Gage Bilt GB808V User manual

GB808V
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

2REV. 2/23
GB808V POWERUNIT
TABLE OF CONTENTS
Page
EU Conformity and Warranty .................................................................................................................................................... 3
Description and Technical Specifications ............................................................................................................................... 4
Safety Warnings ......................................................................................................................................................................... 5
Description of Functions .......................................................................................................................................................... 6
Principle of Operation ............................................................................................................................................................... 7
How to set-up the GB808V Series Power Unit ......................................................................................................................... 8
How to use the GB808V Series Power Unit ............................................................................................................................. 9
Maintenance, Troubleshooting and Hydraulic Thread Preparation..................................................................................... 10
Filling and bleeding ................................................................................................................................................................. 11
Overhaul ..............................................................................................................................................................................11-12
Parts Lists............................................................................................................................................................................13-17
AW-32 Oil Safety Datasheet .................................................................................................................................................... 18
Hydraulic Powerunits .............................................................................................................................................................. 20

3REV. 2/23
GB808V POWERUNIT
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
DECLARATION OF CONFORMITY
MANUFACTURER: Gage Bilt Inc. 44766 Centre Ct., Clinton Twp., Michigan U.S.A. [phone])
WE DECLARE THAT THE EQUIPMENT SPECIFIED HEREIN CONFORMS
TO THE FOLLOWING DIRECTIVES AND STANDARDS
Machinery Directive 2006/42/EC
EN ISO 12100:2010
EN ISO 13849-2:2012
EN 809:1998+A1 Pumps only
EN11148-1-4 Tool only
The Supply of Machinery (Safety) Regulations 2008
EU REPRESENTATIVE: Edgar Hausmann GmbH Förster-Busch-Str. 10 D-34346 Hann. Münden Germany
EQUIPMENT DESCRIPTION: GB808V FASTENER INSTALLATION TOOL
This product specified above conforms to the above dIrectives and standards.
SIGNATURE:
NAME: TIM SIMMONS
PRODUCT MANAGER
CLINTON TWP., MI. U.S.A.
JAN 2023
[phone]
GAGE BILT

4REV. 2/23
GB808V POWERUNIT
The GB808V 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 GB808V 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 GB808V 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 GB808V
Series powerunit can be configured to operate one or more tools simultaneously. The GB808V Series powerunit 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 GB808V Series Powerunit can be operated between 0ºF - 118ºF (-17.8ºC / 47.8ºC)
DESCRIPTION
WARNING: Any other use is forbidden.
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.

5REV. 2/23
GB808V POWERUNIT
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

6REV. 2/23
GB808V POWERUNIT
DESCRIPTION OF FUNCTIONS
Vacuum Inlet
Hydraulic Outlet
Air Inlet
Pintail Evacuation
Spent Pintail Collection
Air Outlet
Regulator
Oil Reservoir Cap
Eyebolt to attach
lanyard assembly
Booster Assembly
PULL/RETURN
Four-way Valve
Muffler/Air exhaust
Muffler/Air exhaust
Muffler/Air exhaust
Pop Safety Valve
Tool rests on hook when not in
use, shutting off air flow to vacuum
Images may not reflect actual tool

7REV. 2/23
GB808V POWERUNIT
PRINCIPLE OF OPERATION
Incoming air is regulated between 80 - 100 psi. (5.5 - 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.
4 WAY VALVE / HYDRAULIC FLOW
FOUR-WAY VALVE
RETURN PULL
HYDRAULIC FLOW
“PULL”
“RETURN”
EXHAUSTED
RETURN PULL
HYDRAULIC FLOW
“PULL”
“RETURN”
EXHAUSTED AIR
Images may not reflect actual tool

