Gage Bilt GB808HVB-100 User manual

GB808HVB-100
POWERUNIT
GAGE BILT TOOLS ARE AVAILABLE WORLDWIDE
E-MAIL US FOR A DISTRIBUTOR NEAR YOU.
ORIGINAL INSTRUCTIONS
44766 Centre Court Clinton Twp. MI 48038 USA
Ph: [phone] Fax: [phone]
[email protected] / www.gagebilt.com
GAGE BILT
MADE in USA

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GB808HVB-100 INSTALLATION TOOL
TABLE OF CONTENTS
Page
Warranty ..................................................................................................................................................................................... 3
Description and Technical Specifications ............................................................................................................................... 4
Description of Functions .......................................................................................................................................................... 5
Safety Warnings ......................................................................................................................................................................... 6
Principle of Operation ............................................................................................................................................................... 7
How to set-up the GB808 Series Power Unit ........................................................................................................................ 8-9
How to use the GB808 Series Power Unit.............................................................................................................................. 10
Maintenance, Troubleshooting and Hydraulic Thread Preparation..................................................................................... 11
Filling and bleeding ................................................................................................................................................................. 12
Overhaul ..............................................................................................................................................................................13-14
Parts Lists............................................................................................................................................................................ 15-19
Wire Diagram............................................................................................................................................................................ 20
AW-32® Oil Safety Data ........................................................................................................................................................... 21
Alternative Styles ................................................................................................................................................................22-24

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GB808HVB-100 INSTALLATION TOOL
Seller warrants that all goods covered by this catalog will conform
to applicable specifications and will replace or repair, EXW our plant, any
goods providing defective from faulty workmanship, or material, for 1 year
from date of shipment.
Said warranty to remain in effect if, and only if, such goods are
used in accordance with all instructions as to maintenance, operation and
use, set forth in manuals and instruction sheets furnished by seller.
Sellers obligation under this warranty shall be limited to the repair
or rework of the goods supplied or replacement thereof, at Seller’s option,
and in no case is to exceed the invoice value of said goods. Under no
circumstances will the seller be liable for incidental or consequential
damages or for damages incurred by the buyer or subsequent user in
repairing or replacing defective goods or if the goods covered by this
warranty are reworked or subjected to any type of additional processing.
This warranty is void if Seller is not notified in writing of any
rejections or defects within 1 year after the receipt of the material by the
customer.
THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES
EXPRESSED OR IMPLIED, INCLUDING MERCHANTABILITY.
WARRANTY

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GB808HVB-100 INSTALLATION TOOL
TECHNICAL SPECIFICATIONS
Weight - 48 lbs. (21.8 kg)
Air Pressure req’d- 90 - 100 psi (6.2 - 6.9 bar)
Hyd. pressure req'd - 4,000 lbs. @ 90 psi (6.2 bar)
Air consumption - 0.5 CF
Hydraulic oil - AW-32 or equivalent
Noise level - 81.5 dB(A)
Vibration - No hazard identified
The tool pump combination emits no sound except when firing a fastener. The tool pump
combination emits 92.5 dB(A) for less than 0.5 seconds. Therefore, hearing protection is
not recommended for long term use.
The GB808 series pneudraulic pump is designed to work in conjunction with Gage Bilt’s split handle (SHA) or split riveter (SRA) fastener
installation tools. When the GB808 is properly configured with the correct installation tool, it is capable of installing 3/32” (2.38mm) -
1/4” (6.35mm) fasteners.
It is designed specifically to improve on the ergonomic and efficiency of fastener installation. The GB808 series pump operates using
90 - 100 psi (6.2 - 6.9 bar) of air and can install a wide range of fasteners when fitted to the appropriate installation tool. The GB808
Series Power Unit can be configured to operate one or more tools simultaneously. The GB808 Series Power Unit can also be configured
to hang, roll with wheels, or to include a vacuum system to collet spent pintails.
ENVIRONMENTAL USE
WARNING: Do not operate in an explosive atmosphere.
The GB808 Series Power Unit can be operated between 0ºF - 118ºF (-17.8ºC / 47.8ºC)
DESCRIPTION
WARNING: Any other use is forbidden.

