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21

2480 Remote Intensifier Tooling                                                      Alcoa Fastening Systems

52

112414

Piston Rod

1

53

127467

Cylinder Assembly

1

54

116173

Gland Assembly

1

55

500786

O-Ring

3

56

501074

Quad Ring

1

57

501090

Back-up Ring

1

58

500784

O-Ring

1

59

505939

Retaining Ring

1

60

123904

Spacer

1

61

506611

Polyseal

1

62

123903

Gland

1

63

124881-2 Hydraulic Hose

2

64

507575

Air Fitting

1

65

125824

Cap

2

66

127469

Reservoir Cylinder

2

67

125827

Piston Assembly

2

68

127476

Manifold Block

1

69

500066

Socket Head Screw

4

70

126030

Cutoff Valve

2

71

505438

O-Ring

3

72

126036

Relief Valve

1

73

104293

Bleed Plug Assembly

1

74

500774

O-Ring

4

75

100309-1 Reservoir Plug

2

76

502328

Retaining Ring

1

77

127470

End Cap (Handle)

1

78

127471

Plug

1

79

501352

Dowel Pin

1

80

500782

O-Ring

1

81

500787

O-Ring

1

82

504054

Port Plug

1

83

114748

Two-way Swivel

1

84

118942

Air Trigger & Housing Assy

1

85

119345-1

Air Trigger

1

86

503902

Air Fitting

1

87

125832

Air Hose

1

88

127472

Upper Bushing

1

89

115503

Lower Bushing

1

90

112501

Pull Gland Assembly

1

91

504547

O-Ring

2

92

506973

1/8NPT-1/4Tube Conn. 

(figure 5)

2

93

T3115HS

1/4 OD Plastic Tube

(figure 5)

2

94

120337

Fill Bottle 

(figure 5)

2

95

127663

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

Retaining Nut

1

3

120588

Stop

1

4

127506

Piston

1

5

505843

Front Wiper Seal

1

6

124870

Front Gland Cap

1

7

505818

Polyseal

1

8

501110

Back-up Ring

3

9

500816

O-Ring

1

10

124869

Front Gland

1

11

505849

O-Ring

1

12

124862

Cylinder

1

13

124872

Rear Gland

1

14

500810

O-Ring

1

15

501104

Back-up Ring

1

16

507108

Rear Wiper Seal

1

17

124876

End Cap

1

18

124210

Pintail Deflector

1

19

124867

Handle

1

20

127426

Swivel Assembly

1

21

127474

Handle

1

22

112502

Return Gland Assembly

1

23

112427

Gland

1

24

500776

O-Ring

3

25

501082

Back-up Ring

2

26

500778

O-Ring

1

27

501084

Back-up Ring

1

28

112426

Gland

1

29

501087

Back-up Ring

1

30

500781

O-ring

1

31

126037

Piston Assembly

1

32

117773

Screw

1

33

503770

O-ring

1

34

126031

Piston 1

35

500773

O-Ring

1

36

127473

Throttle Valve

1

37

504408

O-Ring

3

38

503167

Back-up Ring

2

39

504407

O-Ring

1

40

508131

Spring

1

41

121241

Self-locking Nut

1

42

116585

Muffler End Cap

1

43

115554

Muffler

1

44

500777

O-Ring

1

45

504127

Screw

3

46

126941-2 Gasket

1

47

505025

Retaining Ring

1

48

500873

O-Ring

1

49

111959

Cylinder Head

1

50

100315

Air Piston 

1

51

501460

Quad Ring

1

ITEM

PART#

DESCRIPTION

QTY

ITEM

PART#

DESCRIPTION

QTY

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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