Huck 2480, 2481 Instruction Manual

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Page 1

05-20-2014

HK970

INSTRUCTION MANUAL

MODELS 2480 & 2481 SERIES

HYDRAULIC INSTALLATION TOOLS

Page 2

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

ONTENTS

EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety` . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 & 6

Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Tool Operation/Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Tool Danger Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Maintenance

(Good Service Practices) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Maintenance

(Preventive Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Sticker Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Service Parts Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Specifications for Standard Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Disassembly of Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 19

Assembly of Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 23

Assembly Drawing W/Part Numbers (2480) . . . . . . . . . . . . . . . . . . . . . .24

Assembly Drawing W/Part Numbers (2480L) . . . . . . . . . . . . . . . . . . . . .25

Assembly Drawing W/Part Numbers (2480L-1) . . . . . . . . . . . . . . . . . . . .26

Assembly Drawing W/Part Numbers (2480L-2) . . . . . . . . . . . . . . . . . . . .27

Assembly Drawing W/Part Numbers (2480XL) . . . . . . . . . . . . . . . . . . . .28

Assembly Drawing W/Part Numbers (2481) . . . . . . . . . . . . . . . . . . . . . .29

Assembly Drawing W/Part Numbers (2481L-1) . . . . . . . . . . . . . . . . . . . .30

Assembly Drawing W/Part Numbers (A2480) . . . . . . . . . . . . . . . . . . . . .31

Assembly Drawing W/Part Numbers (2480LS) . . . . . . . . . . . . . . . . . . . .32

Assembly Drawing W/Part Numbers (2480LSL) . . . . . . . . . . . . . . . . . . .33

Air Trigger & Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

I. GENERAL SAFETY RULES:

1. A half hour long hands-on training session with qualified personnel is recommended before using Huck equipment.

2. Huck equipment must be maintained in a safe working condition at all times. Tools and hoses should be inspected at the beginning of each shift/day for damage or wear. Any repair should be done by a qualified repairman trained on Huck procedures.

3. For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining, changing accessories on, or working near the assembly power tool. Failure to do so can result in serious bodily injury.

4. Only qualified and trained operators should install, adjust or use the assembly power tool.

5. Do not modify this assembly power tool. This can reduce effectiveness of safety measures and increase operator risk.

6. Do not discard safety instructions; give them to the operator.

7. Do not use assembly power tool if it has been damaged.

8. Tools shall be inspected periodically to verify all ratings and markings required, and listed in the manual, are legibly marked on the tool. The employer/operator shall contact the manufacturer to obtain replacement marking labels when necessary. Refer to assembly drawing and parts list for replacement.

9. Tool is only to be used as stated in this manual. Any other use is prohibited.

10. Read MSDS Specifications before servicing the tool. MSDS specifications are available from the product manufacturer or your Huck representative.

11.Only genuine Huck parts shall be used for replacements or spares. Use of any other parts can result in tooling damage or personal injury.

12.Never remove any safety guards or pintail deflectors.

13.Never install a fastener in free air. Personal injury from fastener ejecting may occur.

14.Where applicable, always clear spent pintail out of nose assembly before installing the next fastener.

15.Check clearance between trigger and work piece to ensure there is no pinch point when tool is activated. Remote triggers are available for hydraulic tooling if pinch point is unavoidable.

16.Do not abuse tool by dropping or using it as a hammer. Never use hydraulic or air lines as a handle or to bend or pry the tool. Reasonable care of installation tools by operators is an important factor in maintaining tool efficiency, eliminating downtime, and preventing an accident which may cause severe personal injury.

17.Never place hands between nose assembly and work piece. Keep hands clear from front of tool.

18.Tools with ejector rods should never be cycled with out nose assembly installed.

19.When two piece lock bolts are being used always make sure the collar orientation is correct. See fastener data sheet for correct positioning.

II. PROJECTILE HAZARDS:

1. Risk of whipping compressed air hose if tool is pneudraulic or pneumatic.

2. Disconnect the assembly power tool from energy source when changing inserted tools or accessories.

3. Be aware that failure of the workpiece, accessories, or the inserted tool itself can generate high velocity projectiles.

4. Always wear impact resistant eye protection during tool operation. The grade of protection required should be assessed for each use.

5. The risk of others should also be assessed at this time.

6. Ensure that the workpiece is securely fixed.

7. Check that the means of protection from ejection of fastener or pintail is in place and operative.

8. There is possibility of forcible ejection of pintails or spent mandrels from front of tool.

III. 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 and be ready to counteract normal or sudden movements with both hands available.

4. Maintain a balanced body position and secure footing.

5. Release trigger or stop start device in case of interruption of energy supply.

6. Use only fluids and lubricants recommended by the manufacturer.

7. Avoid unsuitable postures, as it is likely for these not to allow counteracting of normal or unexpected tool movement.

