ORIGINAL INSTRUCTIONS GB2480/GB2480(A) HYDRAULIC INSTALLATION TOOL

Transcription

1 ORIGINAL INSTRUCTIONS GB2480/GB2480(A) HYDRAULIC INSTALLATION TOOL GAGE BILT TOOLS ARE AVAILABLE WORLDWIDE US FOR A DISTRIBUTOR NEAR YOU. GAGE BILT MADE in USA Centre Court Clinton Twp. MI USA Ph: +1 (586) Fax: +1 (586) solutions@gagebilt.com /

2 TABLE OF CONTENTS Page EU Conformity and Warranty... 3 Description and Technical Specifications... 4 Description of Functions... 5 Safety Warnings... 6 Principle of Operation... 7 How to set-up the GB2480/GB2480A... 8 How to use the GB2480/GB2480A... 9 Maintenance and Hydraulic Thread Preparation Troubleshooting Overhaul Stroke Limiter & Relief Valve Installation/Removal Parts Lists GB2480 / GB2480A Nose Assembly Selection Chart and Accessories

3 DECLARATION OF CONFORMITY MANUFACTURER: Gage Bilt Inc Centre Ct. Clinton Twp. Michigan U.S.A. +1( ) WE DECLARE THAT THE EQUIPMENT SPECIFIED HEREIN CONFORMS TO THE FOLLOWING DIRECTIVES AND STANDARDS Machinery Directive 2006/42/EC EN & EN EN792-1:2000+A1 EU REPRESENTATIVE: Edgar Hausmann GmbH Förster-Busch-Str. 10 D Hann. Münden Germany EQUIPMENT DESCRIPTION: GB2480/GB2480A FASTENER INSTALLATION TOOL This product specified above conforms to the above directives and standards. SIGNATURE: GAGE BILT NAME: BRIAN LEIGH PRODUCT MANAGER CLINTON TWP., MI U.S.A. MAY (586) WARRANTY 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. 3

4 DESCRIPTION WARNING: Any other use is forbidden. The GB2480 & GB2480(A) are a hydraulic installation tool designed specifically for the efficient installation of blind fasteners, lockbolts and Multi-Grip fasteners thru 1/4" diameter. It weighs just 3 1/2 lbs. (1.59 kg) and can be operated in any position. It has an.875 (22.2 mm) rivet setting stroke and rated pull load of 5,600 lbs. (24.91 kn). The GB2480 (electric actuated) installation tool operates on hydraulic pressure developed by the GB940 Powerunit set at 8,400 psi (579.1 bar) max PULL pressure and 3,200 psi (220.6 bar) max RETURN pressure. The tool comes equipped with 12 ft. (3.66 m) hydraulic hoses and couplings, electric switch and cord. The GB2480(A) (air actuated) installation tool operates on hydraulic pressure developed by the GB910 Powerunits set at 8,400 psi (579.1 bar) max PULL pressure and 3,200 psi (220.6 bar) max RETURN pressure. The tool comes equipped with 12 ft. (3.66 m) hydraulic hoses and couplings, air actuator and tubing. NOSE ASSEMBLIES ARE NOT FURNISHED WITH THE INSTALLATION TOOL AND MUST BE ORDERED SEPARATELY. (See nose assembly selection chart on pg. 16). WARNING: Do not operate in an explosive atmosphere. ENVIRONMENTAL USE The GB2480 and GB2480(A) can be operated between 0ºF - 118ºF (-17.8ºC ºC) SPECIFICATIONS Weight Hyd. Pressure Req'd Hyd. Power Source Hydraulic oil Setting stroke Rated pull load Noise level Vibration - 3 1/2 lbs. (1.59 kg) psi (579.1 bar) MAX PULL psi (220.6 bar) MAX RETURN - GB940 or GB910 Powerunit or equivalent. - See power unit for hydraulic oil specifications -.875" (22.23mm) - 5,600 lbs. (24.91 kn) db (A) - Tested No hazards found. 4

5 DESCRIPTION OF FUNCTIONS GB2480 GB2480A Deflector Deflector Handle Handle Electric Actuator Air Actuator Hydraulic Hose Return Hydraulic Hose Return Air line Electrical Control Cord Hydraulic Hose Pull Hydraulic Hose Pull 5