8REV. 2/23
GB808V POWERUNIT
The tool is shipped with a red 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 shipping plug from air inlet on regulator (A-1291) and screw in your quick disconnect (air) fitting.
2. Open cap on top of oil reservoir and fill with AW-32® oil or equivalent to approximately 3/4 full, if required.
3. Connect the installation tools hydraulic line, air line, vacuum line and lanyard to powerunit. (Make sure all connections are secure).
4. Connect air supply using 1/2” (12.7 mm) air line min. Set air pressure to 80 - 100 P.S.I. (5.5 - 6.9 bar) Max. on (A-1291) regulator.
5. Cycle tool five times.
6. See tool manual for complete set up installation instructions.
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.
● 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.
HOW TO SET-UP THE GB808V SERIES POWER UNIT
Images may not reflect actual tool
Open oil reservoir
cap & fill reservoir
Hydraulic
oil reservoir
Install evacuation hose
from tool into vacuum
regulator fitting.
Install air lines from tool into
A-577 & A-579 on powerunit.
Install hydraulic coupler-male
from tool into hydraulic coupler-
female on power unit
Powerunit shown without frame assembly
Air Hose
Air Inlet
Red Shipping Plug
User Quick Disconnect Fitting
Pintail Collection bottle
Pintails extracted from tool and
collected in collection bottle
Four-Way Valve
Air Filter/ Regulator
Hydraulic oil flows from booster
assembly thru hydraulic line into tool
PULL/RETURN
Booster Assembly
Pop Safety Valve
Tool rests on hook when not in use,
shutting off air flow to vacuum

9REV. 2/23
GB808V POWERUNIT
HOW TO USE THE GB808V SERIES POWER UNIT
The GB808V series powerunit is designed to work in conjunction with Gage Bilt’s split handle (SHA) or split riveter (SRA) fastener
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.

10 REV. 2/23
GB808V POWERUNIT
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.
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 below).
* 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
* 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).
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.

11 REV. 2/23
GB808V POWERUNIT
FILLING AND BLEEDING
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
tool manual for step by step bleeding procedure).
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).
7. Repeat 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 1-8 until stroke met.
HANDLE/TOOL BOOSTER
Bleed port

12 REV. 2/23
GB808V POWERUNIT
If a tool 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.
2. Disconnect hose assemblies (808105 & 808106) connected to booster assembly (808009).
3. Disconnect air line (808023) from elbow (A-1077). (See pg. 14 Quick Exhaust Valve).
4. Loosen and remove (2X) hex nuts (400216) & (2X) split lock washers (400182) from mounting brackets (808049 & 808050) then
carefully remove booster assembly (808009). (See pg. 13).
5. Remove five hex bolts (2X) (407708) & (3X) (407710) and disassemble. (See parts lists pg. 13).
6. Replace o’rings and polyseals (4X) 400826, (2X) 404228, (3X) 407694 & 407693. (See parts lists pg. 13).
7. Reassemble booster assembly (808009). Apply thread sealant (if required) to all necessary fittings. (See hydraulic thread preparation).
8. 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
booster assembly parts lists pg. 13).
9. Secure booster assembly (808009) to mounting brackets (808049 & 808050) and reattach all hose assemblies. (See parts lists pgs. 14 & 15).
10. Bleed tool and booster assembly (808009) per bleeding procedure (See pg. 11).
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.
OVERHAUL BOOSTER ASSEMBLY
WARNING: Only qualified and trained personnel shall perform overhaul.
WARNING: Personnel must read and understand all warnings and cautions.
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 must be done by qualified personnel trained on Gage Bilt procedures.
WARNING: Disconnect tool 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 tool, wear approved eye protection. Do not look in front of tool or
rear of tool when installing fastener.
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).
TOOL DISPOSAL
An oil pan assembly (808148) with a drain plug (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) (drain plug) under powerunit.
3. Using an allen wrench, loosen and remove the button head cap screw (402482) and stat-o-seal (S572) letting the hydraulic oil
drain from the hole into an approved container. It may be necessary to tilt the powerunit to remove all hydraulic oil. Be sure to dispose
of oil in accordance with manufacture safety datasheet. 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.

