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2480 Remote Intensifier Tooling                                                      Alcoa Fastening Systems

Always check out the simplest possible cause of a
malfunction first. For example, an air hose not connected.
Then proceed logically, eliminating each possible cause
until the cause is located. Where possible, substitute
known good parts for suspected bad parts. Use
Troubleshooting chart as an aid in locating and correcting
malfunction.

NOTE:

Piston Drift is when the air piston is in the down position,
but the hydraulic pull piston is not in the full forward
position.  This causes an out of sequence condition.

1  Tool fails to operate when trigger is depressed.

a)   Air line not connected.
b) Vent hole in air cylinder (78) is blocked.
c)

Vent hole in air valve (79) is blocked.

2  Tool does not complete fastener installation and

break pintail.

a) Air pressure too low
b) Air Piston Quad-ring (50) worn or damaged.
c)  Insufficient fluid on pull side: Refer to Fill and 

Bleed section.

d)  Air in hydraulic 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 fluid on return side: Refer to Fill and 

Bleed section.

4

Tool has piston drift. 

a)  Worn or damaged Piston Assembly (31): Inspect

O-rings (33 & 35), and Back-up Rings (38). 
Replace if necessary.

5

Hydraulic fluid exhausts with air or leaks at base of

handle.

a)  Worn or damaged Gland Assembly (54): Inspect

Polyseal (61), O-rings (55 & 58), Quad-ring (56), 
and Back-up Ring (57). Replace if necessary.

6. Hydraulic fluid leaks at rear of Pull Piston (4)

a)  Worn or damaged Rear Gland (8): Inspect

O-rings (9 & 11) and Back-up Ring (10). Replace
if necessary.

7. Hydraulic fluid leaks at front of Pull Piston (4).

a)  Worn or damaged front seal: Inspect Back-up 

Ring (2) and O-ring (3). Replace if necessary.

8.  Pull Piston (4) will not return.

a)  Throttle Valve (36) stuck: Lubricate O-rings (37,

39, 55, & 80).

9. Air leaks at air Cylinder Head (49).

a). Worn or damaged O-ring (48): Replace if 

necessary.

A

CCESSORIES

Harness........................................

123913

Tool Head Service Kit...............

A

2480KIT

Remote Intensifier Service Kit...........

RIKIT

T

ROUBLESHOOTING

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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