Alcoa Huck 2480RI User manual

01-28-2005
HK1009
INSTRUCTION MANUAL
2480RI
PNEUDRAULIC INSTALLATION TOOL

2
2480 Remote Intensifier Tooling Alcoa Fastening Systems
EU Declaration of Conformity
Manufacturer:
Alcoa Fastening Systems, Commercial Products Division, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
Model numbers 2480RI fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery, (89/392/EEC), (91/368/EEC), (93/44/EEC),
(93/68/EEC)
Council Directive related to EMC/EMI, (89/336/EEC)
European Representative:
Rob Pattenden, Huck International, Ltd. Unit C Stafford Park 7, Telford Shropshire TF3 3BQ,
England, United Kingdom
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment specified above conforms to the
above Directive(s) and Standard(s).
Signature: ___________________________________
Full Name: Henk Rosier
Position: Engineering Manager
Installation Systems Division
Place: 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 noise level (Leq) of 74.5
dB (A).
To calculate equivalent noise level for other quantities of
fasteners in an eight hour period, use the formula:
Leq = SEL + 10 log (n/28,800)
where n = number of fasteners in eight hours.
Vibration Levels
Model: 2480RI
For an eight hour work day, installing 5000 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level (Aeq) of 4.3m/s2.
To calculate equivalent vibration level for other quantities of
fasteners in an eight hour period, use the formula:
Equivalent Vibration Level, Aeq (m/s2) = (n/480) x 2.00
where n = number of fasteners in eight hours, and
2.00(m/s2) = Aeq for 60 seconds.
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).

3
2480 Remote Intensifier Tooling Alcoa Fastening Systems
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
C
CONTENTS
ONTENTS

4
2480 Remote Intensifier Tooling Alcoa Fastening Systems
13.5
344.3
5.2
133
8.205
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. in.
• Operating Pressure @ 90 psi: 5745.6
INCHES
MM
S
SPECIFICA
PECIFICATIONS TIONS

5
2480 Remote Intensifier Tooling Alcoa Fastening Systems
This instruction manual must be read with particular
attention to the following safety guide lines, by
any person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will
damage equipment and or structure.
Notes - are reminders of required
procedures.
Bold, Italic type and underlining -
emphasizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with
equipment before connecting equipment to any
primary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye
protection. Where applicable, refer 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 supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote
triggers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in
preventing an accident which may cause severe
personal injury.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is
correct. See fastener data sheet of correct
positioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.
S
SAFETY
AFETY

6
2480 Remote Intensifier Tooling Alcoa Fastening Systems
TOOL DANAGER ZONES

7
2480 Remote Intensifier Tooling Alcoa Fastening Systems
EXHAUST
Hydraulic
Piston
Air Piston
Throttl
Valv
Pull
Piston Pull
Piston
When the trigger is depressed the throttle valve
moves to up position, pressurized air is directed to
the top of the air piston, causing the piston to move
downward. The air below the piston is exhausted
and directed through the center of the throttle
valve and out the bottom of the tool . The air piston
has a rod and a hydraulic piston attached. When
the air piston 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 fastener installation is completed, the trigger
is released. Air pressure, with the assistance of an
air valve, causes the throttle valve to return to its
down position. Pressurized air is re-directed to the
bottom of the air piston, causing the piston to move
upward. The air from below the piston is exhausted
through bottom of tool. The rod and hydraulic
piston move upward; hydraulic pressure is
reversed and the pull piston is returned forward.
PULL RETURN
P
PRINCIPLE
RINCIPLE OF OF O
OPERA
PERATION TION