8. If the assembly power 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.

IV. REPETITIVE MOTION HAZARDS:

1. When using assembly power tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body.

2. When using tool, the operator should adopt a comfortable posture while maintaining a secure footing and avoid awkward or off balanced postures.

3. The operator should change posture during extended tasks to help avoid discomfort and fatigue.

4. If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling, numbness, burning sensations or stiffness, these warnings should not be ignored. The operator should tell the employer and consult a qualified health professional.

V. ACCESSORIES HAZARDS:

1. Disconnect tool from energy supply before changing inserted tool or accessory.

2. Use only sizes and types of accessories and consumables that are recommended. Do not use other types or sizes of accessories or consumables.

VI. WORKPLACE HAZARDS:

1. Be aware of slippery surfaces caused by use of the tool and of trip hazards caused by the air line or hydraulic hose.

2. Proceed with caution while in unfamiliar surroundings; there could be hidden hazards such as electricity or other utility lines.

3. The assembly power tool is not intended for use in potentially explosive environments.

4. Tool is not insulated against contact with electrical power.

5. Ensure there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by use of the tool.

VII. NOISE HAZARDS:

1. Exposure to high noise levels can cause permanent, disabling hearing loss and other problems such as tinnitus, therefore risk assessment and the implementation of proper controls is essential.

2. Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpiece 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 tool 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 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 tool is being operated.

VIII. VIBRATION HAZARDS:

1. Exposure to vibration can cause disabling damage to the nerves and blood supply to the hands and arms.

2. Wear warm clothing when working in cold conditions and keep hands warm and dry.

3. If numbness, tingling, pain or whitening of the skin in the fingers or hands, stop using the tool, tell your employer and consult a physician.

4. Support the weight of the tool in a stand, tensioner or balancer in order to have a lighter grip on the tool.

X. HYDRAULIC TOOL SAFETY INSTRUCTIONS:

1. Do not exceed maximum pressure setting stated on tool.

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 clan and correctly engaged before operation.

6. Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.

7. Be sure all hose connections are tight.

8. Wipe all couplers clean before connecting. Failure to do so can result in damage to the quick couplers and cause overheating.

GLOSSARY OF TERMS AND SYMBOLS:

- Product complies with requirements set forth by the relevant European directives.

- READ MANUAL prior to using this equipment.

- EYE PROTECTION IS REQUIRED while using this equip- ment.

- HEARING PROTECTION IS REQUIRED while using this equipment.

Notes: are reminders of required procedures.

Bold, Italic type and underlining

: emphasizes a specific instruction.

AFETY

NSTRUCTIONS

CAUTIONS: show conditions that will damage equipment and or structure.

WARNINGS: Must be understood to avoid severe personal injury.

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

The 2480, A2480, and 2481 series, with appropriate nose assemblies, install a wide range of Huck blind fasteners and HUCKBOLT® fasteners. The 2480 series has hoses that pass through the handle and 2481 has hoses attached to the top of the tool - - see FIGURE 3 and FIGURE4. These lightweight and compact tools are particularly adapted to installing fasteners in limited clearance areas. Each tool is complete with hydraulic hoses and couplings; electric switch and cord. Tool is basically a cylinder aid piston assembly. An unloading valve, designed to relieve hydraulic pressure at end of the PULL stroke, is posi-

tioned by the piston. The end of the piston rod is threaded - - retaining nut and stop are included for attaching a nose assembly.

Huck Hydraulic Installation Tools are designed to be powered by Huck POWERIG® Hydraulic Units - Models 913H, 918, 918-5, 940, 956. or equivalent, are power sources.

A specific nose assembly is required for each fastener type and size. Nose assemblies must be ordered sep-

arately - - contact your Huck representative.

ESCRIPTION

Model No. Length Width Height

2480 8.63 in. 1.88 in. 6.50 in.

21.9 cm 4.8 cm 1.65 cm

Note: Length and weight does not include hose/cord or nose assembly.

PECIFICATIONS

(

ALL

MODELS

)

POWER SOURCE:

Huck POWERIG Hydraulic Unit

HOSE KITS:

Use only genuine HUCK Hose Kits rated @ 10,000 psi working pressure.

HYDRAULIC FLUID:

Hydraulic fluid shall meet DEXRON III, DEXRON VI, MERCON, Allison C‐4 or equivalent ATF specifica‐ tions.

Fire resistant fluid may be used if it is an ester based fluid such as Quintolubric HFD or equiva‐ lent. Water based fluid shall NOT be used as seri‐ ous damage to equipment will occur.