6 SAFETY WARNINGS TERMS AND SYMBOLS GENERAL SAFETY RULES: 1. For multiple hazards, read and understand the safety warnings 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 should 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 warnings; 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 periodically to verify all ratings and markings required are legible. The employer/user shall contact the manufacturer to obtain replacement marking labels when necessary. 7. Air under pressure can cause severe injury. 8. 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. 9. Never direct air at yourself or anyone else. 10. Whipping hoses can cause severe injury. Always check for damage or loose hoses and fittings. 11. Cold air shall be directed away from hands. 12. Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables shall be used to safeguard against possible hose-to-tool or hose-to-hose connection failure. 13. Do not exceed the maximum air pressure stated on the tool or manual. 14. Never carry an air tool by the hose. ADDITIONAL SAFETY RULES FOR HYDRAULIC POWER TOOLS: 1. Do not exceed the maximum relief-valve setting stated on the tool and manual. 2. Carry out a daily check for damaged or worn hoses or hydraulic connections and replace if necessary. 3. Use only clean oil and filling equipment. 4. Power units require a free flow of air for cooling purposes and should therefore be positioned in a well ventilated area free from hazardous fumes. 5. Ensure that couplings are clean and correctly engaged before operation. 6. Do not inspect or clean the tool while the hydraulic power source is connected. Acci dental engagement of the tool can cause serious injury. 7. Do not install or remove the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. 8. Be sure all hose connections are tight. 9. Wipe all couplers clean before connecting. Failure to do so can result in damage to the quick couplers and cause overheating. 10. Max. hydraulic tool inlet temp. 118ºF 48ºC PROJECTILE HAZARDS: - Product complies with requirements - Read manual prior to using equipment - Hearing protection and eye protection - Wear safety boots 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. 1. Disconnect the tool from the energy source when changing inserted tools/nose assemblies or accessories. 2. Be aware that failure of the workpiece or accessories, or even the inserted tool/nose assembly itself can generate high-velocity projectiles. 3. Always wear impact resistant eye protection during operation of the tool. The grade of protection required should be assessed for each use. 4. The risk to others should also be assessed at this time. 5. Ensure that the workpiece is securely fixed. 6. Check that the means of protection from ejection of fastener and/or stem is in place and operative (such as the deflector). 7. 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 maintaining 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 recommended 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 surfaces 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 insulated 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). Therefore, risk assessment and the implementation of appropriate controls for these hazards are essential. 2. Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpieces from ringing. 3. Use hearing protection in accordance with employer's instructions and as required by occupational health and safety regulations. 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. 6

7 PRINCIPLE OF OPERATION When the tool is connected to a powerunit, operation is controlled by a actuator or switch in the handle. The GB2480A incorporates an air actuator to send a signal; the GB2480 an electric switch. When the button is depressed, a directional valve in the powerunit directs oil to the front side of the piston forcing it and the nose assembly collet rearward. This action causes the jaws to clamp on the fastener pintail and pull the sheets together. The anvil is forced over the collar, swaging it into the locking grooves of the fastener. Further force breaks the pintail off, approximately flush with the collar. When the piston nears the end of its stroke it exposes flats on the back of the unloading valve. These flats "dump" oil back to the powerunit tank. When the button is released the directional valve reverses oil flow to the back of the piston and pushes the nose assembly off of the swaged fastener. The spent pintail is released and drops out the back of the tool. HYDRAULIC DIAGRAM Piston Travel Piston Travel Actuator Actuator PULL (Pressurized Oil) PULL (Unpressurized Oil) RETURN (Unpressurized Oil) RETURN (Pressurized Oil) RETURN (Unpressurized Oil) PULL (Pressurized Oil) Pressurized Oil Unpressurized Oil Images may not reflect actual tool 7