8
2480 Remote Intensifier Tooling Alcoa Fastening Systems
The Model 2480RI Installation Tool is shipped with a plastic
plug in the air swivel connector. The swivel has 1/4-18
female pipe threads to accept the air hose fitting. Quick
disconnect fittings and 1/4” inside diameter air hose are -
recommended. An air supply of 90-100 psi capable of 11.5
CFM must be available.Air supply should be equipped with
a filter-regulator-lubricator unit.
1. Remove plastic shipping plug from Air Inlet Connector
and screw quick disconnect fitting into Air Inlet
Connector.
2. Set air pressure on regulator to 90-100 psi.
3. Connect air hose to tool.
4. Cycle tool a few times by depressing and releasing
trigger.
5. Select proper Nose Assembly for fastener to be
installed.
6. Attach nose assembly to tool .
7. Install fastener(s) in test plate of proper thickness with
proper size holes and inspect fastener(s).
NOTES:
1 Air quick disconnect fittings and air hoses are not
available from Huck International, Inc.
GENERAL
1. The efficiency and life of any tool depends upon proper
maintenance. Regular inspection and correction of
minor problems will keep tool operating efficiently and
prevent downtime. The tool should be serviced by
personnel who are thoroughly familiar with how it
operates.
2. A clean, well-lit area should be available for servicing
the tool. Special care must be taken to prevent
contamination of pneumatic and hydraulic systems.
3. Proper hand 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 be
disassembled and assembled in a straight line without
bending, cocking, or undue force. Disassembly and
assembly procedures outlined in this manual should
be followed.
5. Service Parts Kit 2480RIKIT includes consumable parts
and should be available at all times. Other components,
as experience dictates, should also be available.
DAILY
1. If a Filter-Regulator-Lubricator unit is not being used,
uncouple air disconnects and put a few drops of
Automatic Transmission Fluid or light oil into the air
inlet of the tool. If the tool is in continuous use, put a
few drops of oil in every two to three hours.
2. Bleed the air line to clear it of accumulated dirt or water
before connecting air hose to the tool.
3. Check all hoses and couplings for damage or air leaks,
tighten or replace if necessary.
4. Check the tool for damage or air/hydraulic leaks,
tighten or replace if necessary.
5. Check the nose assembly for tightness or damage,
tighten or replace if necessary.
6. Check oil level in tool reservoir, replenish if necessary.
WEEKLY
1. Disassemble and clean nose assemblies and
reassemble per applicable NOSE ASSEMBLY DATA
SHEET.
2. Check the tool and all connecting parts for damage or
oil/air leaks, tighten or replace if necessary.
!
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged or
worn, as severe personal injury may occur.
P
PREP
REPARA ARATION TION FOR FOR U
USE
SE
S
SER
ERVICING VICING THE THE T
TOOL
OOL

DISASSEMBLY
9
2480 Remote Intensifier Tooling Alcoa Fastening Systems
NOTE: The following procedure is for complete
disassembly of tool. Disassemble only components
necessary to replace damaged O-rings, Quad rings,
Back-up rings, and worn or damaged components.
Always use soft jaw vice to avoid damage to tool.
DISASSEMBLY OF HEAD
For list of Item Numbers and their locations, refer to
complete Tool Assembly Drawing and Parts List.
I. See WARNING above. Disconnect tool’s electrical
connector from hydraulic unit. Uncouple tool’s
hydraulic hoses.
2. Remove nose assembly from tool.
3. Remove four Socket Head Cap Screws (99) and
Locknuts (100) from handle assembly. Separate
Handle (19) halves. (Figure 1)
4. LiftAir TriggerAssembly (1) from Handle half. PullAir
Hose out of handle’s built-in strain relief. (Figure 1)
5. Unscrew Hydraulic Hoses (63) from tool. (Figure 9)
Drain hoses into container. 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 Assembly Tool onto Piston. If
Cylinder contains fluid, push Piston to rear and
drain into container. Discard fluid.
b.) Remove Pintail Deflector (18) from tool by twisting
and pulling in one motion. With a 1 5/16 open end
wrench, unscrew End Cap (17).
c.) Thread Piston Insertion Tool into back of Cylinder.
(Figure 2b)
d.) Supporting tool as shown, press (or drive) Piston,
Rear Gland (13) assembly and Front Gland (10)
assembly out of Cylinder. (Figure 2c)
continued
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.
!
L ft half of
Handl (19)
Right half of
Handl (19)
Locknut
(100) Qty. 4
Hydraulic Hos s
(63) Qty. 2
H ad Ass mbly
Air Trigg r
and Hos
Ass mbly (1)
Sock t H ad
Cap Scr w (99)
Qty. 4
Figure 1

