12
Rev. 5/22
GB204/GB204(A) INSTALLATION TOOL
•
Note: Gage Bilt does not recommend using a pneumatic lubricator or adding pneumatic oil to the air inlet on our tools or powerunits.
OVERHAUL
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 data sheet 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).
WARNING:
Do not exceed the maximum relief
-
valve setting stated on the tool and manual.
WARNING:
Relief valve must be installed with four flats towards the rear of the cylinder.
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) or equivalent during reassembly to prevent tearing or distorting of o'rings.
1. Disconnect electric cord (206136) / air line (208126) from power supply.
2. Disconnect hydraulic hoses (206119) from power supply.
3. Remove hydraulic coupler
-
male (585047) & hydraulic coupler
-
female (585038) from hydraulic hoses (206119) and drain into a
container. Remove nose assembly.
4. Push piston assembly (204111) rearward until remaining hydraulic oil is drained. Push piston back to the front of cylinder assembly (204103).
5.
Unscrew socket head cap screw (206118) from retaining ring (206117) using a spanner wrench to remove retaining ring.
6.
Push piston assembly (204111) back until cylinder cap assembly (206115) falls out of cylinder assembly (204103).
7.
Continue pushing piston assembly (204111) rearward until piston assembly (204111) is out of cylinder assembly (204103).
Remove relief valve (206109) or (206110) and stroke limiter (206112), depending on stroke requirements, from the piston assembly (204111).
8.
Remove all O
’
rings and Back
-
up rings. Clean parts in mineral spirits or other o'ring compatible solvent being sure to clean
o'ring grooves. Inspect components for scoring, excessive wear or damage.
9. Reassembly sequence is opposite of disassembly. Be sure relative positions of o'rings and back
-
up rings are as shown in
exploded view and part list. When reinstalling relief valve (206109 or 206110) be sure flats are to rear of tool (see pg. 13).
Coat hose fitting threads with a non
-
hardening Teflon thread compound such as Slic
-
tite®. DO NOT USE TEFLON TAPE.
(
See hydraulic thread preparation pg.10)
.
Apply hot glue to wire connections of the electric actuator (240122) to ensure wires DO NOT contact each other. (Electric actuated
installation tool GB204 only).
TOOL DISPOSAL
1.
When tool life is met, drain hydraulic oil from tool and dispose of the hydraulic oil in accordance with the safety datasheet.
2.
Disassemble tool and remove all rubber o
’
rings, seals, wipers and hydraulic hoses. All tool materials are recyclable except rubber
o
’
rings, seals, wipers and hydraulic hoses. Dispose of rubber materials in accordance with the material safety datasheet.
Note:
•
Dispose of hydraulic oil in accordance with manufacture safety datasheet.
•
All tool materials are recyclable except rubber o
’
rings, seals and wipers.
•
Use of SERIVE KIT (206100), which contains a complete set of o'rings, back
-
up rings and screws, can achieve a
complete overhaul.