8 HOW TO SET-UP THE GB2480 / GB2480A WARNING: Only qualified and trained operators should 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 safety boots be worn at all times while handling this equipment. WARNING: The users or the user s employer should assess specific risks that could be present before each use based on their application. 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. 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. Verify that hydraulic hose fittings and couplings, air and electrical connections are secure before each use. WARNING: Do not pull fastener in the air. Personal injury from fastener ejecting may occur. WARNING: Do not carry from hoses or use as a hammer. WARNING: Do not use in explosive atmosphere. WARNING: Ensure air hose is securely connected to avoid possible hose whipping. WARNING: Always disconnect air supply, where applicable, when tool is not in use to prevent accidental start-up. WARNING: Do not exceed the maximum relief-valve setting stated on the tool and manual. WARNING: Do not operate when recommended pressures are exceeded as it could cause severe personal injury and or damage the equipment. WARNING: Use only Gage Bilt hydraulic hoses and couplings, or equivalent, rated for 10,000 psi. (689.5 bar) working pressure. CAUTION: Do not use beyond the design intent. #1. Set hydraulic power unit to the recommended pressure, 8,400 psi (579.1 bar) Max. for the pull and 3,200 psi (220.6 bar) Max. for the return. Gage Bilt pressure gage assy (942280) is recommended to aid in this procedure. See hydraulic power unit manual for correct procedure when adjusting pressures. 8,400 psi (510.2 bar) Max. for the pull 3,200 psi (220.6 bar) Max. for the return Images may not reflect actual p.s.i. settings Note: Power units require a free flow of air for cooling purposes and should therefore be positioned in a well ventilated area free from hazardous fumes. #2. Attach deflector (756120) to rear of end cap (248019) located on rear of handle & cylinder machined (248004). Rotate deflector (756120) away from operator and other persons working in the vicinity. #3. Turn off the hydraulic power unit. Wipe all couplers clean before connecting. Failure to do so can result in damage to the couplers and cause overheating. Connect hydraulic hoses then electric cord / air line to power supply. #4. Turn hydraulic power unit on and cycle tool five times by depressing actuator to ensure piston assy (248010) is in the full forward position. #5. Disconnect hydraulic hoses (206119) and electric cord (206136) / air line (208126) from power supply. #6. Select proper Nose Assembly. (See nose assembly selection chart on pg.16 and proper data sheet). #7. Hold piston assy (248010) in place using a 3/8 allen wrench in the back of the piston and screw collet securely on piston assy. #8. Slide anvil over collet, slide retaining nut stop (240102) and retaining nut (211102) over anvil and tighten retaining nut (211102). (See proper data sheet for further instructions). #9. Re-connect electric cord (206136) / air line (208126) and hydraulic hoses (206119) to power supply. 8

9 HOW TO USE THE GB2480 / GB2480A WARNING: Only qualified and trained operators should 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 safety boots be worn at all times while handling this equipment. WARNING: The users or the user s employer should assess specific risks that could be present before each use based on their application. 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. 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. Verify that hydraulic hose fittings and couplings, air and electrical connections are secure before each use. WARNING: Do not pull fastener in the air. Personal injury from fastener ejecting may occur. WARNING: Do not carry from hoses or use as a hammer. WARNING: Do not use in explosive atmosphere. WARNING: Ensure air hose is securely connected to avoid possible hose whipping. WARNING: Always disconnect air supply, where applicable, when tool is not in use to prevent accidental start-up. WARNING: Do not exceed the maximum relief-valve setting stated on the tool and manual. WARNING: Do not operate when recommended pressures are exceeded as it could cause severe personal injury and or damage the equipment. WARNING: Use only Gage Bilt hydraulic hoses and couplings, or equivalent, rated for 10,000 psi. (689.5 bar) working pressure. CAUTION: Do not use beyond the design intent. Lockbolts 1. Insert fastener through the work piece. 1. Insert fastener. Blind Fasteners 2. Slide collar over fastener. 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. Insert fastener into nose assembly. 3. Press actuator to start cycle. 4. Press actuator to start cycle. 5. Release actuator as soon as fastener breaks. 6. Repeat steps Release actuator as soon as fastener breaks. 5. Repeat steps 1-4. Images may not reflect actual tool or fastener 9