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GB808HVB-100 INSTALLATION TOOL
DESCRIPTION OF FUNCTIONS
Vacuum Inlet
Hydraulic Outlet
Air Inlet
Pintail Evacuation
Air Outlet
Spent Pintail
Collection
Hanging Lever
for Tool
Regulator
Oil Reservoir Cap
Inductive Sensor
Connection Wire
Hooks for hanging
powerunit (2X)
Power Supply 110V Power Cord
Image may not reflect actual tool

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GB808HVB-100 INSTALLATION TOOL
SAFETY WARNINGS
GENERAL SAFETY RULES:
1. For multiple hazards, read and understand the safety instructions before installing,
operating, repairing, maintaining, changing accessories on, or working near the
assembly power tool for non-threaded mechanical fasteners.
2. Only qualified and trained operators shall install, adjust or use the assembly power
tool for non threaded mechanical fasteners.
3. Do not modify this assembly power tool for non-threaded mechanical fasteners. Modifications can
reduce effectiveness of safety measures and increase the risks to the operator.
4. Do not discard safety instructions; give them to the operator.
5. Do not use assembly power tool for non-threaded mechanical fasteners if it has been damaged.
6. Tools shall be inspected monthly to verify all ratings and markings required are legible.
The employer/user shall contact the manufacturer to obtain replacement marking
labels when necessary.
ADDITIONAL SAFETY RULES FOR PNEUDRAULIC POWER TOOLS:
1. Air under pressure can cause severe injury.
2. Always shut off air supply, drain hose of air pressure and disconnect tool from air
supply when not in use, before changing accessories or when making repairs.
3. Never direct air at yourself or anyone else.
4. Whipping hoses can cause severe injury. Always check for damage or loose hoses and fittings.
5. Cold air shall be directed away from hands.
6. Whenever universal twist couplings (claw couplings) are used, lock pins shall be
installed and whip check safety cables shall be used to safeguard against possible
hose-to-tool or hose-to-hose connection failure.
7. Do not exceed the maximum air pressure stated on the tool or manual.
8. Never carry an air tool by the hose.
PROJECTILE HAZARDS:
1. Disconnect the tool from the energy source when changing inserted tools/nose as-
semblies or accessories.
2. Be aware that failure of the workpiece, accessories, or the inserted tool/nose assembly
itself can generate high-velocity projectiles.
3. Always wear impact resistant eye protection during operation of the tool.
4. Ensure that the workpiece is securely fixed.
5. Check that the means of protection from ejection of fastener and/or stem is in place
and operative (such as the deflector, pintail collection bottle or catcher bag).
6. Forcible ejection of the mandrel from the front of the nose assembly is possible.
OPERATING HAZARDS:
1. Use of tool can expose the operator’s hands to hazards, including crushing, impacts,
cuts, abrasions and heat. Wear suitable gloves to protect hands.
2. Operators and maintenance personnel shall be physically able to handle the bulk,
weight and power of the tool.
3. Hold the tool correctly; be ready to counteract normal or sudden movements and have
both hands available.
4. Maintain a balanced body position and secure footing.
5. Release the start-and-stop device in the case of interruption of energy supply.
6. Use only lubricants recommended by the manufacturer.
7. Avoid unsuitable postures as it is likely for these positions not to allow counteracting
of normal or unexpected movement of the tool.
8. If the tool is fixed to a suspension device, make sure that fixation is secure.