10
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 Ass mbly Tool
Spac r
Piston
Ins rtion
Tool
push Piston to full rearward position
Pintail
D fl ctor
End Cap
Figure 2c
Support
Pr ss
Figure 2d R ar Gland
Ass mbly
Front Gland
Ass mbly
Cylind r
112555
Trigger
Stem
500772
O-Ring
500777
O-Ring
112556
Trigger
Body
114887
Trigger
Housing
127537
Air Hose and
Trigger Assemb y
124888
Air Hose
119345 Air Trigger Assemb y
505741
Hose
Fitting
Figure 3

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.
3. Unscrew both Swivel Assemblies (20) from Manifold
Block.
4. Remove Lower Guard (97) from Cylinder Assy (53)
by unfastening two Screws (98).
5. Remove Retaining Ring (76) from top of Cylinder.
6. Remove End Cap (77) from Cylinder.
7. Remove Throttle Valve (36) from Cylinder.
8. Remove four Socket Head Screws (69) from
Manifold Block (68) at top of Handle (21), and
carefully lift Manifold Block straight up from Handle.
9. Remove two Reservoir Plugs (75) from top of
Manifold Block.
10. Remove Pull GlandAssembly (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 Cylinder Assembly
inverted in a vice and unscrew three Button Head
Screws (45) with 1/8 hex key.
12. Remove Muffler End Cap (42), Bottom Exhaust
Gasket (46), Muffler (43) and O-ring (44).
13. Remove Retaining Ring (47) from CylinderAssembly
(53).
14. Screw Button Head Screws (45) into Cylinder Head
(49). Carefully pry under screws to remove Cylinder
Head.
15. PushAir Piston (51) all the way down in Cylinder. Lay
the tool on its side. Hold Nut (41) with a 9/16 socket
and extension, and with 7/64 hex key, remove piston
Screw (32). (Figure 6)
16. Turn Cylinder and Handle upside down again and
secure in a vise.
continued
36
76
22
68
20 64
63
69
90
21
53
77
97
98
75
96
95
Figure 4
21
54
53
52
50
51
48
49
47
44
43
46
42
45
41
Figure 5

12
2480 Remote Intensifier Tooling Alcoa Fastening Systems
DISASSEMBLY OF BASE (continued)
17.Grip Self-locking Nut (41) underAir Piston with pliers
and pull piston and rod assembly from handle and
cylinder assembly. CAUTION: Care must be taken
not to scratch piston rod or cylinder during
removal. (Figure 6)
18. With a 1 3/8 socket and extension, 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 must be
used to avoid damaging the handle bore.
21. To remove Polyseal (61) from GlandAssembly (54),
remove Retaining Ring (59) and Spacer (60).
32
41
78
31
21
53
54
Remove
Piston
Screw
After removing Gland
Assembly 54), use a
plastic or wooden drift
to press out remainder
of Piston Assembly 31).
52
61
60
59
Separate
Handle
from
Cylinder
Figure 6