MAX OPERATING TEMP:

125°F (51.7°C)

MAX FLOW RATE:

2 gpm (7.5 l/m)

MAX PULL PRESSURE:

8400 psi (580 bar)

MAX RETURN PRESSURE:

3200 psi (220 bar)

PULL CAPACITY:

5380 lbs (24 kN) @ 8400 psi

STROKE:

.875 inches (2.22 cm)

WEIGHT:

2.2 lbs (1 kg)

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

PECIFICATIONS

(

CONTINUED

)

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 2

Main Components

An electric trigger controls the PULL and RETURN strokes. Press trigger to direct the hydraulic pressure to PULL side of the piston - fastener installation begins.

At the end of PULL stroke, before the trigger is released, piston uncovers flats ofunloading valve - - pressure is unloaded by allowing fluid to flow back to POW-

ERIG® Hydraulic Unit. Release the trigger at end of PULL stroke when fastener is installed - - pressure is directed to RETURN side of the piston and moves piston forward. Nose assembly, with tool, is pushed off fastener.

RINCIPLE

PERATION

(

SEE

FIGURE

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Note:

Where a part number (P/N) is given, Huck sells that part.

Rub Slic-Tite TEFLON thread compound, or equivalent, on pipe threads to prevent leaks and for ease of assembly.

1. Use Huck POWERIG Hydraulic Unit, or equivalent, that has been prepared for operation per INSTRUCTION MANUAL. Check both PULL and RETURN pressures, and if required, adjust to pressures given in SPECIFICATIONS of this manual. See both hydraulic unit’s and T-124883’s Instruction manuals before/during checking procedure.

Visually inspect for leaks and to verify that End Cap is installed correctly.

2. First, turn hydraulic unit to OFF, and then,

disconnect power supply from hydraulic unit — disconnect trigger control system from hydraulic unit.

3. Connect tool hoses to hydraulic unit. If

required, adjust position of trigger assembly on return pressure hose. Connect trigger control system to hydraulic unit.

4. Connect hydraulic unit to power supply

(air or electric). Turn hydraulic unit to ON. Hold Tool trigger depressed for 30 seconds; depress trigger a few times to cycle tool and to circulate hydraulic fluid — observe action of Tool and check for leaks.

5. Select nose assembly from SELECTION

CHART for fastener to be installed. Disconnect hydraulic unit from power supply; disconnect Tool’s trigger control system from hydraulic unit. Attach nose assembly to Tool per instructions in NOSE ASSEMBLY DATA SHEET.

6. Reconnect Tool’s trigger control system to

hydraulic unit; reconnect unit to power supply. Check operation of nose assembly — see NOSE ASSEMBLY DATA SHEET. Install fasteners in test plate of correct thickness with proper size holes — inspect installed fasteners. If fasteners do not pass inspection, see TROUBLESHOOTING CHART to locate and correct Tool’s malfunction.

7. Operator should receive training on proper use

from qualified personnel.

REPARATION

FOR

WARNING: Correct PULL and RETURN pressures are required for operator’s safety and for Installation TooI’s function. Gauge Set-Up T-124883CE is available for checking pressures. See Tool’s SPECIFICATIONS and Gauge Instruction Manual. Failure to verify pressures may result in severe personal injury.

WARNING: Be sure to connect Tool’s hydraulic hoses to POWERIG Hydraulic Unit before connecting Tool’s switch control cord to unit. If not connected in this order, severe personal Injury may occur.

CAUTION: Do not let disconnected hoses and couplers contact a dirty floor. Keep harmful material out of hydraulic fluid. Dirt in hydraulic fluid causes valve failure In Tool and In POWERIG Hydraulic Unit.

CAUTION: Do not use TEFLON

* tape on pipe threads. Pipe threads may cause tape to shred resulting in tool malfunction. (Slic-Tite is available in stick form as Huck P/N 503237.)

* Slic-Tite is a registered trademark of LA-CO Industries, Inc. * TEFLON is a registered trademark of DuPont Corp.

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

For safe operation. Please read completely

Blind Fastener Installation:

Fastener may be placed in workpiece or in end of nose assembly - - see WARNING. In either case, tool/nose must be held against work and at right angles to it. Depress trigger - - hold trigger depressed until fastener is installed and pintail breaks. Release trigger. Tool will go into its return stroke. Tool/nose are ready for next installation cycle.

NOTE: Reasonable care of tools by operators is an

important factor in maintaining efficiency and reducing downtime.

General

Operators should receive training from qualified personnel.

Do not bend tool to free if stuck.

Tool should only be used to install fasteners. NEVER use as a jack/spreader or hammer.

HUCKBOLT® Fastener Installation:

Place pin in workpiece and place collar over pin - see WARNING. (If Collar has only one tapered end, that end MUST be out toward tool - - not next to sheet.) Hold pin and push nose assembly onto pin protruding through collar until nose anvil touches collar. Depress trigger - - hold trigger depressed until collar is swaged and pintail breaks. Release trigger. Tool will go into its return stroke. fool/nose are ready for next installation cycle.