9. Beware of the risk of crushing or pinching if nose equipment is not fitted.
10. Due to the tool weight, it is recommended safety shoes be worn during operation.
11. It is recommended tool be operated not more than 50 out of every 60 minutes, where
prolonged use is expected.
REPETITIVE MOTIONS HAZARDS:
1. When using the tool, the operator can experience discomfort in the hands, arms,
shoulders, neck or other parts of the body.
2. While using the tool, the operator should adopt a comfortable posture while maintain-
ing a secure footing and avoiding awkward or off balanced postures. The operator
should change posture during extended tasks; this can help avoid discomfort and
fatigue.
3. If the operator experiences symptoms such as persistent or recurring discomfort, pain,
throbbing, aching, tingling, numbness, burning sensations or stiffness, these warning
signs should not be ignored. The operator should tell the employer and consult a
qualified health professional.
ACCESSORY HAZARDS:
1. Disconnect tool from energy supply before changing the nose assembly or accessory.
2. Use only sizes and types of accessories approved by the manufacturer. Do not use
other types or sizes of accessories.
WORKPLACE HAZARDS:
1. Slips, trips and falls are major causes of workplace injury. Be aware of slippery surfac-
es caused by use of tool and also of trip hazards caused by the air line or hydraulic
hose.
2. Proceed with care in unfamiliar surroundings. There could be hidden hazards, such as
electricity or other utility lines.
3. The tool is not intended for use in potentially explosive atmospheres and is not insu-
lated against contact with electrical power.
4. Ensure that there are no electrical cables, gas pipes, etc., which can cause a hazard if
damaged by the tool.
NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent, disabling hearing loss and other
problems, such as tinnitus (ringing, buzzing, whistling or humming in the ears). There-
fore, risk assessment and the implementation of appropriate controls for these haz-
ards are essential.
2. Appropriate controls to reduce the risk may include actions such as damping materials
to prevent workpieces from “ringing”.
3. Always use hearing protection.
4. Operate and maintain the assembly power tool for non-threaded mechanical fasteners
as recommended in the instruction handbook, to prevent an unnecessary increase in
the noise level.
5. Select, maintain and replace the consumable/inserted tool as recommended in the
instruction handbook, to prevent an unnecessary increase in noise.
6. If the power tool has a silencer, always ensure that it is in place and in good working
order when the power tool is being operated.
VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the nerves and blood supply of
the hands and arms.
2. Wear warm clothing when working in cold conditions and keep your hands warm and
dry.
3. If you experience numbness, tingling, pain or whitening of the skin in your fingers or
hands, stop using the assembly power tool for non-threaded mechanical fasteners,
tell your employer and consult a physician.
4. Support the weight of the tool in a stand, tensioner or balancer, because a lighter grip
can then be used to support the tool.
TERMS AND SYMBOLS
- Product complies with requirements
- Hearing protection and eye protection
WARNINGS - Must be understood to avoid severe
personal injury.
CAUTIONS - show conditions that will damage
equipment and/or structure.
Notes - are reminders of required procedures.
- Read manual prior to using equipment
- Wear safety boots
- Product complies with requirements