13
2480 Remote Intensifier Tooling Alcoa Fastening Systems
ASSEMBLY
GENERAL ASSEMBLY GUIDELINES
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
rings supplied in SERVICE PARTS KIT 2480RIKIT.
Smear LUBRIPLATE 130AA or equivalent on O-rings,
back-up rings and mating components for ease of
assembly. Assemble Tool taking care not to damage
either O-rings or back-up rings.
ASSEMBLY OF HEAD (Figures 7 & 8)
NOTE: Be sure that all seals are in place and oriented
correctly in the Cylinder (12) and on the Piston (4)
and Gland (10) prior to assembling.
1. Thinly coat SUPER 0-LUBE, or equivalent, on seals
and mating surfaces. Assemble O-rings and back-up
rings to piston, front gland, and rear gland. Press
Polyseal into front gland housing. Caution: Be
carefull that Polyseal does not hang up on the
edge of the Piston chamfer. Seal will be damaged
and leakage 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 Assembly
over Piston Assembly Tool and into Piston. Slide
Wiper onto Piston as shown.
3. Thread Piston Insertion Tool into cylinder. Lightly coat
internal surfaces of tool and Cylinder with lubricant.
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. (Figure 7) Remove Piston Assembly
Tool.
5. Lightly coat Cylinder and Rear Gland
O-rings with lubricant. Hold Cylinder
upright on a bench or in a vice fitted
with soft jaws. Install Rear Gland
Assembly using suitable spacer, plate,
and soft mallet. Remove Piston
Insertion Tool.
6. Press Wiper into groove of End Cap.
Thread End Cap into Cylinder and
tighten. Install Pintail Deflector.(Figure8)
continued
Support
Press
Piston
5
6
7
8
9
10
8
11
14
9
8
15
13
Spacer
Piston
Assemb y
Too
Piston
Insertion
Too
Note
Polyseal
Orientation
Front
G and
Assy
Rear
G and
Assy
Note
Poly
Orie
Figure 7
End
Cap
Wip r Pintail
D fl ctor
W
Figure 8

14
2480 Remote Intensifier Tooling Alcoa Fastening Systems
L ft half of
Handl (19)
Right half of
Handl (19)
Locknut
(100) Qty. 4
Hydraulic Hos s
(63) Qty. 2
Air Trigg r
and Hos
Ass mbly (1)
Sock t H ad
Cap Scr w (99)
Qty. 4
H ad
Ass mbly
Built-in
Strain
R li f
Figure 9
ASSEMBLY OF HEAD (continued)
7. Assemble Hydraulic Hoses to Cylinder head
assembly. Use SLIC-TITE TEFLON thread
compound, or equivalent, on pipe threads.
8. Assemble Air Trigger Assembly as follows: (Figure 3)
NOTE: For ease of assembly, heat end 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.
a.) Push O-Ring 500777 over threads of Trigger
Body.
b.) Push Trigger Stem through Trigger Body, then
Stretch O-Ring 500772 over Trigger Stem and
into first groove.
c.) Screw Trigger Body with Stem in place into
Trigger Housing.
d.) Screw Hose Fitting into Trigger Housing. PushAir
Hose onto Hose Fitting.
e.) Slide Quick Disconnect nut over Air Hose. Push
Hose onto Quick Disconnect and tighten nut.
9. Assemble Handle as follows: (Figure 9)
a.) Position Air Trigger Assembly into left handle half.
Press air hose into handles built-in strain relief.
b.) Position assembled Cylinder and hoses in left
handle half. Align right handle half with left
(locators help align halves).
c.) Insert Locknuts and Screws into Handle. Tighten
Screws.

15
2480 Remote Intensifier Tooling Alcoa Fastening Systems
ASSEMBLY OF BASE (Figures 10 & 14)
NOTE: See FILL AND BLEED PROCEDURE FOR
DISASSEMBLED TOOLS before proceeding.
1. Insert Plug (78).
2. Holding handle inverted in a vice, Place Cylinder
(53) on Handle (21) with Dowel (79) and Plug (78)
with O-Rings (74) in place positioned in matching
holes. (Figure 10a)
3. Assemble Gland Assembly (54) with Vibratite
505125. Screw complete Gland Assembly into
Handle. Torque to 100-120 ft. lbs. using 1-3/8 socket
wrench. (Figure 10b)
4. Push Air Piston/Rod assembly with Quad Ring (50)
in place into Air Cylinder (51) until it bottoms at top
of Cylinder (53). (Figure 10b)
5. Turn tool upright. Install Hydraulic Piston (34) (with
O-ring (33) and Back-up rings (38) in place) in
handle. Press in from top of handle taking care not
to damage seals. (Figure 14)
6. Push Screw (32) with O-ring (35) in place through
Hydraulic Piston (34) and screw into top of piston
rod. Hold Nut (41) with 9/16 socket and 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
into cylinder. Install Retaining Ring (47).
8. Position O-ring (44) and Muffler (43) on center of
Cylinder Head (49). Place Gasket (46) on Cylinder
Assembly (53). NOTE: Lip must face Bottom Plate
(42). Place Muffler End Cap (42) on top of Gasket
(46) and secure with 3 Button Head Screws (45)
using 1/8 hex key.
9. Turn tool upright. Install O-Ring (74) at top of Handle
(21).
10. Install O-rings (24 & 30) & Back-up Rings (25 & 29) on
Pull Gland (28) Install O-rings (24 & 26) & Back-
upRings (25 & 27) on Return Gland (23). Push Gland
Assemblies into Manifold Block (68). NOTE: Be sure
that all O-rings and Back-up Rings are in place
and oriented correctly on the Glands prior to
assembling.
11. Push Manifold Block down on Handle (21). Place tool
in a vise Head down and install 4 Screws (69) and
torque to 170 inch pounds. continued
78
74 2)
21
53
79
Press Handle 21) and Cylinder 53) together with Dowel 79) and Plug 78) in place.
Figure 10a Figure 10b
41
51
50
52
53
54
Torque to
100-120 ft.lbs.
Figure 10