PERATING

NSTRUCTIONS

WARNING: Do not pull on a pin without placing fastener/collar in a workpiece, and also, collar chamfer MUST

be out toward tool - - these conditions cause pin to eject with great velocity and force when the pintail breaks off or teeth/grooves strip. This may cause severe personal injury.

CAUTION: Remove excess gap from between the sheets. This permits enough pintail to emerge from collar for ALL jaw teeth to engage with pintail - - if ALL teeth do not engage properly, jaws will be damaged.

WARNING: To avoid severe personal injury: Wear approved eye and ear protection Be sure of adequate clearance for Operator’s hands before proceeding with fastener installation. Be sure that pintail deflector is on tool and directed away from all personnel.

WARNING: Do not pull on a pin without placing fastener in a workpiece - fastener will eject from front with velocity and force when pintail breaks off or teeth/grooves strip - - this may cause severe personal injury.

CAUTION: Remove excess gap from between the sheets to permit correct fastener installation and prevent jaw damage. ALL jaw teeth must engage pintail to avoid damaging teeth.

CAUTIONS: BOM blind fasteners jam in nose assembly if pulled when not in workpiece.

To avoid structural and tooI damage, be sure enough clearance is allowed for nose assembly at full stroke.

Do not abuse tool by dropping it, using it as a hammer or otherwise causing unnecessary wear and tear.

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

CAUTION:

- Keep dirt and other material out of hydraulic system.

- Separated parts most be kept away from dirty work surfaces.

- Dirt/debris in hydraulic fluid causes unloading valve failure in Tool and in POWERIG® Hydraulic Unit’s valves.

- Always check tool assembly drawing for the proper direction of the flats on the Dump or Unloading Valve.

- Insure tool has been properly assembled prior to use.

Good Service Practices

The efficiency and life of your Installation Tool depends upon proper maintenance and good service practices. Using our manual will help give you a clear understanding of your tool and basic maintenance procedures — please read entire page before proceeding with maintenance/repair.

Use proper hand tools in a clean well-lighted area formaintenance/repair — always be careful to keep dirt/debris out of pneumatic and hydraulic systems. Only standard hand tools are required in most cases; where a special tool Is required, the description and part number are given.

While clamping Installation Tool and/or parts in a vise, and when parts require force, use suitable soft materials to cushion impact — for example, using a halfinch brass drift, wood block and/or vise with soft jaws greatly diminishes the possibility of a damaged tool. Remove components in a straight line without bending, cocking or undue force — reassemble tool with the same care.

Note: Individual parts must be handled carefully and examined for damage or wear —replace parts where required. Always replace O-rings and back-up rings when the tool Is disassembled for any reason — see SERVICE PARTS KIT.

Note: Consult manual’s TROUBLESHOOTING CHART if malfunction occurs — then see appropriate section of DISASSEMBLY, ASSEMBLY and SECTIONAL VIEW W/TOOL P/N’s.

Note: Where a part number (P/N) is given, Huck sells that part.

Fluid Maintenance

For fluid maintenance please refer to NAS 1638 class 9 or ISO CODE 18/15 or SAE level 6

Standard Sealants, Lubricants and SERVICE PARTS KIT

Rub SLIC-TITE TEFLON thread compound, or equivalent, on pipe threads to prevent leaks and for ease of assembly — CAUTION: Do not use TEFLON tape on pipe threads — particles of shredded tape cause hydraulic unit valve failure/malfunction. (SLIC-TITE — In stick form, P/N 503237.)

Smear LUBRIPLATE 130AA, or equivalent lubricant, on O-rings and mating surfaces this prevents nicking/pinching O-rings on any rough/tight spot and increases ease of assembly. (LUBRIPLATE 130AA — in tube, P/N 502723.)

SERVICE PARTS KIT contains perishable parts for your specific Tool — see NOTES FOR TOOL. For conve ience and as experience indicates, keep extra Kits (O-rings; back-up rings: other standard items) and Tool parts on hand. As an alternative, you can obtain O- rings and back-up rings from any regular retailer of these items — ask for: O-ring size (AS 568number): material and durometer. For additional information/specifications on O-rings and back-up rings, see NOTES AND SPECIFICATlONS FOR STANDARD PARTS.

Inspect tool daily. Check hoses, fittings and disconnects for leaks or damage.

AINTENANCE

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

PREVENTIVE MAINTENANCE

System Inspection

Operating efficiency of the Tool is directly related to performance of complete system, including tool/nose assembly, hydraulic hoses, control trigger assembly and the POWERIG® Hydraulic Unit Therefore, an effective preventive maintenance program includes scheduled inspections of the system to detect and correct minor troubles.