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GB808HVB-100 INSTALLATION TOOL
PRINCIPLE OF OPERATION
Incoming air is regulated between 90 - 100psi. (6.2 - 6.9 bar) through the air filter / regulator. When the actuator lever assembly is depressed
on the installation tool, pressurized air inside the four-way valve is released allowing a plunger to unseat a valve ball allowing the air
to be redirected to the rear of the booster starting the cycle. As the air piston in the booster begins to move forward the air in the front
side is being exhausted out of the muffler and simultaneously forcing hydraulic oil up and into the front side of the head cylinder assembly,
causing the head piston to move to the rear of the head cylinder assembly. The internal components of the attached nose assembly
are also moving with the head piston to start the fastener installation. When the fastener installation is completed, the actuator lever
assembly is released. Air pressure is then built up inside of the four-way valve re-seating the valve ball that in return directs the air to
the front side of the booster and to the rear of the head cylinder reversing the sequence while vacuuming the spent pintail into the collection bottle.
RETURN PULL
EXHAUST
HYDRAULIC FLOW
“PULL”
“RETURN”
RETURN PULL
4 WAY VALVE / HYDRAULIC FLOW
FOUR WAY VALVE
Images may not
reflect actual
tool

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GB808HVB-100 INSTALLATION TOOL
HOW TO SET-UP THE GB808HVB-100 POWER UNIT
WARNING: Only qualified and trained operators shall install, adjust or use the assembly power tool for non-threaded
mechanical fasteners.
WARNING: Operator MUST read and understand all warnings and cautions.
WARNING: It is required that eye protection, hearing protection and foot protection be worn during operation.
WARNING: The users or the user’s employer must assess specific risks that could be present as a result after each use
based on their application.
● Ensure there is adequate clearance for tool and operator's hands before proceeding. Keep fingers clear of any
moving parts. Keep fingers clear from fasteners and installed materials. Severe personal injury may result.
● Verify that hydraulic hose fittings and couplings, air and electrical connections are secure.
● Verify the air lines and/or hydraulic hoses are not a trip hazard.
● Ensure that there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by the tool.
● Ensure Do not use as a hammer to force fasteners into holes or otherwise abuse tool.
WARNING: Do not actuate fastener in the air. Personal injury from fastener ejecting may occur.
WARNING: Do not use in explosive atmosphere.
WARNING: Ensure air hose is securely connected to avoid possible hose whipping.
WARNING: Always disconnect air supply when tool is not in use to prevent accidental start-up.
CAUTION: Do not use beyond the design intent.
Images may not reflect actual tool
The powerunit is shipped with a plastic plug in the air inlet connector. The connector has a 1/4 - 18 NPT female pipe thread to accept
end-user air hose fitting. The tool comes with oil and is ready to use.
1. Remove red plastic plug in the air inlet connector and install male air fitting with 1/4 - 18 NPT. (Not sold with powerunit).
2. Connect powerunit to power unit by attaching hydraulic hose, air line and vacuum line.
3. Connect air supply to powerunit using 1/2” air line min. (90 - 100 P.S.I.) (6.2 - 6.9 bar) required.
Note: Gage Bilt does NOT recommend using a pneumatic lubricator or adding oil to the air inlet on our tools or powerunit.
4. Connect connection wire to inductive sensor. Plug power cord into 110V outlet. (Power supply in electrical enclosure and inductive
sensor have lights that turn green when power supplied).
5. Cycle the powerunit (with tool attached) several times. Re-check the hydraulic oil reservoir level with the powerunit in the RETURN position.
Check for leaks.
See installation tool manual for complete set up installation instructions.
Tool rests on hook when
not in use, shutting off air
flow to vacuum
Pintails extracted from tool and
collected in collection bottle
Connect pintail evacuation
tube to tool
PNP Output
Air Filter/Regulator
Incoming Plant Air
90 PSI (6.2 bar) Min.
Pintail Collection bottle 110V Power Cord
Power Supply
Inductive Sensor
Connection Wire
Electrical Enclosure

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GB808HVB-100 INSTALLATION TOOL
Open oil reservoir cap &
fill reservoir
hydraulic
oil reservoir
PULL/RETURN
Booster Assembly
Four-Way Valve
Air flow pushes booster assembly
piston back to RETURN position
Incoming Plant Air
90 PSI (6.2 bar) Min.
Pintail Collection bottle
Connect pintail evacuation
tube to tool
Pintails extracted from tool and
collected in collection bottle
Connect hydraulic line to tool
Hydraulic oil flows from booster
assembly thru hydraulic line into
tool
Tool rests on hook when not in use,
shutting off air flow to vacuum
Air flow pushes booster assembly
piston forward to PULL position
Air Filter/Regulator
Air flows from tool and into
four-way valve when actuator
depressed. When actuator is
released, four-way valve
spring returns
Connect air line to tool
direction of
PULL
pressurization
direction of RETURN
pressurization
Air flows from regulator and
into tool
When actuator in tool is released,
return pressure begins air flow from
four-way valve thru valve on front of
powerunit and into vacuum regulator
HOW TO SET-UP THE GB808HVB-100 POWER UNIT Cont.
WARNING: Only qualified and trained operators shall install, adjust or use the assembly power tool for non-threaded
mechanical fasteners.
WARNING: Operator MUST read and understand all warnings and cautions.
WARNING: It is required that eye protection, hearing protection and foot protection be worn during operation.
WARNING: The users or the user’s employer must assess specific risks that could be present as a result after each use
based on their application.
● Ensure there is adequate clearance for tool and operator's hands before proceeding. Keep fingers clear of any
moving parts. Keep fingers clear from fasteners and installed materials. Severe personal injury may result.
● Verify that hydraulic hose fittings and couplings, air and electrical connections are secure.
● Verify the air lines and/or hydraulic hoses are not a trip hazard.
● Ensure that there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by the tool.
● Ensure Do not use as a hammer to force fasteners into holes or otherwise abuse tool.
WARNING: Do not actuate fastener in the air. Personal injury from fastener ejecting may occur.
WARNING: Do not use in explosive atmosphere.
WARNING: Ensure air hose is securely connected to avoid possible hose whipping.
WARNING: Always disconnect air supply when tool is not in use to prevent accidental start-up.
CAUTION: Do not use beyond the design intent.
Image may not reflect actual tool