10 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 SDS 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. The performance of any tool depends upon good maintenance practices. Following these minimal requirements daily will extend the life of your tool. *Only use a clean dry air supply set at p.s.i. ( bar) Max. equipped with a filter-regulator to prevent wear. *Check tool and nose assembly for damage. (Replace/Repair if necessary). See Overhaul (pg. 12) for 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 electrical 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. *Only use a hydraulic power source equipped with relief valves and pressures set within specific limits (See required max pressure for pull and return). * Keep hydraulic system free of dirt. Avoid letting couplers contact a dirty floor. * Do not use as a hammer to force fasteners into holes or otherwise abuse tool. * Proper care by operators is necessary in maintaining full productivity and reducing downtime. *Keep nose assemblies, especially jaws, clean and free of chips and debris. Lube jaws and collet surfaces that jaws ride on with light machine oil on a daily basis. *All Screwed End Caps, Base Covers, Air Fittings, Air Actuators, Screws and Nose Assemblies are to be examined at the end of each working shift to check that they are secure. SEE TROUBLESHOOTING (PG. 11) AND OVERHAUL (PG. 12) FOR FURTHER GUIDANCE. 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 malfunction or damage. CLEANING AND LUBRICATING PROCEDURE Daily cleaning and lubrication of nose assembly will greatly reduce downtime and increase life of components. Using sewing machine oil, or an equivalent cleaner/lubricant, follow instructions below. CLEANING Clean nose assy daily or as often as needed. 1. Dip nose assy into mineral spirits or similar solvent to clean jaws and wash away metal chips and debris. DO NOT allow jaws to come in contact with other solvents. DO NOT let jaws soak. Dry jaws immediately. 2. Disassemble nose assy and use a sharp pick to remove embedded particles from grooves of jaws. LUBRICATING Lubricate nose assy after each cleaning and as often as needed. 1. Disconnect tool vacuum line (if equipped). 2. Point nose assembly into oil as shown. 3. Cycle tool 8-10 times and wipe dry. Image may not reflect actual tool 10

11 TROUBLESHOOTING Providing all maintenance conditions have been met, follow this systematic approach to diagnosis. 1. NO OPERATION WHEN ELECTRIC ACTUATOR (240122) OR AIR ACTUATOR ASSY (240123) IS DEPRESSED. a.) Check powerunit power source. b.) Control cord may be loose or damaged. c.) Faulty actuator. Replace. d.) Check hydraulic couplings; tighten, repair or replace. 2. SLOW OR PARTIAL OPERATION WHEN ELECTRIC ACTUATOR (240122) OR AIR ACTUATOR ASSY (240123) IS DEPRESSED. a.) Low hydraulic pressure. Check powerunit, adjust. b.) Back-up ring (401110) or o'ring (403806) on the piston assy (248010) could be worn or damaged. Replace. c.) Solenoid pin in directional valve on powerunit worn or peened over. Replace. d.) Excessive wear or scoring on moving parts. Check and replace faulty parts. 3.TOOL OPERATES IN REVERSE. a.) Tool stops in back position. Hydraulic hoses are reversed. Correct. 4. HYDRAULIC OIL OVERHEATS. a.) Powerunit motor rotation reversed. Electrical connections reversed. See powerunit instructional manual. b.) Restrictions in either hydraulic lines, hoses or couplings. Check and Tighten, clean or replace. 5. 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. 6.PINTAIL GROOVES STRIPPED DURING PULL STROKE. a.) Nose Assembly must be pushed onto fastener fully. b.) Chips may have collected in chuck jaws. Disassemble nose assembly, clean jaws in mineral spirits using sharp pointed object and re-lube surfaces jaws ride on. c.) Chuck jaws may be worn or damaged. Replace d.) Pintail too short for jaws to properly grip. Select proper grip length fastener. e.) Excessive gap between sheets. Reduce gap before attempting to install fastener. 7. NOSE ASSEMBLY WON'T ACCEPT FASTENER PINTAIL. a.) Spent fastener stem may be jammed in pulling head. Disassemble and check for worn or broken parts in nose assembly. Replace defective parts, clean and re-lube before reassembling. 8. PINTAIL OF FASTENER FAILS TO BREAK. a.) Improper tool operation. b.) Pull grooves on fastener stripped. (See #6 above). c.) Pull pressure too low. d.) Worn relief valve. 11