1. Inspect Tool for external damage.

2. Verify that hoses and fittings, and trigger connections are secure.

3. Inspect hydraulic hoses for signs of damage. Replace if required.

4. Inspect tool, hoses, and POWERIG Hydraulic Unit during operation to detect abnormal heating, leaks or vibration.

POWERIG Hydraulic Unit Maintenance

Maintenance and repair instructions are in applicable POWERIG Hydraulic Unit Instruction Manual.

Tool/Nose Assembly Maintenance and Precautions

Whenever disassembled, and also at regular intervals (depending on severity and length of use), replace all O-rings and back-up rings. Spare Parts Kits should be kept on hand. Inspect cylinder bore, piston and rod/extension, and unloading valve for scored surfaces, excessive wear or damage — replace parts as necessary. On any assembly with UNITIZED

Jaws, clean all parts in mineral spirits or isopropyl alcohol only — under no circumstances let jaws come in contact with other solvents — also, do not let jaws soak; dry the jaws immediately after cleaning; dry other parts before assembling. Urethane soaks up other solvents, then swells up and becomes unusable. Use a sharp pointed “pick” to remove imbedded particles from the pull grooves of the jaws.

AINTENANCE

(

CONTINUED

)

Page 12

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

I. Tool fails to operate when trigger is depressed. a. Inoperative POWERIG® Hydraulic Unit. See applicable

instruction manual. b. Loose air or electric connections. c. Damaged trigger assembly d. Loose or faulty hydraulic hose couplings e. Unloading valve not installed in Tool.

2. Tool operates in reverse. connections a. Reversed hydraulic hose between hydraulic unit and Tool.

3. Tool leaks hydraulic fluid. a. Defective Tool 0-rings or loose hose connections at Tool.

4. Hydraulic couplers leak fluid. a. Damaged or worn 0-rings in coupler body — see Coupler,

110440.

5. Hydraulic fluid overheats. a. Hydraulic unit not operating properly — see manual. b. Unloading valve installed incorrectly. c. POWERIG Hydraulic Unit running in reverse (918; 918-5

only) — see unit’s manual.

6. Tool operates erratically and fails to install a. Low or erratic hydraulic pressure — air in system.

fastener properly.

b. Damaged or worn piston 0-ring in Tool. c. Unloading valve installed incorrectly. d. Excessive wear on sliding surfaces of Tool parts. e. Excessive wear of unloading valve in Tool.

7. Pull grooves on fastener pintail stripped during a. Operator not sliding anvil completely onto fastener pintail.

PULL stroke.

b. Incorrect fastener grip. c. Worn or damaged jaw segments. d. Metal particles in pull grooves of jaw segments. e. Excessive sheet gap.

8. Collar of HUCKBOLT® fastener not completely a. Improper Tool operation — see Trouble 6.

swaged. b. Scored anvil.

9. Shear collar on Huck blind fastener not driven. a. Improper Tool operation. b. Worn or damaged driving anvil in nose assembly.

10. Tool ”hangs-up” on swaged collar of HUCKBOLT a. Improper Tool operation — see Trouble 6.

Fastener. b. RETURN pressure too low.

c. Nose assembly not installed per NOSE DATA SHEET.

11. Pintail of fastener fails to break. a. Improper Tool operation — see Trouble 6. b. Pull grooves on fastener stripped. — see Trouble 7. c. PULL pressure too low. d. Worn unloading valve.

Always check the simplest possible cause of a malfunction first. For example, a loose or disconnected trigger line. Then proceed logically, eliminating each possible cause until the defective part is located. Where possible, substitute known good parts for suspected defective parts. Use Trouble Shooting Chart as an aid for locating and correcting trouble.

ROUBLESHOOTING

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

The quantity of spare parts that should be kept on hand varies with the application and number of tools in service. Spare service kits, 2480KIT, containing perishable parts such as seals, back-up rings, etc. should be kept on hand at all times - - see below. This kit is for all tools.

Service Kit, 2480KIT

Part No. Description Quan.

505843 WIPER 1

507108 WIPER 1

505818 POLY-SEAL 1

505849 O-RING 1

500773 O-RING 1

500777 O-RING 1

500816 O-RING 2

500810 O-RING 1

504438 O-RING 1

501102 BACK-UP RING 1

501104 BACK-UP RING 1

501110 BACK-UP RING 3

8-2480 2480 H.I.T. ASSEMBLY DWG. 1

8-A2480 A2480 H.I.T. ASSEMBLY DWG. 1

Specifications for Standard Parts

1. All part numbers shown in this manual are available from Huck.

2480B Pintail Bottle Assembly

Also available is part no. 128017 Pintail Bottle Assembly to convert tool to 2480B

(Refer to fig 3-3g for optional assembly tool kits and notes)

PARE

ARTS

ERVICE

TICKER

OCATIONS

The 2480 and 2481 series tools come labeled with Sticker part number 590424, which contains safety and pressure settings information. It is necessary that this sticker remain on the tool and is easily read. If sticker becomes damaged or worn, or if it have been removed from the tool, or when replacing Cylinder, this sticker must be ordered and placed in the location shown. Sticker locations and part numbers may be found in Figure3 through 3j.

