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2480 Remote Intensifier Tooling                                                      Alcoa Fastening Systems

6. e.) Remove Piston Assembly Tool and Spacer

from Piston. Remove Rear Gland assembly
and Front Gland assembly. Remove Piston
Insertion Tool from Cylinder. 

(Figure 2d)

f.) Use a small diameter dull pointed rod to

remove all O-rings and seals. Clean parts,
including O-ring grooves. Examine all
components for wear or defects. Replace
parts as required.

7. Disassemble Air Trigger and Hose Assembly as

follows:

(Figure 3)

NOTE: When removing Air Hose from either
fitting, slice hose lengthwise, at fitting, just
enough to remove easily. Then cut hose
squarely across to be ready for assembly.

a.) Remove Air Hose from Hose Fitting, and

unscrew Hose Fitting from Trigger Housing.

b.) Unscrew Air Trigger Assembly from Trigger

Housing. Pull Trigger Stem out of Trigger
Body, and remove O-rings from Trigger
Stem and Trigger Body.

Figure 2a

Figure 2b

Piston Assembly Tool

Spacer

Piston

Insertion

Tool

push Piston to full rearward position

Pintail

Deflector

End Cap

Figure 2c

Support

Press

Figure 2d

Rear Gland

Assembly

Front Gland

Assembly

Cylinder

112555

Trigger

Stem

500772

O-Ring

500777

O-Ring

112556

Trigger

Body

114887

Trigger

Housing

127537

Air Hose and

Trigger Assembly

124888

Air Hose

119345 Air Trigger Assembly

505741

Hose

Fitting

Figure  3

Summary of Contents for Huck 2480RI

Page 1: ...01 28 2005 HK1009 INSTRUCTION MANUAL 2480RI PNEUDRAULIC INSTALLATION TOOL...

Page 2: ...lace Kingston New York USA Date January 2005 Sound Levels Model 2480RI SEL 82 dB A peak value 108 2 dB C For an eight hour work day installing 5000 typical Huck fasteners will result in an equivalent...

Page 3: ...3 SPECIFICATIONS 4 SAFETY 5 TOOL DANGER ZONES 6 PRINCIPLE OF OPERATION 7 PREPARATION FOR USE 8 SERVICING THE TOOL General 8 Daily 8 Weekly 8 Disassembly 9 12 Assembly 13 16 Fill and Bleed 17 18 SERVIC...

Page 4: ...205 208 3 32 84 3 5 425 138 1 41 36 6 55 166 Stroke 875 500 without Stroke Limiter Weight 2 2 lbs Tool Head only Air Pressure 90 psi Pull Capacity 3946 lbs 90 psi Intensifier Displacement 8298526 cu...

Page 5: ...efer to ANSI Z87 1 1989 6 Disconnect primary power source before doing maintenance on Huck equipment 7 If any equipment shows signs of damage wear or leakage do not connect it to the primary power sup...

Page 6: ...6 2480 Remote Intensifier Tooling Alcoa Fastening Systems TOOL DANAGER ZONES...

Page 7: ...rod moves downward a column of pressurized fluid is forced into the tool which moves the pull piston back The attached nose assembly moves with the pull piston to start fastener installation When fast...

Page 8: ...tools both standard and special must be available 4 All parts must be handled carefully and examined for damage or wear Always replace Seals when tool is disassembled for any reason Components should...

Page 9: ...r Piston 4 can be pushed to rear of Cylinder 12 to drain fluid Discard fluid 6 Disassemble cylinder and piston assembly as follows a Place Spacer over threaded end of Piston Figure 2a Thread Piston As...

Page 10: ...itting just enough to remove easily Then cut hose squarely across to be ready for assembly a Remove Air Hose from Hose Fitting and unscrew Hose Fitting from Trigger Housing b Unscrew Air Trigger Assem...

Page 11: ...top of Manifold Block 10 Remove Pull Gland Assembly 90 and Return Gland Assembly 22 from the separated Handle and Manifold Block and remove seals from glands Figure 5 11 Hold remaining Handle and Cyl...

Page 12: ...nsion remove Gland Assembly 54 Handle and Cylinder will now separate 19 Remove Plug 78 20 Push hydraulic Piston Assembly 31 out of handle Push out from top to bottom CAUTION A plastic or wooden drift...

Page 13: ...ge may result 2 Thread Piston Assembly Tool onto Piston Lubricate Polyseal inside diameter and external diameters of Piston and Piston Assembly Tool Press evenly against Gland Cap to slide Front Gland...

Page 14: ...ard plastic ferrule from nut before attaching air hose to quick disconnect a Push O Ring 500777 over threads of Trigger Body b Push Trigger Stem through Trigger Body then Stretch O Ring 500772 over Tr...

Page 15: ...nd extension and torque Screw 32 using 7 64 hex key to 55 60 in lbs Torque Nut 41 to 28 32 ft lbs 7 Hold handle in vise with bottom facing up Push Cylinder Head 49 with O ring 48 in place squarely int...

Page 16: ...seated 15 Push End Cap 77 with O ring 81 in place into Cylinder and secure with Retaining Ring 76 16 Attach Lower Guard 97 with two screws 98 17 Slide Top Guard 95 over ends of Swivel Assemblies 17 a...

Page 17: ...ssary If stroke is correct install a test fastener 7 Remove the Reservoir Assemblies and replace the two Reservoir Plugs 75 and tighten CAUTION Oil may be present in Reservoir tubes Remove with care R...

Page 18: ...ertical Disconnect Tool from air supply 5 Push tool Piston 4 into the full forward position and hold tool upside down Fill PULL and RETURN ports with hydraulic fluid 6 With tool still upside down care...

Page 19: ...19 2480 Remote Intensifier Tooling Alcoa Fastening Systems S SER ERVICE VICE N NOTES OTES...

Page 20: ...6 55 78 22 74 68 20 64 63 To Air Trigger 69 4 66 2 67 65 52 90 31 71 2 21 70 2 53 54 See Detail See Detail See Detail 81 77 88 74 2 82 79 89 91 2 97 98 2 See Detail A A 68 Ref 20 Ref 72 Ref 75 Ref Fig...

Page 21: ...27663 Top Guard 1 96 500047 Socket Head Cap Screw 2 97 127664 Lower Guard 1 98 500060 Socket Head Cap Screw 2 99 500064 Screw 4 100 507107 Locknut 4 1 127537 Air Trigger Hose Assembly 1 2 111795 Retai...

Page 22: ...draulic system Refer to Fill and Bleed section 3 Pintail stripped and or swaged collar not ejected a Check for broken or worn jaws in nose assembly Refer to nose assembly data sheet b Insufficient flu...

Page 23: ...stom products described above and Huck shall inspect products for which such claim is made Tooling Part s and Other Items not manufactured by Huck HUCK MAKES NO WARRANTY WITH RESPECT TO THE TOOLING PA...

Page 24: ...ducts France Operations Clos D Asseville BP4 95450 Us Par Vigny France 33 1 30 27 9500 FAX 33 1 34 66 0600 A Global Organization Alcoa Fastening Systems AFS maintains company offices throughout the Un...

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