12 OVERHAUL WARNING: Only qualified and trained personnel should 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 should 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 should be avoided (See SDS 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. Note: Dispose of hydraulic oil in accordance with manufacture safety datasheet. All tool materials are recyclable except rubber o rings, seals and wipers. If a tool is performing poorly or leaking, a complete overhaul may be necessary. Service Kit (248001) for (GB2480) and (248002) for (GB2480A) contains a complete set of o'rings, back-up rings and screws. 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 ) or equivalent during reassembly to prevent tearing or distorting of o'rings. 1. Disconnect electric cord (206136) / air hose (208126) from power supply. 2. Disconnect hydraulic hose (206119) from power supply. 3. Remove hydraulic coupler-male (585047) & hydraulic coupler-female (585038) from hydraulic hose (206119) and drain into a container. 4. Remove retaining nut (211102), retaining nut stop (240102), and nose assembly. 5. Push piston assy (248010) back into handle & cylinder machined (248004) to empty all oil from tool. 6. Push piston assy (248010) back to the front of handle & cylinder machined (248004). Remove deflector (756120) and end cap (248019) from handle & cylinder machined (248004). 7. Push piston assy (248010) back until rear gland assembly (248017) falls out of cylinder. Push piston assy (248010) further back and guide it out the rear of the handle & cylinder machined (248004). 8. Remove relief valve (248013) from piston assy (248010). 9. Use an arbor to push wiper seal (405843), front gland assy (248006) and polyseal (405818) out the rear of the cylinder taking care not to mar cylinder bore. 10. Remove all O rings, Back-up rings, Wipers, Polyseals and Glyd 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. 11. 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. 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 or handle assy. (Electric actuated installation tool GB2480 only). TOOL DISPOSAL 1. When tool life is met, drain hydraulic oil from tool and dispose of the hydraulic oil in accordance with SDS 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 all environmental regulations applicable in your area. 12

13 STROKE LIMITER & RELIEF VALVE - INSTALLATION & REMOVAL WARNING: Disconnect the tool from power source when adding or removing stroke limiters and relief valves. Note: Gage Bilt does not recommend using a pneumatic lubricator or adding pneumatic oil to the air inlet on our tools or powerunits. Stroke limiters are designed for the protection of the operator and equipment. Failure to operate tool without a stroke limiter will result in damage to the nose assembly or tool and may result in personal injury. If you are unsure your nose assembly requires a stroke limiter, contact Gage Bilt. For use when a shorter stroke tool is required. (Sold separately). 1. To install or remove stroke limiter ( / ), see overhaul instructions (#1 thru #8) on pg.12 and diagrams #1 & #2 below. 2. To reduce stroke, remove relief valve (248013) from the piston assy (248010). Install stroke limiter ( / ) and relief valve ( / ), flats to rear of the tool, to piston assy (248010). Note positions and locations shown below. Note: See adapter (751204) data sheet for complete instructions on how to assemble it onto an installation tool. Dia. #1 Dia. #2 When using with RIGHT ANGLE nose assemblies, the relief valve (248155) and stroke limiter (248153) also must be used. See Chart pg. 16 Rear of tool. When using with adapter (751204) the relief valve (248154) and stroke limiter (248152) also must be used. See Chart pg. 16 Front of tool. Dia. #3 Dia. #4 Do NOT position relief valve flats to front of tool. Images may not reflect actual tool Position relief valve flats to REAR of tool. 13