Page 14

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

The following procedure is for complete disassembly - - disassemble only subassemblies necessary to check and replace damaged seals, wipers, back-up rings and components. Always replace

seals, wiper, O-rings and back-up rings of disassembled sub-assemblies.

I. See WARNING on this page.

Disconnect tool’s electrical connector from hydraulic unit. Uncouple tool’s hydraulic hoses.

2. Remove tools retaining nut - - use 1 1/16 open end wrench. Slide nose anvil away from tool. Unscrew collet from tool’s piston.

3. Unscrew four socket screws from handle assembly. Remove screws and nuts. Separate handle halves - see FIGURE 5.

4. 2480: Lift switch assembly from handle half. Pull control cord out of handle’s built-in strain relief. Pull both bullet connectors apart - see FIGURE 5.

A2480: Lift trigger assembly from handle half. Pull air hose out of handle’s built-in strain relief.

(REFER TO FIGURES 5, 6, 6A, 6B, 6C, 7 AND 7A)

Figure 5

NOTE - For proper Assembly/Disassembly

Tools please refer to the NOTES Section on the proper Assembly Drawing for the model 2480 that is being repaired.

ISASSEMBLY

WARNING: Be sure to disconnect Tool’s control trigger system from POWERIG® Hydraulic Unit before disconnecting Tool’s hydraulic hoses from unit. If not disconnected in this order before any maintenance or cleaning is done, severe personal injury may occur.

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

5. Unscrew hoses from tool. Drain hoses into container. Piston can be pushed to rear of cylinder to drain fluid. Discard fluid.

6. Disassemble cylinder and piston

assembly. (refer to Cylinder and Piston

Assembly Section)

7. Disassemble switch and cord assembly.

(refer to Switch and Cord Assembly Section)

1. See FIGURE 6. Place spacer over

threaded end of piston. Thread piston assembly tool onto piston. If cylinder contains fluid, push piston to rear and drain into container. Discard fluid.

2. Remove pintail deflector from tool by twisting and pulling in one motion. With a 1 5/16 open end wrench, unscrew end cap.

3. Thread piston insertion tool into cylinder- -FIGURE 6.

CYLINDER AND PISTON ASSEMBLY (Refer to Figure 6 through 6c.)

Figure 6

Figure 6a

ISASSEMBLY

(

CONTINUED

)

Page 16

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

4. See FIGURE 6b. Supporting tool as shown, press (or drive) piston, rear gland assembly, dump valve, and front gland assembly out of cylinder.

5. See FIGURE 6c. Remove piston assembly tool and spacer from piston. Remove rear gland assembly and dump valve. Remove front gland assembly. Remove piston insertion tool from piston.

6. 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.

Figure 6b

Figure 6c

ISASSEMBLY

(

CONTINUED

)

Page 17

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

1. Loosen set screw in top of button - use 5/64 hex key. Remove button.

2. Unscrew switch from housing.

3. To remove male connector from control cord, unscrew two screws at connector.

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.

1. After unscrewing nut from quick dis connect body, cut and remove hose.

2. After removing hose from trigger housing, unscrew air fitting from housing.

3. Unscrew air trigger assembly from housing. Remove O-ring from stem - pull stem out. Remove O-ring from housing.

AIR TRIGGER AND HOSE ASSEMBLY (Refer to fig. 7a)

Figure 7a

SWITCH AND CORD ASSEMBLY (Refer to fig. 7)

Figure 7

ISASSEMBLY

(

CONTINUED

)

Page 18

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Refer to Figures 8, 8a, 8b, 8c, 8d, 9, 10 and 11

and

MAINTENANCE: General Precautions - - clean out O-ring grooves and reinstall perishable parts (seals, etc.) - - see below. Use service kit,

2480KIT.

NOTE - The small inner ring insert of POLY-SEALS must remain positioned as shown. If it is forced out of seal body, it may be pinched against gland inner edge. A damaged seal will permit leakage.

1. Thinly coat SUPER 0-LUBE, or equiv alent, on seals and mating surfaces. Assemble O-rings and back-up rings to piston, front gland, and rear gland as shown in Fig. 8. See caution above

- - press POLY-SEAL into front gland

housing.

Figure 8

2. See FIGURE 8a - - thread piston assembly tool onto piston. Lubricate POLY-SEAL inside diameter and exter nal diameters of piston and piston assembly tool. Press evenly against gland cap to slide front gland assem bly over piston assembly tool and into piston. Slide wiper onto piston as shown. Install dump valve into piston as shown.