13 REV. 2/23
GB808V POWERUNIT
OVERHAUL BOOSTER ASSEMBLY

14 REV. 2/23
GB808V POWERUNIT
GB808V POWER UNIT (BOOSTER ASSEMBLY)
GB808V POWER UNIT (QUICK EXHAUST VALVE )

15 REV. 2/23
GB808V POWERUNIT
GB808V POWER UNIT (VALVE ASSEMBLY)
GB808V POWER UNIT (REGULATOR ASSEMBLY)

16 REV. 2/23
GB808V POWERUNIT
GB808V POWER UNIT
GB808V POWER UNIT (VACUUM & BOTTLE ASSEMBLY)

17 REV. 2/23
GB808V POWERUNIT
GB808V POWER UNIT (FRAME ASSEMBLY)

18 REV. 2/23
GB808V POWERUNIT
FIRST AID MEASURES
Eye: In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.
Skin: In case of contact, immediately wash skin with soap and plenty of water. If irritation develops, consult a physician.
Ingestion: If swallowed, do not induce vomiting. Give large quantities of water. Never give anything by mouth to an
unconscious person. Call a physician.
Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen.
Call a physician.
Additional: Gastric lavage by qualified medical personnel may be considered, depending on quantity of material ingested.
FIRE
Leaks/ruptures in high pressure system using materials of this type can create a fire hazard when in the vicinity of ignition
sources (e.g. open flame, pilot lights, sparks, or electric arcs).
FLAMMABLE PROPERTIES:
Flashpoint: > 300
EXTINGUISHING MEDIA: Water spray, dry chemical, CO2, Foam.
PROTECTION OF FIRE FIGHTERS:
Special Firefighting Procedures: Water or foam may cause frothing. Use water to keep fire-exposed containers cool.
Water spray may be used to flush spills away from exposures.
Unusual Fire & Explosion: Products of combustion may contain carbon monoxide, carbon dioxide and other toxic
materials. Do not enter enclosed or confined space without proper protective equipment including respiratory protection.
SPILL OR LEAK PROCEDURES
Spill Procedures: Contain spill immediately in smallest possible area. Recover as much of the product a possible by shovel,
vacuuming or other mechanical means. Non-recoverable product, contained soil, debris and other materials should he
placed in proper containers for ultimate disposal. Avoid washing, draining or directing material to storm or sanitary sewers.
Waste Disposal: Recycle as much of the recoverable product as possible. Treatment, storage, transportation and disposal
must be in accordance with applicable Federal, State/Provincial, and Local regulations
AW-32® OIL SAFETY DATA

19 REV. 2/23
GB808V POWERUNIT
This page intentionally left blank

20 REV. 2/23
GB808V POWERUNIT
Hydraulic Powerunits
Compatible with Gage Bilt and Huck® Air/hydraulic installation tools
Images may not reflect actual tool
Hose kits available up to 26 ft. Contact
Gage Bilt for all other hose lengths.
Hose Kits available to 26 ft (7.92 m)
Pressure 4,000 lbs. (177.93kN) @ 90 PSI (6.2 bar)
Fast Acting Cylinder
Requires 1/2" (12.7 mm) Air Hose
POWER: 80-100 PSI compressed air (5.2-6.9 bar)
GB808 Dimensions & weight shown below.
For all other models dimensions & weights contact
Gage Bilt.
WEIGHT: 40 lbs (18.1)
HEIGHT: 16.5” (419.1 mm)
WIDTH: 9.0" (228.6 mm)
LENGTH: 24" (609.6 mm)
LUBRIPLATE® IS A REGISTERED TRADEMARK OF FISKE BROTHERS REFINING. TEFLON® IS A REGISTERED TRADEMARK OF E.I. DUPONT DE NEMOURS & CO. LOCTITE® IS A REGISTERED TRADE-
MARK OF HENKEL CORPORATION. HUCK® IS A REGISTERED TRADEMARK OF HOWMET AEROSPACE. AW-32® IS A REGISTERED TRADEMARK OF CHEVRON INTELLECTUAL PROPERTY LLC. SLIC-
TITE® IS A REGISTERED TRADEMARK LA-CO INDUSTRIES.
GB808HVB
HANGING POWERUNIT WITH VACUUM
(Sold Separately)
*GB808 WHEELS OPTIONAL
GB808
POWERUNIT
(Sold Separately)
GB808HVB-100
HANGING POWERUNIT WITH VACUUM
& PINTAIL SENSOR
(Sold Separately)
GB808HVB-100
HANGING POWERUNIT WITH VACUUM
& PINTAIL SENSOR
(Sold Separately)