Gage Bilt GB902 User manual

GAGE BILT Inc.
44766 Centre Court [phone]
Clinton Twp. MI 48038 [phone] Fax
e-mail:solutions
@g
a
g
ebilt.com / www.
g
a
g
ebilt.com
GAGE BILT
MADE IN U.S.A.
GB902
HYDRAULIC POWERUNIT

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.35 inches
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.35 inches
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.00 inches
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.5 lbs
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(.4) gallons
Power Source - compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-175 psi
Air Consumption (continuous operation): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 CFM
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Motor
Pump - Air Hydraulic, Rapid Advance and Swage . . . . . . . . . . . . . . . . . . . 25 cu. in./min. @ 5000 psi
Output Pressure:
NOTE: ADJUST AIR PRESSURE ACCORDING TO REQUIRED PULL PRESSURE FOR TOOL BEING USED,
CONSULT TOOL MANUALS FOR PROPER SETTINGS.
Pull & Return max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 psi.
60 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,200 lbs.
70 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,200 lbs.
80 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,200 lbs.
90 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,200 lbs.
100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 lbs.
110 psi (MAXIMUM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (MAXIMUM OUTPUT) 10,000 lbs.
Operating temperature:
Ambient . . . . . . . . . . . . . . . . . . . . . . . . . . min. 0 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -18 C
Hydraulic Fluid...max. 150 F . . . . . . . . . . . . 65 C
Hydraulic Fluid:
Good Quality Hydraulic Oil.
2
GB902 POWERUNIT SPECIFICATIONS

3
WARNING
Do not pull fastener unless it is placed in
an assembly, pin will eject forcibly when
pintail breaks off. Severe personal injury
may result.
WARNING
Hydraulic power units that deliver high
pressure for the "PULL" and "RETURN"
and are not equipped with relief valves
are specifically not recommended and
may be dangerous.
WARNING
When operating installation equipment
always wear approved eye protection. Do
not look in front of nose assembly or rear
of tool when installing fastener.
CAUTION
Insure that nose assembly is properly
matched for the fastener being installed.
WARNING
Be sure 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.
WARNING
Installation of fasteners may exceed
acceptable noise levels. Use approved
hearing protection.
WARNING
Proper pull and return pressures are
important for proper function of
installation tools. Severe personal injury
or damage to equipment may occur
without correct pressures.
CAUTION
Keep Nose Assemblies clean and free of
chips and debris.
CAUTION:
Keep dirt and other foreign matter out of hydraulic systems of tools, hoses, couplers and
powerunit . Do not let hose fittings and couplers contact a dirty floor or unclean working
surface. Foreign matter in hydraulic fluid may cause tool and the powerunits valves to
malfunction.
WARNING
Always disconnect tool from powerunit
before performing any maintenance to
any tool or nose assembly. Insure that all
connections are proper and there are no
visible leaks from tool or hoses before
connecting to power.
NOTE:
Please read this manual before servicing or using this tool. Complete
with warnings and cautions to prevent severe personal injury or damage
the tool.

DESCRIPTION:
The GB902 Hydraulic Powerunit is a portable power source designed to operate a wide range of
hydraulic installation tools with. It delivers up to 10,000 psi working pressure. It is fired manually
by the operator and will accept any GAGE BILT or HUCK® hydraulic tool regardless of trigger
style. The unit is activated via a control valve knob and foot pedal. The GB902 consists of a two
position air hydraulic pump, four way control valve and relief valve mounted on the reservoir.
Hydraulic quick disconnect couplers are supplied for connecting the tool hoses from the
installation equipment.
INITIAL USE:
1. Filling the Reservoir.
A. Clean the area around the filler cap to remove all dust and grit. Any dirt or dust in the oil
can damage the pump.
B. Set all pistons to the return position.
C. Remove the filler cap and fill with hydraulic oil to within 3/4" from the top of the filler hole.
Replace filler breather cap.
D. Important: Use only a good quality hydraulic jack fluid. Never use brake fluid, transmission
fluid, turbine oil, motor oil, alcohol, glycerin etc. Use of other than good quality hydraulic oil
will void warranty and damage the pump, hose, and application. We recommend Mobil DTE
13M or equivalent.
EF. Cycle the pump (with tool attached) several times. Re-check the oil level in the pump reservoir
with the tool in the relaxed) position.
F. Check for leaks.
PREPARATION:
To avoid poor performance and down time, keep foreign material from getting into the hydraulic
system. Observe the following points:
1. Check tool manual for recommended pressures.
2. Wipe off couplers before connecting them.
3. Do not let hose fittings or couplers lie on the ground or dirty floor.
4. Clean area around filler cap before filling the reservoir with hydraulic fluid.
5. Use a clean funnel with filter.
6. Drain and clean reservoir and fill with clean fluid on a regular basis.
4
CAUTION:
THE AIR PRESSURE TO THE UNIT CONTROLS THE OUTPUT AND RETURN PRESSURE TO
THE TOOL AND MUST BE PROPERLY ADJUSTED FOR EACH TOOL. CONSULT TOOL
MANUALS FOR PROPER SETTINGS.
CAUTION:
SEVERE PERSONAL INJURY OR DAMAGE TO THE SYSTEM AND PERIPHERAL
EQUIPMENT MAY OCCUR IF PRESSURES ARE NOT PROPERLY ADJUSTED. CONSULT
YOUR INSTALLATION TOOL MANUAL FOR RECOMMENDED PRESSURES, AND ON PAGE
5 & 6 OF THIS MANUAL FOR DIRECTIONS.