3. Thread piston insertion tool into cylin der. Lightly coat internal surfaces of tool and cylinder with lubricant -

-FIGURE 8a.

Figure 8a

SSEMBLY

CAUTIONS:

Do not use TEFLON®* tape on pipe threads. Pipe threads may cause tape to shred resulting in tool malfunction. (Slic-Tite is available in stick form as Huck P/N 503237.)

Insure tool has been properly assembled prior to use.

CAUTION: Always make sure the large flats of the dump valve face the rear of the tool. (See Fig. 8a)

CAUTION: Be carefull that POLY-SEAL does not hang up on the edge of the piston chamfer. Seal will be damaged and leakage may result.

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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

4. Lightly coat cylinder, piston O-rings, and front gland O-rings with lubricant. While supporting tool, as shown, press assembled piston and components into cylinder. Remove piston assembly tool

- - FIGURE 8b.

Figure 8b

5. See FIGURE 8c - - lightly coat cylinder and rear gland O-rings with lubricant. As shown, hold cylinder upright on a bench or in a vice fitted with soft jaws. Install rear gland assembly using suit able spacer, plate, and soft mallet.

6. Press wiper into groove of end cap. Thread end cap into cylinder and tight en. Install deflector - - FIGURE 8d.

Figure 8d

7. Assemble hoses to cylinder head assembly. Use SLIC-TITE TEFLON thread compound, or equivalent, on pipe threads - - see Caution above. Hose with male connector must be on PULL (front) side of cylinder.

8. Assemble switch assembly, see Fig. 9

for Electric Trigger ,or Fig. 10 for Air Trigger.

9. Assemble handle assembly to tool, see TO ASSEMBLE HANDLE

ASSEMBLY TO ASSEMBLED TOOL

Figure 8c

SSEMBLY

(

CONTINUED

)

CAUTION: To avoid damaging dump valve, do not use arbor press.

Page 20

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

AIR TRIGGER AND HOSE ASSEMBLY (Refer to fig. 10)

NOTE -For ease of assembly, heat ends of hose before pushing onto fittings.

When using a new quick disconnect, remove and discard plastic ferrule from nut before attaching air hose to quick disconnect.

1. Push O-ring over threads of air trigger body.

2. Push stem through body. Stretch O-ring over stem and into groove.

3. Screw trigger into housing.

4. Screw hose fitting into housing. Push hose onto fitting.

5. Slide nut over hose. Push hose onto quick disconnect. Tighten nut.

Figure 10

1. Screw switch into housing.

2. Slide button onto switch. Tighten down set screw using 5/64 hex key.

ELECTRICAL SWITCH ASSEMBLY

(Refer to fig. 9)

Figure 9

SSEMBLY

(

CONTINUED

)

Page 21

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

HANDLE ASSEMBLY TO ASSEMBLED TOOL (Refer to fig. 11)

Figure 11

2. Position assembled cylinder and hoses in left handle half. Align right handle half with left (locators help align halves).

3. Insert locknuts and screws into han dle. Tighten screws.

SSEMBLY

(

CONTINUED

)

Page 22

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3 - 2480

Page 23

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3a - 2480L

Page 24

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3b - 2480L-1

Page 25

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3c - 2480L-2

Page 26

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3d - 2480XL

Page 27

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3e - 2481

Page 28

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3f - 2480L-1

Page 29

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3g

A2480

Page 30

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3h

2480LS

Page 31

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 3j

2480LSL

Page 32

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

Figure 4 - A2480 Air Trigger & Hose Assembly

Page 33

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems

IMITED

ARRANTIES

TOOLING WARRANTY:

Huck warrants that tooling and other items (excluding fasteners, and hereinafter referred as "other items") manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase.

WARRANTY ON "NON STANDARD OR CUSTOM

MANUFACTURED PRODUCTS":

With regard to non-standard products or custom manufactured products to customer's specifications, Huck warrants for a period of ninety (90) days from the date of purchase that such products shall meet Buyer's specifications, be free of defects in workmanship and materials. Such warranty shall not be effective with respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures that are not in good condition or repair and suitable for their intended purpose.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS FOR ANY PARTICULAR PURPOSE AND HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Huck's sole liability and Buyer's exclusive remedy for any breach of warranty shall be limited, at Huck's option, to replacement or repair, at FOB Huck's plant, of Huck manufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workmanship and materials not otherwise the direct or indirect cause of Buyer supplied molds, material, tooling or fixtures. Buyer shall give Huck written notice of claims for defects within the ninety (90) day warranty period for tooling, other items, nonstandard or custom products described above and Huck shall inspect products for which such claim is made.

