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Alcoa Huck 2480RI Instruction Manual

Pneudraulic installation tool
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I
M
NSTRUCTION
ANUAL
2480RI
P
I
T
NEUDRAULIC
NSTALLATION
OOL
01-28-2005
HK1009

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Summary of Contents for Alcoa Huck 2480RI

  • Page 1 NSTRUCTION ANUAL 2480RI NEUDRAULIC NSTALLATION 01-28-2005 HK1009...

  • Page 2: Eu Declaration Of Conformity

    = number of fasteners in eight hours. Test data to support the above information is on file at Alcoa Fastening Systems, Commercial Products Division, Kingston Operations, Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (1990).

  • Page 3: Table Of Contents

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ONTENTS ONTENTS EU D ......2 ECLARATION OF CONFORMITY .

  • Page 4: Specifications

    2480 Remote Intensifier Tooling Alcoa Fastening Systems PECIFICA TIONS PECIFICA TIONS 8.205 5.425 INCHES 3.32 84.3 6.55 1.41 13.5 344.3 • Stroke: .875 (.500 without Stroke Limiter) • Weight: 2.2 lbs (Tool Head only) • Air Pressure: 90 psi • Pull Capacity: 3946 lbs @ 90 psi •...

  • Page 5: Afety

    2480 Remote Intensifier Tooling Alcoa Fastening Systems AFETY AFETY This instruction manual must be read with particular When repairing or operating Huck installation attention to the following safety guide lines, equipment, always wear approved any person servicing or operating this tool.

  • Page 6: Tool

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ANAGER ONES...

  • Page 7: Principle Of Operation

    2480 Remote Intensifier Tooling Alcoa Fastening Systems RINCIPLE PERA TION RINCIPLE PERA TION Pull Pull Piston Piston Hydraulic Piston Throttle Valve Air Piston EXHAUST PULL RETURN When the trigger is depressed the throttle valve When fastener installation is completed, the trigger moves to up position, pressurized air is directed to is released.

  • Page 8: Use

    2480 Remote Intensifier Tooling Alcoa Fastening Systems TION TION The Model 2480RI Installation Tool is shipped with a plastic 5. Select proper Nose Assembly for fastener to be plug in the air swivel connector. The swivel has 1/4-18 installed. female pipe threads to accept the air hose fitting. Quick disconnect fittings and 1/4”...

  • Page 9: Disassembly

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ISASSEMBLY NOTE: The following procedure is for complete Locknuts (100) from handle assembly. Separate disassembly of tool. Disassemble only components Handle (19) halves. (Figure 1) necessary to replace damaged O-rings, Quad rings, Back-up rings, and worn or damaged components.
  • Page 10 2480 Remote Intensifier Tooling Alcoa Fastening Systems Press Pintail End Cap Piston Assembly Tool Deflector Spacer Figure 2a push Piston to full rearward position Piston Insertion Tool Support Figure 2b Figure 2c Front Gland Figure 2d Rear Gland Cylinder Assembly Assembly 6.
  • Page 11 2480 Remote Intensifier Tooling Alcoa Fastening Systems DISASSEMBLY OF BASE (Figure 4) 1. Disconnect Top Guard (95) from Manifold Block (68) by unfastening two Screws (96), and slide it over the Hydraulic Hoses out of the way. 2. Disconnect Air Fitting (64) from Manifold Block.
  • Page 12 2480 Remote Intensifier Tooling Alcoa Fastening Systems Figure 6 DISASSEMBLY OF BASE (continued) 17. Grip Self-locking Nut (41) under Air Piston with pliers Remove After removing Gland Piston Assembly (54), use a and pull piston and rod assembly from handle and...

  • Page 13: Assembly

    2480 Remote Intensifier Tooling Alcoa Fastening Systems Figure 7 SSEMBLY GENERAL ASSEMBLY GUIDELINES Press Clean all tool components with mineral spirits or similar solvent. Inspect for wear/damage and replace as necessary. Always replace all seals on/in disassembled components. Use O-rings and back-up...
  • Page 14 2480 Remote Intensifier Tooling Alcoa Fastening Systems ASSEMBLY OF HEAD (continued) d.) Screw Hose Fitting into Trigger Housing. Push Air 7. Assemble Hydraulic Hoses to Cylinder head Hose onto Hose Fitting. assembly. SLIC-TITE TEFLON thread e.) Slide Quick Disconnect nut over Air Hose. Push compound, or equivalent, on pipe threads.
  • Page 15 2480 Remote Intensifier Tooling Alcoa Fastening Systems Torque to 100-120 ft.lbs. Figure 10b Figure 10a Figure 10 ASSEMBLY OF BASE and torque Screw (32) using 7/64 hex key to 55-60 (Figures 10 & 14) in. lbs. Torque Nut (41) to 28-32 ft. lbs.
  • Page 16 2480 Remote Intensifier Tooling Alcoa Fastening Systems ASSEMBLY OF BASE (continued) 12. Install two Cutoff Valves (70) with O-Rings (71) in place, Relief Valve (72) with O-Ring (71) in place, and Bleed Plug Assembly (73). 13. Drop Spring (40) into Throttle valve hole in cylinder.

  • Page 17: Fill And Bleed

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ILL AND LEED ROCEDURE Equipment Required: WARNING: Avoid - Shop airline with 90 - 100 psi max. contact with hydraulic - Air regulator fluid. Hydraulic fluid Fill Point - Fill Bottle (94), Tube (93), and Connector (92) must be disposed of in (supplied with tool).
  • Page 18 2480 Remote Intensifier Tooling Alcoa Fastening Systems FILL AND BLEED PROCEDURE FOR Figure 13 Step 2 DISASSEMBLED TOOLS PULL RETURN Fill handle PULL and PORT PORT RETURN ports with (Figures 11-13) hydraulic fluid. 1. Before assembling Manifold Block onto Cylinder and...

  • Page 19: Service Notes

    2480 Remote Intensifier Tooling Alcoa Fastening Systems VICE OTES VICE OTES...

  • Page 20: Assembly Drawing

    2480 Remote Intensifier Tooling Alcoa Fastening Systems Figure 14...

  • Page 21: Parts

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ITEM PART# DESCRIPTION ITEM PART# DESCRIPTION 112414 Piston Rod 127537 Air Trigger & Hose Assembly 127467 Cylinder Assembly 111795 Retaining Nut 116173 Gland Assembly 120588 Stop 500786 O-Ring 127506 Piston 501074 Quad Ring...

  • Page 22: Troubleshooting

    2480 Remote Intensifier Tooling Alcoa Fastening Systems ROUBLESHOOTING Always check out the simplest possible cause of a 7. Hydraulic fluid leaks at front of Pull Piston (4). malfunction first. For example, an air hose not connected. a) Worn or damaged front seal: Inspect Back-up Then proceed logically, eliminating each possible cause Ring (2) and O-ring (3).
  • Page 23 2480 Remote Intensifier Tooling Alcoa Fastening Systems IMITED ARRANTIES Tooling Warranty: Huck warrants that tooling and other DESIGN, OPERATION, MERCHANTABILITY items (excluding fasteners, and hereinafter referred as FITNESS FOR USE OF ANY TOOL, PART(S), OR "other items") manufactured by Huck shall be free from...
  • Page 24 NOTICE: The information contained in this publication is only for HWB898 1003-5M general guidance with regard to properties of the products shown © 2003 Alcoa Fastening Systems 1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • E-mail: hkitoolinfo@alcoa.com • www.alcoafasteningsystems.com...

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