10 8/18 REV. 2/23
GB808HVB-100 INSTALLATION TOOL
HOW TO USE THE GB808HVB-100 POWER UNIT
The GB808 series pneudraulic pump is designed to work in conjunction with Gage Bilt’s split handle (SHA) or split riveter (SRA) rivet
installation tools.
WARNING: Only qualified and trained operators shall install, adjust or use the assembly power tool for non-threaded
mechanical fasteners.
WARNING: Operator MUST read and understand all warnings and cautions.
WARNING: It is required that eye protection, hearing and foot protection be worn during operation.
WARNING: The users or the user’s employer must assess specific risks that could be present as a result after each use
based on their application.
● Ensure there is adequate clearance for tool and operator's hands before proceeding. Keep fingers clear of any
moving parts. Keep fingers clear from fasteners and installed materials. Severe personal injury may result.
● Verify that hydraulic hose fittings and couplings, air and electrical connections are secure.
● Verify the air lines and/or hydraulic hoses are not a trip hazard.
● Ensure that there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by the tool.
● Do not use with any unapproved installation tool.
WARNING: Do not actuate fastener in the air. Personal injury from fastener ejecting may occur.
CAUTION: Do not use beyond the design intent.
Images may not reflect actual tool or fastener
Blind Fasteners
1. Insert fastener into workpiece.
2. Insert fastener into nose assembly.
Note: Always hold tool so pulling head is perpendicular to surface
of material in which fastener is being installed. Exert firm pressure
against fastener during installation.
3. Press actuator to start cycle.
4. Release actuator as soon as fastener breaks.
5. Repeat steps 1 - 4.