TOOLING, PART(S) AND OTHER ITEMS NOT MANU-

FACTURED BY HUCK:

HUCK MAKES NO WARRANTY WITH RESPECT TO THE TOOLING, PART(S) OR OTHER ITEMS

MANUFACTURED BY THIRD PARTIES. HUCK EXPRESSLY DISCLAIMS ANY WARRANTY EXPRESSED OR IMPLIED, AS TO THE CONDITION, DESIGN, OPERATION, MERCHANTABILITY OR FITNESS FOR USE OF ANY TOOL, PART(S), OR OTHER ITEMS THEREOF NOT MANUFACTURED BY HUCK. HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, PART(S) OR OTHER ITEMS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

The only warranties made with respect to such tool, part(s) or other items thereof are those made by the manufacturer thereof and Huck agrees to cooperate with Buyer in enforcing such warranties when such action is necessary.

Huck shall not be liable for any loss or damage resulting from delays or nonfulfillment of orders owing to strikes, fires, accidents, transportation companies or for any reason or reasons beyond the control of the Huck or its suppliers.

HUCK INSTALLATION EQUIPMENT:

Huck International, Inc. reserves the right to make changes in specifications and design and to discontinue models without notice.

Huck Installation Equipment should be serviced by trained service technicians only.

Always give the Serial Number of the equipment when corresponding or ordering service parts.

Complete repair facilities are maintained by Huck International, Inc. Please contact one of the offices listed below.

Eastern One Corporate Drive Kingston, New York 12401-0250 Telephone (845) 331-7300 FAX (845) 334-7333

Outside USA and Canada Contact your nearest Huck International Office, see back cover.

In addition to the above repair facilities, there are Authorized Tool Service Centers (ATSC's) located throughout the United States. These service centers offer repair services, spare parts, Service Parts Kits, Service Tools Kits and Nose Assemblies. Please contact your Huck Representative or the nearest Huck office listed on the back cover for the ATSC in your area.

Page 34

Americas

Alcoa Fastening Systems

Aerospace Products Tucson Operations

3724 East Columbia Tucson, AZ 85714 800‐234‐4825 520‐747‐9898 FAX: 520‐748‐2142

Alcoa Fastening Systems

Aerospace Products Carson Operations

PO Box 5268 900 Watson Center Rd. Carson, CA 90749 800‐421‐1459 310‐830‐8200 FAX: 310‐830‐1436

Alcoa Fastening Systems

Industrial Products Waco Operations

PO Box 8117 8001 Imperial Drive Waco, TX 76714‐8117 800‐388‐4825 254‐776‐2000 FAX: 254‐751‐5259

Alcoa Fastening Systems

Industrial Products Kingston Operations

1 Corporate Drive Kingston, NY 12401 800‐278‐4825 845‐331‐7300 FAX: 845‐334‐7333

Alcoa Fastening Systems

Industrial Products Latin America Operations

Avenida Parque Lira. 79‐402 Tacubaya Mexico, D.F. C.P. 11850 FAX: 525‐515‐1776 TELEX: 1173530 LUKSME

Far East

Alcoa Fastening Systems

Industrial Products Australia Operations

14 Viewtech Place Rowville, Victoria Australia 3178 03‐764‐5500 Toll Free: 008‐335‐030 FAX: 03‐764‐5510

Europe

Alcoa Fastening Systems

Industrial Products United Kingdom Operations

Unit C, Stafford Park 7 Telford, Shropshire England TF3 3BQ 01952‐290011 FAX: 0952‐290459

Alcoa Fastening Systems

Aerospace Products 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 United States and Canada, with subsidiary offices in many other countries. Authorized AFS distributors

are also located in many of the world’s

Industrial and Aerospace centers, where they provide a ready source of AFS fasteners, installation tools, tool parts, and application assistance.

For The Long Haul, The Future of Fastening Technology, The Future of Assembly Technology, The Future of Tooling Technology, and Tools of Productivity are service marks of Huck International. Huck provides technical assistance regarding the use and application of Huck fasten‐ ers and tooling.

NOTICE: The information contained in this publi‐ cation is only for general guidance with regard to properties of the products shown and/or the

means for selecting such products, and is not intended to create any warranty, express, implied, or statutory; all warranties are contained only in Huck’s written quotations, acknowledge‐ ments, and/or purchase orders. It is recommend‐ ed that the user secure specific, up‐to‐date data and information regarding each application and/or use of such products.

HWB898 1003‐5M

1 Corporate Drive, Kingston, NY 12401 • Tel: 800‐431‐3091 • Fax: 845‐334‐7333 • www.alcoafasteningsystems.com

One Great Connection

Alcoa Fastening Systems world-wide locations:

For the Long Haul

™

Certified to

ISO 9001:2008

Industrial Products

Certified to

ISO 14001:2004

Industrial Products