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.
Push Throttle Valve (36) with O-rings (37 & 39) in
place into Cylinder.
14.Carefully press Throttle Valve (79) with O-rings (37,
39 and 55) in place into Cylinder until 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) and Air Fitting (64), and screw
SwivelAssemblies and Air Fitting into Manifold Block
(68). Secure Top Guard in place with two Screws
(96).
18. Install two Reservoirs (66) with O-Rings (91) in
place into Manifold Block.
NOTE: See SERVICING THE TOOL section of this
manual for WARNINGS, CAUTIONS, procedure for
tool set-up, reference to nose assembly, and
checking installed fasteners. Tool is now completely
assembled and ready for Fill & Bleed.

Fill Point
Fill Bottl
(94)
Plastic
Tub (93)
Conn ctor
(92)
17
2480 Remote Intensifier Tooling Alcoa Fastening Systems
FILL AND BLEED PROCEDURE FOR
ASSEMBLED TOOLS THAT NEED RE-
BLEEDING (Figure 12)
If the tool is not developing full stroke or is not
developing enough force to either install a fastener or
eject off an installed fastener, it may be necessary to add
oil to the pull and return system of the tool.
1. To add fluid to the PULL or RETURN side ports, first
make sure Cutoff Valves (70) are in the fully closed
position.
2. Remove Reservoir Plugs (75) and thread two
Reservoirs (66) with O-Rings (91) in place into the
ports of the Manifold Block (68).
3. Remove the Caps (65) and Piston Assys (67) from
the Reservoirs, and add fluid to the Reservoirs.
NOTE: Do not fill past the inside shoulder of the
Reservoirs (NO higher than Vent Hole). See Step
2of figure 6
4. Replace Piston Assemblies and Caps on
Reservoirs.
5. Open the Cutoff Valves 1/4 turn counterclockwise.
Thread Piston Assemblies down to force fluid into
the system, and until Piston Assemblies cannot be
turned further.
6. Close Cutoff Valves tightly, and check tool stroke.
Repeat Steps 3 through 5 if necessary. 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
P
RETURN
PULL
Step 1
Turn Threaded Rod of Piston Assy
counterclockwise until the Cap
unscrews out of the reservoir.
Step 2
Fill Reservoir with
hydraulic fluid to
top of piston bore
Re ief
Va ve (72)
B eed P ug
Assemb y (73)
Step 3
Thread Rod
down flush to
top of Cap.
Threaded
Rod
Cap (65)
Piston
Assy (67)
Reservoir
(66)
Manifo d
B ock (68)
Cutoff
Va ves (70)
R
P
Step 4
Thread two
Reservoir Plugs
back into ports.
Vent Ho e
Figure 12
WARNING: Avoid
contact with hydraulic
fluid. Hydraulic fluid
must be disposed of in
accordance with
Federal, State and
Local Regulations.
Please see MSDS for
Hydraulic fluid
shipped with tool.
!
Figure 11
FILL AND BLEED PROCEDURE
Equipment Required:
- Shop airline with 90 - 100 psi max.
- Air regulator
- Fill Bottle (94), Tube (93), and Connector (92)
(supplied with tool).
- Large flat blade screwdriver
-Nose assembly
-Fasteners (Optional)
Preparation:
1. Install air regulator in airline and set
pressure to 20-40 psi.
2. Fill bleed Bottle (94) almost full of DEXRON III
ATF or equivalent and secure Bottle cap.
(Figure 11)
3. Install Plastic Tube (93) and Connector (92) on
tip of Bottle Cap.
USE AUTOMATIC TRANSMISSION FLUID
DEXRON III, OR EQUIVALENT.
(Not to Scale)