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GB808HVB-100 INSTALLATION TOOL
Note:
• Dispose of hydraulic oil in accordance with manufacture safety datasheet.
• All tool materials are recyclable except rubber o’rings, seals and wipers.
• SERVICE KIT (808020) should be kept on hand at all times.
This powerunit requires a minimum amount of maintenance. Inspection and correction of minor problems will keep it operating
efficiently and prevent downtime.
At regular intervals, depending upon use, replace all seals in booster. Inspect both hydraulic pistons, and the head cylinder assembly
piston rod for scored surfaces, excessive wear or damage. Replace as necessary.
* Inspect all hoses and couplings for wear, damage and leaks. Replace/Repair if necessary. (See hydraulic thread preparation).
* Verify that hydraulic hose fittings and couplings and air connections are secure. Tighten, Replace or Repair if necessary.
(See hydraulic thread preparation below).
* Cycle the tool several times to assure there are no leaks during use.
* Keep hydraulic system free of dirt. Avoid letting couplers contact a dirty floor.
* Proper care by operators is necessary in maintaining full productivity and reducing downtime.
DAILY MAINTENANCE
WARNING: Tool must be maintained in a safe working condition at all times and examined on a daily basis for damage or
wear. Any repair should be done by qualified personnel trained on Gage Bilt procedures.
WARNING: Excessive contact with hydraulic oil and lubricants should be avoided.
WARNING: Maintenance personnel MUST read and understand all warnings and cautions.
WARNING: Disconnect tool from its power source before performing maintenance, cleaning or when replacing worn or
damaged components. Severe personal injury may occur if power source is not disconnected.
WARNING: Read safety datasheet documents for all applicable materials.
* Check oil level in reservoir weekly. Use AW-32® or equivalent to maintain correct oil level. Available in quart size Gage Bilt # (A-768).
WEEKLY MAINTENANCE
703515 Vacuum Regulator
Tube
(4) S.H.C.S.
Fitting
Image may not reflect
actual tool
HOW TO CLEAN VACUUM REGULATOR
1. Remove vacuum regulator (703515) from tube and fitting.
2. Remove (4) S.H.C.S. from front of regulator and disassemble.
3. Clean both pieces in clean mineral spirits and blow dry.
4. Reassemble and connect hoses.
5. Check vacuum pressure using vacuum gage (703567) (sold separately).
Press gage against the vacuum line or nose assembly to create seal.
Optimum vacuum pressure at nose assembly must be
between 15 - 22 inHg. (381 - 558.8 mmHg).
Note: The vacuum regulator may visually appear clean, but may still be
contaminated with a thin film. Therefore, the steps above should
be performed to assure best performance.
TROUBLESHOOTING
Providing all maintenance conditions have been met, follow this systematic approach to diagnosis.
1. OIL LEAKAGE:
a.) Hydraulic oil leaks from connections. Tighten threaded connections. Do not use Teflon® tape.
b.) Oil leaks from tool. Determine source of leak and replace worn or defective o'rings and back-up rings.
2. WILL NOT VACUUM PINTAIL:
a.) Check the vacuum line is not kinked and that the bend radius is not too small.
b.) Check vacuum pressure using vacuum gage (703567) (sold separately). Press gage against the vacuum line or nose assembly
to create seal.
Optimum vacuum pressure at nose assembly must be between 15 - 22 inHg. (381 - 558.8 mmHg).
c.) Clean vacuum regulator. (See how to clean vacuum regulator above).
HYDRAULIC THREAD PREPARATION
IMPORTANT: Be sure to use thread sealant on all hydraulic fittings, Loctite® 545 or equivalent or a non-hardening Teflon® thread
compound such as Slic-tite®. Tighten until fitting feels snug and then continue to tighten 1/2 to 1 full turn. CAUTION: Over tightening
can easily distort the threads. DO NOT USE TEFLON® TAPE. CAUTION: Teflon® tape is an excellent thread sealer, however, if it is not
properly applied, pieces of Teflon® may enter the hydraulic system and cause a malfunction or damage.

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GB808HVB-100 INSTALLATION TOOL
WARNING: Use extreme caution when cycling tool with bleed screw removed. Pressurized oil will spray out of the bleed port.
Severe personal injury may occur.
Images may not reflect actual tool
Fill oil reservoir approx. 3/4 full
1. Disconnect air supply from the powerunit.
2. Fill oil reservoir approximately 3/4 full. Use hydraulic oil (AW-32® or equivalent).
3. Remove bleed screw and stat-o-seal from head cylinder/handle assembly. (See handle/tool picture below for reference and see
installation tool manual for step by step filling and bleeding procedures).
4. Provide a suitable container to bleed oil into.
5. Connect air supply to powerunit. Reduce air pressure to 50 psi. (3.45 bar) during bleeding procedure.
6. Point the bleed port towards a container, push actuator lever down and hold. (Block bleed port using a small piece of rubber material
before releasing actuator lever to prevent ingestion of air into powerunit).
7Repeat until clear oil streams from port. Check reservoir after each cycle and refill when required. Do NOT drain reservoir below
minimum.
8. On last cycle of oil, hold actuator lever. Install bleed screw and stat-o-seal prior to releasing the actuator lever and torque to 35 - 40
inch lbs. (3.95 - 4.52 Nm). This may require two people. (Do NOT over-tighten)
9. See tool manual for the correct stroke requirements by checking the piston in the forward and rearward positions. If stroke does
not reach manual recommendations, repeat steps 1 - 9 until stroke met.
HANDLE/TOOL BOOSTER
FILLING AND BLEEDING
Bleed Screw &
stat-o-seal

