Screw the Outer extension onto Head Assembly 50 Fit the nose assembly onto the extension Loosen Locknut 39 using 16mm AF Spanner Unscrew and remove both Male T Adaptor 40 and Locknut 39 Replace Locknut 39 with Sealed Nut 71213 02200 screw Sealed Nut onto Head Piston 35 to disable Vacuum System Male T Adaptor 40 must be tightened onto Head Piston 35 finally tightening Sea...

Page 14: ...oy Stainless Steel Stainless Steel Steel Steel Stainless Steel Stainless Steel Al Alloy Al Alloy Al Alloy Al Alloy 1 8 1 8 5 32 5 32 3 16 5 32 3 16 1 8 5 32 1 8 5 32 1 8 5 32 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 3 81 1 95 4 11 2 00 4 11 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 7 87 6 35 6 35 7 62 7 62 07345 03000 07345 03100 07345 03100 07345 03200 07345 0...

Page 15: ... 1 0 RIGHT ANGLE SWIVEL HEAD capability 1 In inches then in millimetres 2 Long nose tip for deep placing COMPLETE TOOL PART NUMBER precede with 71203 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 7 6 32 20 52 56 74 97 A B 360 rotation 07346 03100 07346 03200 07346 03...

Page 16: ...h Pin 6 J Insert Pin 12 through the front slot of Body 5 into Jaw Carrier 3 K 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 L Remove Screws 23 4 off and Guard 1 On a straight swivel head also remove Screw 21 and Platform 22 M Push Pin s 6 out and let Spindle 11 drop out Screw Spindle 11 onto...

Page 17: ...el 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 jaws part numbers see the tables on pages 14 and 15 17 ITEM DESCRIPTION STRAIGHT SWIVEL RIGHT ANGLE SWIVEL 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 18 19 20 21 22 23 GUARD CIRCLIP ...

Page 18: ... assembly with special attention to the jaws Lubricate with MolyLithium grease before assembling Check for oil leaks and air leaks in the air supply hose and fittings 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 i...

Page 19: ...ical 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 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 ...

Page 20: ...o remove the nose equipment For instructions see the nose assemblies section pages 8 to 12 or if a swivel head was fitted pages 14 to 16 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 Annually or every 500 000 cycles whichever ...

Page 21: ...e Seal Retainer 42 Push Lip Seal 7 and Bearing Tape 25 to the rear and out of Head Assembly 50 taking care not to damage the cylinder bore Remove Seal Housing 48 and Lip Seal 2 Assemble in reverse order noting the following points Place Lip Seal 7 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 th...

Page 22: ...00706 Unscrew Clamp Nut 38 and remove together with Clamp Plate 43 together with Transfer Tube Assembly 52 Valve Rod Assembly 55 and O Rings 13 Remove tool from vice and separate Body 29 from Handle Assembly 70 Remove O Ring 16 Push out the Valve Seat 33 from the Body 29 together with O Rings 13 Pull out Valve Spool Assembly 51 from Handle Assembly 70 Remove O Ring 6 from handle counterbore Assemb...

Page 23: ...antling Instructions noting the following Seals should be checked for damage and replaced if necessary lubricated with Molykote 55m grease Ensure Rotary Valve 37 is assembled in correct orientation to align valve pins with forks on the Trigger Assembly 32 See illustration below Rotary Valve Dismantling Using a 2mm pin punch 07900 00158 drive Trigger Pin 45 out and remove Trigger Assembly 32 Unscre...

Page 24: ...Plate Shut Off 3 into the assembled parts 1 2 4 and 5 Retain parts in place using grease Molykote 55m Place O Ring 4 into the recess of Cover Plate 6 retain in position using grease Molykote 55m Place Spring 7 into position locate using the recesses in both Plate Shut Off 3 and Bottle Adaptor Assembly 31 Position the above assembled parts onto Bottle Adaptor Assembly 31 Secure in position using tw...

Page 25: ...25 Notes ...

Page 26: ...8 Assy 50 2 7 16 70 Assy 20 45 Assy 32 41 18 14 34 Assy 35 8 64 12 27 10 9 X 25 63 19 69 Assy 24 Assy 47 13 33 13 6 61 59 Assy 51 62 60 3 21 13 22 43 53 Assy 23 65 31 66 3 Suspension Ring A A 44 Detail X 26 17 16 15 54 Assy 58 38 46 29 57 30 28 49 52 Assy 55 Assy 36 43 56 A A ...

Page 27: ...27 Parts List for 71203 02000 ...

Page 28: ... 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 ent...

Page 29: ... into bleed screw port utilising Bonded Seal 5 Actuate Priming Pump by pressing down and releasing several times until resistance is evident and the 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 Scre...

Page 30: ...or broken spring in nose assembly Fit new spring 8 9 10 12 Incorrect component in nose assembly Identify and replace 9 10 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 10 12 Weak or broken spring in nose assembly Fit new spring 9 10 12 Air or oil leak...

Page 31: ...onformity 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 2006 42 EC This box contains a power tool which is in conformity with Machines Directive 2006 42 EC The Declaration of Conformity is contained within A Seewraj Product Engineering Manager Aut...

Page 32: ...del Deutschland GmbH Klusriede 24 30851 Langenhagen Tel 49 0 511 7288 0 Fax 49 0 511 7288 133 AvdelDeutschland infastech com INDIA Infastech Fastening Technologies India Private Limited Plot No OZ 14 Hi Tech SEZ SIPCOT Industrial Growth Center Oragadam Sriperumbudur Taluk Kanchipuram District 602105 Tamilnadu Tel 91 44 4711 8001 Fax 91 44 4711 8009 info in infastech com ITALY Avdel Italia S r l Vi...

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