PRESSURE SETTING:
NOTE: Preset air regulator to approximate pressure.
90 psi = 8200 lb (not to exceed 110 psi) 10 psi of air is approximately equal to 1000 lbs of
hydraulic pressure.
1. Connect Hydraulic gage to pump.
2. Turn handle to -A- position.
3. Hold down foot pedal and read hydraulic gage.
4. Put handle in center (neutral) Position.
5. Adjust air pressure accordingly.
6. Repeat until correct hydraulic pressure is set.
OPERATION:
1. Put pump handle in center (neutral) position.
2. Connect tool to pump.
3. Connect air supply to pump.
4. Insert rivet into nose assembly.
5. Turn handle on pump to position -A-.
6. Hold down on foot pedal until rivet breaks then release pedal.
7. Turn handle to center position for 2 to 5 seconds to release hydraulic pressure.
8. Turn handle on pump to position -B-.
9. Hold down on foot pedal until tool is pushed off of rivet then release pedal.
10. Turn handle on pump to center ( neutral ) position.
5
CAUTION:
HYDRAULIC PRESSURE MUST BE SET BEFORE CONNECTING TOOL:
Ensure powerunit does not exceed recommended installation tool pressures. Adjust
hydraulic pressure for required pull pressure of tool being used (refer to tool manual).
DO NOT exceed 110 psi air pressure.

MAINTENANCE:
1. Scheduled inspections to detect and correct minor problems are part of an effective
preventive maintenance program. 902000 service kit contains a complete set of gaskets,
seals and washers these items should be kept on hand at all times.
2. Inspect hydraulic fittings to make sure they are secure.
3. Inspect hoses for signs of damage. Replace hoses if necessary. Inspect during operation to
detect any leakage, abnormal heating or vibration.
4. Inspect hydraulic fluid on a regular basis. Clean reservoir and replace fluid if contamination
5 Keep exterior surfaces clean.
TROUBLESHOOTING:
Use the Troubleshooting Chart as an aid in locating problems and correcting them. Always
check out the simplest possible cause of malfunction first. Eliminate each possible cause until
the part is located. Substitute good parts for suspected bad parts.
TROUBLE SHOOTING CHART:
1. Tool will not reciprocate when motor is running.
A. Improperly coupled hoses.
B. Bind in tool or nose assembly.
C. Pump to motor coupling damaged.
D. Hydraulic fluid level is low or viscosity not proper.
E. Unloading valve in tool improperly installed or missing.
2. Fastener pintail fails to break off.
A. PULL pressure set too low.
B. Defective hose couplers.
C. Defective internal relief valve or set too low.
D. Overheated hydraulic fluid.
E. Hydraulic fluid level low or viscosity not proper.
F. Defective pump.
3. Tool will not return or push nose assembly off swaged fastener when switch is released.
A. Pressure set too low.
4. Pump making noise throughout operating cycle.
A. Pump is cavitating, the fluid viscosity is too heavy or the fluid level may be too low.
B. Filter is clogged or dirty.
6. Tool operates slow throughout entire cycle.
A. Pump is cavitating, the fluid viscosity is too heavy or the fluid level may be too low.
B. Filter is clogged or dirty.
C. Defective pump.
6
WARNING:
MAKE SURE AIR IS DISCONNECTED BEFORE SERVICING ANY COMPONENTS.

