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6

 

REV. 6/22

 

 

GB786/204 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 equip

-

  

ment and/or structure.

 

 

Notes 

-

 

are reminders of required procedures.

 

 

-

 Read manual prior to using equipment 

 

-

 Wear safety boots

 

Summary of Contents for GB786

Page 1: ...WIDE E MAIL US FOR A DISTRIBUTOR NEAR YOU GB786 204 INSTALLATION TOOL ORIGINAL INSTRUCTIONS 44766 Centre Court Clinton Twp MI 48038 USA Ph 1 586 226 1500 Fax 1 586 226 1505 solutions gagebilt com www...

Page 2: ...cations 4 Description of Functions 5 Warnings 6 Principle of Operation 7 How to set up the GB786 204 8 How to use the GB786 204 9 Maintenance 10 Filling Bleeding 11 12 Troubleshooting 13 Overhaul 14 1...

Page 3: ...equent 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 not...

Page 4: ...s 23 1 kN at 90 psi 6 2 bar air pressure at the air inlet The GB786 204 comes with 8 ft 2 4 m of hose and a remote actuator The GB204 cylinder when held in your hand weighs just 2 0 lbs 0 91 kg while...

Page 5: ...6 204 INSTALLATION TOOL DESCRIPTION OF FUNCTIONS Image may not reflect actual tool Head Cylinder Actuator Assembly Air Air Line Hydraulic Hose Return Hydraulic Hose Pull Air Inlet Handle Manifold Hand...

Page 6: ...ue 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...

Page 7: ...the rear of the head cylinder is directed to the bottom of the piston rod assembly inside the handle assembly The internal components of the attached nose assembly are also moving with the piston asse...

Page 8: ...whipping WARNING Always disconnect air supply when tool is not in use to prevent accidental start up WARNING Ensure there is adequate clearance for tool and operator hands CAUTION Do not use beyond t...

Page 9: ...at eye protection hearing protection and safety boots be worn at all times while handling this equipment WARNING The users or the user s employer must assess specific risks that could be present as a...

Page 10: ...or tool repair 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 air and el...

Page 11: ...303 8 Attach air bleeder assembly 704153 to the pressure side marked P on the rear of cylinder 204300 9 Squeeze fill bottle 745263 on manifold handle 745303 until no air rises into air bleeder assembl...

Page 12: ...old handle 786303 Torque to 35 40 in lbs 3 95 4 52 Nm Do not over tighten 4 With tool connected to air slowly loosen button head cap screw 402482 marked P on back of cylinder 204300 CAUTION TOOL IS UN...

Page 13: ...ir valve and the piston assembly 204203 will retreat to its full stroke without returning b If o ring 400787 on valve plug 870158 is worn or damaged replace c If o rings 400780 on valve spool assembly...

Page 14: ...ck up rings screws washers and gasket can achieve a complete overhaul TOOL DISPOSAL 1 When tool life is met drain hydraulic oil from tool and dispose of the hydraulic oil in accordance with the safety...

Page 15: ...ch air piston 870169 to piston rod assembly 786133 Insert cotter pin 401314 5 With the piston rod in the down position fill oil passage on top of handle 870149 with automatic transmission oil Dexron I...

Page 16: ...16 REV 6 22 GB786 204 INSTALLATION TOOL PARTS LIST 1 204203 Piston Assembly includes 403810 401114 2 206115 Cylinder Cap Assembly includes 405758 401105 405832...

Page 17: ...LIST WARNING This tool incorporates a patented hydraulic relief valve When overhauling tool o ring A 287 back up ring 401101 retaining ring 400936 and spring 50806 must be replaced Failure to do so co...

Page 18: ...is material undergoes combustion ACCIDENTAL RELEASE MEASURES Protective Measures Eliminate all sources of ignition in vicinity of spilled material Spill Management Stop the source of the release if yo...

Page 19: ...4D 37OS 1 8 MBC04 204D 27OS MBC04 204D 37OS 5 32 MBC05 204D 27OS MBC05 204D 37OS 3 16 MBC06 204D 27OS MBC06 204D 37OS 13 64 GS8 204D 32OS GS8 204D 42OS 17 64 GS10 204D 32OS GS10 204D 42OS GP M GP LGP...

Page 20: ...lt also supplies pin collar swage inspection gages to certify correct swage installation Sold Separately Grip Gage GB105093 For NAS LOCKBOLTS and blind fasteners Sold Separately Accessories Cont Appro...

Page 21: ...les Sold Separately GB745 204 Stroke 500 12 7mm Hand held weight 1 5 lbs 68 kg Entire tool weight 9 lbs 4 kg Pull load 5 600 lbs 24 9 kN Standard Hyd Hose Length 8ft 2 4m 5ftHyd Hosesarerecommendedwit...

Page 22: ...ength 12ft 3 7m Hydraulicpowerunitisrequiredtoruntool soldseparately ContactGageBiltformoreinformation Alternative Styles Sold Separately GB204ASH Stroke 500 12 7mm Hand held weight 3 5 lbs 1 58 kg En...

Page 23: ...23 REV 6 22 GB786 204 INSTALLATION TOOL This page intentionally left blank...

Page 24: ...I DUPONT DE NEMOURS CO LUBRIPLATE IS A REGISTERED TRADEMARK OF FISKE BROTHERS REFINING CO SLIC TITE IS A REGISTERED TRADEMARK OF LA CO INDUSTRIES INC Riveter Kits Available Sold Separately Gage Bilt...

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