14 GB2480 PARTS LIST 14

15 GB2480A PARTS LIST 15

16 ACCESSORIES GB2480/GB2480A NOSE ASSEMBLY SELECTION CHART STRAIGHT RIGHT ANGLE OFFSET Grip Gage #269G3 For CHERRYMAX and CHERRYLOCK fasteners Grip Gage #GB For NAS LOCKBOLTS and blind fasteners GAGE BILT ALSO SUPPLIES PIN & COLLAR SWAGE INSPECTION GAGES TO CERTIFY CORRECT SWAGE INSTALLATION. FASTENER DIA. STRAIGHT *RIGHT ANGLE 1 OFFSET 3 5/32 LGP LGP LGP05-204C-25OS LGP05-204C-30OS LGP LGP LGP05-204C-34OS 3/16 LGP LGP LGP06-204C-25OS LGP06-204D-30OS Lightw eight LGP LGP06-204C-34OS Groove 7/32 LGP LGP LGP07-204C-25OS LGP07-204D-30OS Proportion LGP LGP07-204C-34OS LOCKBOLT 1/4 LGP LGP LGP08-204C-25OS LGP08-204D-30OS LGP LGP08-204C-34OS 5/32 NASS NAST05-730B-20 NASS05-204C-25OS NAST05-204C-25OS LOCKBOLT, NASS NAST NASS05-204C-30OS NAST05-204C-30OS NAS SHEAR PULL TYPE, NASS NAST NASS05-204C-34OS NAST05-204C-34OS NAS TENSION PULL TYPE, 3/16 NAS06-730B-10 NAS NAS06-204C-25OS NAS06-204D-30OS NASS = SHEAR & GP NAS NAS06-204C-34OS NAST = TENSION 1/4 NAS08-730B-10 NAS NAS08-204C-25OS NAS08-204D-30OS NAS NAS08-204C-34OS COMMERCIAL LOCKBOLTS MULTI-GRIP LOCKBOLTS BLIND BOLT (SINGLE ACTION) WIT H OR W/ OUT D R IVE WA SH ER M S90353S & U / M S90354S & U M S21140S & U / M S21141S & U M AXI-BOLT, BACB30YY, YU, & YT BLIND BOLT (SINGLE ACTION) WITH DRIVE WASHER MS90353S & U / MS90354S & U MS21140S & U / MS21141S & U CR7000 SERIES, BACB30YY, YU, & YT EN6122 & UAB130-EU EN6127 & UAB6127-EU EN6128 & UAB100-EU EN6129 & UABP-EU BLIND RIVET (SINGLE ACTION) WITH OR W/OUT DRIVE WASHER NAS1900 S & U SERIES UNIMATIC SINGLE ACTION NAS1919S & U/NAS1921S & U "U" TYPE BLIND BOLT WITH DRIVE WASHER "A" CODE NAS1398A & NAS1399A T RIVET PROTRUDING HEAD, MULTI-GRIP BLIND RIVETS MONOBOLT 3/16 LB NAS06-204C-25OS 1/4 LB NAS08-204C-25OS 3/16 MG CN MG /4 MG MG /8 SB04-752C-20 SB04-752C-45 SB04-751C-54RA SB04-752B-43OS 5/32 SB05-752C-20 SB05-752C-45 SB05-751C-54RA SB05-752A-43OS SB05-752C-80 3/16 SB06-752B-20 SB06-752B-45 SB06-751B-54RA SB06-204D-27OS SB06-752B-80 1/4 SB SB08-713A-58RA SB08-204D-27OS SB08-204D-37OS 1/8 UBB04-752C-20 UBB04-752C-45 UBB04-751C-54RA UBB04-752B-43OS 5/32 UBB05-752C-20 UBB05-752C-45 UBB05-751C-54RA UBB05-752B-43OS UBB05-752C-80 3/16 UBB06-752B-20 UBB06-752B-45 UBB06-751B-54RA UBB06-204D-27OS UBB06-752B-80 1/4 UBB UBB08-713A-58RA UBB08-204D-27OS UBB08-204D-37OS 5/32 3/16 1/4 UAB08-204D-27OS 1/8 SMLS04-752C-20 SMLS04-752C-45 SMLS04-751C-54RA SMLS04-752B-43OS 5/32 SMLS05-752C-20 SMLS05-752C-45 SMLS05-751C-54RA SMLS05-752B-43OS 3/16 SMLS06-752B-20 SMLS06-752B-45 SMLS06-751C-54RA SMLS06-752B-43OS 1/4 SMLS SMLS SMLS08-713B-58RA SMLS08-752B-43OS 1/8 UBR04-752C-20 UBR04-752C-45 UBR04-751C-54RA