18
2480 Remote Intensifier Tooling Alcoa Fastening Systems
FILL AND BLEED PROCEDURE FOR
DISASSEMBLED TOOLS
(Figures 11-13)
1. Before assembling Manifold Block onto Cylinder and
Handle assembly, pushAir Piston (51) and intensifier
Piston Rod (52) assembly down to its full bottom
position. Use a nonmetallic rod to prevent damage to
handle bores and intensifier rods.
2. Fill handle pull and return ports with hydraulic fluid.
3. Install hose sleeves onto hoses and airline.
NOTE: Identify each end of one hose before
assembly. Assemble the Manifold Block with Hoses
and Reservoirs onto the Handle.
4. Attach Fill Bottles with Connector (Figure 11) to ends
of each Hydraulic Hose (63). With Handle lower than
the end of the Hoses and Fill Bottles, connect Tool to
40psi air, and cycle the intensifier to remove all air
from the Hoses. Remove fill bottles and keep Hoses
vertical. 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, carefully attach Hydraulic
Hoses. NOTE: A slight amount of fluid will be lost
from the Hoses at this point. This is acceptable.
CAUTION: Use protection under Tool and Base to
catch or absorb any hydraulic fluid which may
drip or spill. See WARNING in Figure 11.
7. Attach plastic Handle halves (19), with Air Trigger
Assembly attached, to sides of tool.
8. Connect 60 psi air to the Cylinder and cycle the tool
and measure the specified stroke.
9. To properly pressurize the system follow all
instructions in the FILL AND BLEED PROCEDURE FOR
ASSEMBLED TOOLS THAT NEED RE-BLEEDING section of
this manual.
RETURN
PORT
PULL
PORT
Step 1
Push Air Piston 51) and
intensifier Piston Rod
52) assembly down to
the full bottom position.
Air Piston (50)
Int nsifi r Piston
Rod (52)
Step 2
Fill handle PULL and
RETURN ports with
hydraulic fluid.
Figure 13
S
SER
ERVICE VICE N
NOTES
OTES

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

20
2480 Remote Intensifier Tooling Alcoa Fastening Systems
17
16 18
63 2)
View is shown with two Reservoirs 66) in place. When removed, Reservoirs are replaced by two Reservoir Plugs 75) as shown in figure 9a above).
56
12
19
4
1
2
3
8910 11
73
72 71
75 2)
VIEW A-A
45 3) 44 43 42
46
47
48
49
41
51
50
40
39
83
37 3)
80
36
76
55
78
22
74
68
20
64
63
To Air Trigg r
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
A68
Ref.
20 Ref.
72 Ref.
75 Ref.
Figure 9a
View of Intensifier top
with Top Guard in Place
96 2)
95
70 Ref.
28 24
25
29 30
23 24
25
27
26
35
34 38
2)
33
32
78
13
14 15
98
99 4) 100 4)
1
9
Figure 9a
59
60
61
62
58 57
56
55
54 - (G and
Assemb y)
R
P
RETURN
PULL
90 - (Pu G and
Assemb y)
PULL
RETURN
22 - (Return
G and Assemb y)
31 - (Piston
Assemb y)
RETURN
PULL
Figure 14