Re f. No. Par t Num be r De s cription Qty. Re f. No . Par t Nu m be r De s cr iption Qty.
1 902001 A llen Screw 9 43 902043 Pump piston 1
2 902002 Control valve cover 1 44 902044 Compression spring 1
3 902003 Set screw 1 45 902045 Pump piston guide 1
4 N/A A llen Screw 4 46 902046 Bushing 1
5 N/A Control valve base 1 47 * Back-up ring 1
6 N/A Bearing Washer 2 48 * U-cup 1
7 N/A Bearing 2 49 902049 Pump piston cylinder 1
8 * O'ring 2 50 902050 Spacer 1
9 N/A Control valve 1 51 * Crush w asher 1
10*O'ring 1 52*Gasket 1
1 1 N/A O il o u tle t v a lv e 3 5 3 * O 'rin g 3
12 N/A Spring w asher 3 54 902054 Compression spring 1
13 * Back-up ring 3 55 902055 Screw 1
14 * O'ring 3 56 902056 Air entrance cover 1
15 902015 Manifold plug (oil output port) 2 57 * O'ring 1
16 N/A Screw 2 58 902058 Plastic cap (air inlet port) 1
17 902017 Carry Handle 1 59 902059 Screw 2
18 * gasket 1 60 902060 Air entrance base 1
19 * O'ring 2 61 902061 Air entrance cover 1
20 * Back-up ring 2 62 * O'ring 1
21 902021 Oil outlet valve 1 63 N/A C-clip 1
22 * Compression spring 1 64 902064 Noise suppressor 1
23 902023 Steel ball 1 65 902065 Foot pedal 1
2 4 * O 'r in g 1 6 6 N /A O il m a n if o ld 1
25 * Washer 6 67 N/A Screw 1
26 N/A Top reservoir plate 1 68a 902068 Shipping plug (red) 1
27 N/A Base 1 68b 902068-1 A ir vent plug (black) 1
28 * Crush Washer 2 69 N/A Spring pin 1
29 902029 Relief valve screw 1 70 N/A Compression spring 2
30 902030 Relief valve stem 1 71 902071 Steel ball 2
31 * Compression spring 1 72 902072 Control valve lever 1
32 902032 Relief valve screw 1 73 902073 Control valve knob 1
33 902033 Steel ball 1 74 403683 Nipple 2
34 902034 Oil entrance valve 1 75 585038 Coupler-female 1
35 902035 Filter 1 76 585047 Coupler-male 2
36 * Gasket 1 77 403912 Reducer 1
37 902037 Oil Reservoir 1 78 A -1080 Hydraulic pressure gauge 1
38 902038 A llen Screw 4 79 A-1079 Regulator 1
39 902039 End plate, air motor 1 80 A -1030 Pressure gauge 1
40 902040 Washer 2 81 A-92 Nipple 1
41 902041 A ir motor piston 1 (*) 902000 Service Kit
42 902042 Cylinder, air motor 1
GB902 Parts List
*Indicates items included in, an available only as part of 902000 service kit.
N/A = Not all components of the pump are replacement items, but are illustrated as a reference of location and position in the assembly.

W ARR ANTY
Seller warrants that all goods covered by this catalog will conform to
applicable specifications and will replace, or repair, F.O.B. our plant, any
goods providing defective from faulty workmanship, or material, for 90 days
from date of shipment.
Said warranty to rem ain 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 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 th e 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 90 days after the receipt of the material by the customer.
THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY.
GB902 Powerunit Kits
The GB902 Powerunit is available in various kits to suit your particular need. The kits include
the GB902 Powerunit, hoses and hydraulic couplers.
The GB902-12 Kit includes the GB902 Powerunit and a 12-foot Hose Kit, part number 902701
The GB902-26 Kit includes the GB902 Powerunit and a 26-foot Hose Kit, part number 902705
The GB902-38 Kit includes the GB902 Powerunit and a 38-foot Hose Kit, part number 902709
The GB902-52 Kit includes the GB902 Powerunit and a 52-foot Hose Kit, part number 902714
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