UBR04-752B-43OS 5/32 UBR05-752C-20 UBR05-752C-45 UBR05-751C-54RA UBR05-752B-43OS 3/16 UBR06-752B-20 UBR06-752B-45 UBR06-751C-54RA UBR06-752B-43OS 1/4 UBR UBR UBR08-713B-58RA UBR08-752B-43OS 3/32 3A-352B-25 3A-751C-54RA 1/8 4A-752C-20 4A-752C-45 4A-751C-54RA 4A-752B-43OS 5/32 5A-752C-20 5A-752C-45 5A-751C-54RA 5A-752B-43OS 3/16 6A-752B-20 6A-752B-45 6A-751C-54RA 6A-752B-43OS 1/4 SMLS SMLS08-204D-27OS 3/16 6T-752A-21 6T-752A-61 1/4 8T-752A-21 8T-752A-61 3/16 MGL06-752A-21 MGL06-752A-61 MGL06-751C-54RA 1/4 MGL08-752A-21 MGL08-752A-61 3/16 MB06-752A-21 MB06-752A-61 MB06-751C-54RA 1/4 MB08-752A-21 MB08-752A-61 CONTAINER BOLT(R 12) HLPP, HLPM, HLPE, HLPS 3/8 HT HLPSC & HLPSM TLR RIVET 1/4 8TLR TLR CHERRYMAX, CHERRYMAX 'AB', BACR15FR/FP, BACR15GF/GK, NAS1900 S & U SERIES BLIND RIVET WITH DRIVE WASHER ASP ASP 2, ASP PF, ASP 4 FF, ASP 2 F, ASP 2 LC STANDARD MBC NAS1719, NAS1720 NAS1721 MBC LOCK CREATOR NAS1719X(L), NAS1720X(L) NAS1721X(L) GROUND STUD, M83454 & BACS53B 5 OPEN END, CLOSED END, C'SUNK, PROTRUDING HEAD COMMERCIAL NAIL RIVETS 1/ MAX MAX-751A MAX-751D-54RA 2 456MAX OS 5/32 3/16 4 UAB UAB UAB06-751B-54RA UAB06-752B-43OS UAB08-204D-27OS 1/4 08MAX-752B-20 08MAX-752B-45 08MAX-713A-58RA 08MAX-204D-27OS 08MAX-204D-37OS 13/64 ASP06-752C-20 ASP06-752C-45 ASP06-751B-54RA ASP06-752B-43OS 17/64 ASP08-752B-20 ASP08-752B-45 ASP08-752B-43OS 21/64 ASP ASP ASP10-204D-27OS ASP10-204D-37OS 1/8 MBC04-752C-20 MBC04-752C-45 MBC04-751C-54RA MBC04-752C-43OS 5/32 MBC05-752C-20 MBC05-752C-45 MBC05-751C-54RA MBC05-752C-43OS 3/16 MBC06-752B-20 MBC06-752B-45 MBC06-751C-54RA MBC06-752C-43OS 1/8 5/ MAX MAX-751A MAX-751D-54RA 2 456MAX OS 3/16 8/32 GS8-752C-20 GS8-752C-45 GS8-751C-54RA GS8-751A-43OS 10/32 GS10-752C-20 GS10-752C-45 GS10-752A-54RA GS10-751A-43OS 3/32 3N N N-751B-54RA 3N-751A-43OS 1/8 4N N N-751B-54RA 4N-751A-43OS 5/32 5N N N-751B-54RA 5N-751A-43OS 3/16 6N N N-751C-54RA 6N-751A-43OS UNIM ATIC,LGP, GP, BOM, AND ASP ARE REGISTERED TRADEM ARKS OF ARCONIC INC. M ONOBOLT AND TLR ARE REGISTERED TRADEM ARKS OF AVDEL UK LIM ITED. T RIVET, CHERRYM AX, M AXI-BOLT, AND M BC ARE REGISTERED TRADEM ARKS OF CHERRY AEROSPACE. GAGE BILT CERTIFIES THE GB2480(A) TOOL WILL INSTALL THE ABOVE FASTENERS *REDUCING POWER UNIT PRESSURE TO 3500PSI IS RECOMMENDED. 1) RIGHT ANGLE NOSE ASSY'S REQUIRE STROKE LIMITER & RELIEF VALVE. (SOLD SEPARATELY) 2) INSTALLS 1/8", 5/32" AND 3/16" DIAMETERS. 3) OFFSET NOSE ASSY'S REQUIRE ADAPTER AND STROKE LIMITER & RELIEF VALVE. (SOLD SEPARATELY) 4) INSTALLS 5/32", 3/16" AND 1/4" DIAMETERS. 5) BACS53B -10 ONLY NOTE: THE LAST 2 DIGITS OF THE NOSE ASSEMBLY REPRESENTS THE LENGTH THE NOSE EXTENDS FROM THE TOOL I.E. -20 = 2.0 INCHES 16 9/18