13 8/18 REV. 2/23
GB808HVB-100 INSTALLATION TOOL
If a powerunit is performing poorly or leaking, a complete overhaul may be necessary.
Perform overhaul in a clean, well lit area using care not to scratch or nick any smooth surface that comes in contact with an o'ring.
Use of Lubriplate® #630-AA (Gage Bilt part no. 402723) during reassembly to prevent tearing or distorting of o'rings.
1. Take picture of the booster assembly (808009) for reference when re-assembling. (See page 14).
2. Remove booster assembly (808009).
3. Remove five hex bolts (407708 (2X) & 407710 (3X) and disassemble.
4. Replace o’rings and seals (400826 (4X), 404228 (2X), 407694 & 407693 (3X).
5. Reassemble booster assembly (808009).
6. Torque three hex bolts (407710) to 20 - 25 ft lbs. (27 - 34 Nm) and two hex bolts (407708) 12 - 15 ft. lbs. (16.3 - 20.3 Nm). (See
overhaul booster assembly parts list pg. 14).
7. Reinstall booster assembly (808009).
8. Rethread nipple-brass (A-1680) to booster assembly (808009), secure to frame and attach hose assembly (808105).
9. Bleed tool and booster assembly (808009) per bleeding procedure on pg. 12.
OVERHAUL BOOSTER ASSEMBLY
WARNING: Only qualified and trained personnel shall perform overhaul.
WARNING: Personnel must read and understand all warnings and cautions.
WARNING: Powerunit must be maintained in a safe working condition at all times and examined on a daily basis for damage
or wear. Any repair must be done by qualified personnel trained on Gage Bilt procedures.
WARNING: Disconnect powerunit from its power source before performing overhaul. Severe personal injury may occur if
power source is not disconnected.
WARNING: Excessive contact with hydraulic oil and lubricants must be avoided (See safety datasheet documents for all applicable materials).
WARNING: When operating, repairing or overhauling powerunit, wear approved eye protection.
WARNING: Use only Gage Bilt hydraulic hoses and couplings, or equivalent, rated for 10,000 psi. (689.5 bar) working pressure.
WARNING: Ensure air hose is securely connected to avoid possible hose whipping (Air Actuated Tools only).
Drain all hydraulic oil and dispose of oil in accordance with manufacture safety datasheet. All tool materials are recyclable except
plastic panels and rubber o’rings, seals, wipers and hoses.
TOOL DISPOSAL
An oil pan assembly (808148) with a button head cap screw (402482) & stat-o-seal (S572) and gasket - oil pan (808147) is attached to
this powerunit.
To drain oil pan:
1. Place container under drain to collect oil.
2. Place allen wrench into button head cap screw (402482) under powerunit.
3. Holding allen wrench, loosen and remove the button head cap screw (402482) and stat-o-seal (S572). Let the hydraulic oil drain
from the hole into an approved container. It may be necessary to tilt powerunit to remove all hydraulic oil. Be sure to dispose of
oil in accordance with manufacture safety datasheet.
4. Wipe oil pan (808146) and any related parts down with a clean dry rag and dispose of accordingly.
OIL PAN
Note:
• Dispose of hydraulic oil in accordance with manufacture safety datasheet.
• All tool materials are recyclable except rubber o’rings, seals and wipers.
• SERVICE KIT (808020), which contains a complete set of o'rings, back-up rings and screws, can achieve a complete
overhaul.

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GB808HVB-100 INSTALLATION TOOL
OVERHAUL BOOSTER ASSEMBLY

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT (BOOSTER ASSEMBLY)
GB808HVB-100 POWERUNIT (QUICK EXHAUST VALVE)

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT (VALVE ASSEMBLY)
GB808HVB-100 POWERUNIT (REGULATOR ASSEMBLY)

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT
GB808HVB-100 POWERUNIT

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT (VACUUM & BOTTLE ASSEMBLY)
GB808HVB-100 POWERUNIT (FRAME ASSEMBLY)

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT (SENSOR & ELECTRICAL ENCLOSURE)

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GB808HVB-100 INSTALLATION TOOL
GB808HVB-100 POWERUNIT (WIRE DIAGRAM)