17 ACCESSORIES Adapter Assy # Adapts offset nose assemblies to GB2480(A) installation tool. Other adapters available. Contact Gage Bilt for more information. Relief Valve # Required with stroke limiter (258152) for use with adapter (751204) for offset series noses. See Chart pg. 16 Relief Valve # Required with stroke limiter (258153) for Right Angle series noses. See Chart pg. 16 Stroke Limiter # Required with Relief Valve (248154) used with adapter (751204) for offset series noses. See Chart pg. 16 Stroke Limiter # Required with Relief Valve (248155) used with adapter (751204) for offset series noses. See Chart pg. 16 Images may not reflect actual parts 17

18 ACCESSORIES GB940 ELECTRIC POWERUNIT The GB940 Hydraulic Powerunit is a light-weight, portable power source designed to operate on a wide range of hydraulic installation tools. The unit is electrically powered and delivers up to 10,000 psi ( bar) working pressure with simple adjustable hydraulic outputs. The 24 volt remote control circuit, in the installation equipment, controls the pump output directional valve. The GB940 Hydraulic Powerunit is available in 115 volt or 230* volt, single phase, alternating current. Output pressures as shipped are: PULL psi, RETURN psi. The GB940 Hydraulic Powerunit is available separately or in kits including hydraulic quickdisconnect couplers, electrical connectors and hose cord kits in various lengths. GB includes the GB940 and 12 ft. (3.7m) Hose Kit, part # GB includes the GB940 and 26 ft. (7.9m) Hose Kit, part # GB includes the GB940 and 38 ft. (11.6m) Hose Kit, part # GB includes the GB940 and 52 ft. (15.8m) Hose Kit, part # GB910 HYDRAULIC POWERUNIT The GB910 Hydraulic Powerunit is a portable power source designed to operate a wide range of hydraulic installation tools. The unit air powered, air actuated and delivers up to 10,000 psi ( bar) working pressure. The actuator on the installation tool remotely controls the hydraulic oil directional flow. The unit consists of a two position air hydraulic pump, four way control valve and relief valve mounted on the reservoir. The GB910 Hydraulic Powerunit is available separately or in kits including hydraulic quickdisconnect couplers, air connectors, air lines and hydraulic hoses in various lengths. GB includes the GB910 and 12 ft. (3.7m) Hose Kit-Air, part # GB includes the GB910 and 26 ft. (7.9m) Hose Kit-Air, part # GB includes the GB910 and 38 ft. (11.6m) Hose Kit-Air, part # GB includes the GB910 and 52 ft. (15.8m) Hose Kit-Air, part # GB912 HYDRAULIC POWERUNIT The GB912 Hydraulic Powerunit is a portable power source designed to operate a wide range of hydraulic installation tools. The unit air powered, air actuated and delivers up to 10,000 psi ( bar) working pressure. The actuator on the installation tool remotely controls the hydraulic oil directional flow. The unit consists of a two position air hydraulic pump, four way control valve and relief valve mounted on the reservoir. The rapid tool piston movement is obtained through a higher (12 cubic inches a minute) output pump. Quick disconnect hydraulic couplings and air control socket are included to attach the equipment hydraulic hoses and air control tube. The GB912 Hydraulic Powerunit is available separately or in kits including hydraulic quickdisconnect couplers, air connectors, air lines and hydraulic hoses in various lengths. GB includes the GB912 Powerunit and 12 ft. (3.7m) Hose Kit-Air, part # GB includes the GB912 Powerunit and 26 ft. (7.9m) Hose Kit-Air, part # GB includes the GB912 Powerunit and 38 ft. (11.6m) Hose Kit-Air, part # GB includes the GB912 Powerunit and 52 ft. (15.8m) Hose Kit-Air, part # Images may not reflect actual tools 18

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20 Riveter Kits Available Gage Bilt offers a wide selection of standard and custom kits tailored to your needs. Contact us for more information. DEXRON IS A REGISTERED TRADEMARK OF GENERAL MOTORS CORPORATION. LUBRIPLATE IS A REGISTERED TRADEMARK OF FISKE BROTHERS REFINING. LOCTITE IS A REGISTERED TRADEMARK OF HENKEL CORPORATION. TEFLON IS A REGISTERED TRADEMARK OF E.I DUPONT DE NEMOURS & CO. SLIC-TITE IS A REGISTERED TRADEMARK OF LA-CO INDUSTRIES INC. CHERRYMAX AND CHERRYLOCK ARE REGISTERED TRADEMARKS OF CHERRY AEROSPACE FASTENERS. 20