Arconic 2480 series User manual

November 16, 2018
HK970
Instruction Manual
2480 and 2481 series
Hydraulic Installation Tools
Declaration of Conformity
2
Safety Instructions
3-4
Description
5
Specifications
5
Principle of Operation
6
Tool Setup
6
Preparation for Use
7
Operating Instructions
8
Maintenance
9
Disassembly Procedure
10-11
Assembly Procedure
12
Components Drawings
13-16
Optional Equipment
17
Sticker Locations
17
Troubleshooting
18

2480 & 2481 series Hydraulic Installation Tools (HK970)
2

2480 & 2481 series Hydraulic Installation Tools (HK970)
3
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.
Continued on next page...
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 equipment.
-HEARING PROTECTION IS REQUIRED while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
WARNINGS: must be understood to avoid
severe personal injury.
CAUTIONS: show conditions that will
damage equipment and/or structure.
Safety Instructions

2480 & 2481 series Hydraulic Installation Tools (HK970)
4
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.
X. HYDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Carry out a daily check for damaged or worn hoses or
hydraulic connections and replace if necessary.
2. Wipe all couplers clean before connecting. Failure to do
so can result in damage to the quick couplers and cause
overheating.
3. Ensure that couplings are clean and correctly engaged
before operation.
4. Use only clean oil and filling equipment.
5. 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.
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.
Safety Instructions
WARNING: Do not exceed maximum pull or
return settings on tool.

2480 & 2481 series Hydraulic Installation Tools (HK970)
5
Description
The 2480, A2480, and 2481 series, with appropriate nose
assemblies, install a wide range of Huck blind fasteners and
HUCKBOLT® fasteners. 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. An unloading
valve, designed to relieve hydraulic pressure at end of the
PULL stroke, is positioned by the piston. The end of the
piston rod is threaded, and a retaining nut and stop are
included for attaching a nose assembly.
The 2480 series has hoses that pass through the handle,
and 2481 has hoses attached to the top of the tool.
Huck Hydraulic Installation Tools are designed to be
powered by Huck Powerig® Hydraulic Units, models 913F,
918, 918-5, 940, 968, or equivalent.
A specific nose assembly is required for each fastener type
and size. Nose assemblies must be ordered separately by
contacting your Huck representative.
Specifications
POWER SOURCE: Huck Powerig® Hydraulic Power Source
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 Automatic
Transmission Fluid (ATF) specifications. Fire-resistant fluid
may be used if it is an ester-based fluid such as
Quintolubric® HFD or equivalent. Water-based fluid shall
NOT be used as serious 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 (STANDARD): .875 inches (22.2 mm)
STROKE (LS): 1.250 inches (31.7 mm)
WEIGHT: 2.2 lbs (1 kg)
Where the following trade names are used in this manual, please
note:
DEXRON is a registered trademark of General Motors Corporation.
Loctite is a registered trademark of Henkel Corporation, U.S.A.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
MERCON is a registered trademark of Ford Motor Corp.
MOLYKOTE is a registered trademark of Dow Corning Corporation
Never-Seez is a registered trademark of Bostik, Inc.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Slic-tite is a registered trademark of LA-CO Industries, Inc.
Spirolox is a registered trademark of Smalley Steel Ring Company
Teflon is a registered trademark of E. I. du Pont de Nemours and Company.
Threadmate is a registered trademark of Parker Intangibles LLC.
TRUARC is a trademark of TRUARC Co. LLC.
Vibra-Tite is a registered trademark of ND Industries, Inc. USA.
8.20
(208)
5.42
(137) 3.32
(84)
1.41
(36)
6.55
(166)
1.81
(46)
.719
(18)
1.81
(46)
Figure 1
Inches
(mm)

Tool Setup
2480 & 2481 series Hydraulic Installation Tools (HK970)
6
Principle of Operation
A trigger controls the PULL and RETURN strokes. When the
trigger is pressed, hydraulic pressure is directed to PULL
side of the piston, and fastener installation begins. At the
end of PULL stroke, before the trigger is released, piston
uncovers flats of unloading valve, thus unloading pressure
by allowing fluid to flow back to Powerig® Hydraulic Unit.
When the trigger is released at end of PULL stroke when
fastener is installed, the pressure is directed to RETURN side
of the piston and moves piston forward. Nose assembly,
with tool, is then pushed off fastener.
Powerig
Hose Kit
Installation Tool
Nose
Assembly
Figure 2
TOOL AND NOSE ASSEMBLY
SHOWN ENGAGED ON
FASTENER. CYLINDER HOME
POSITION (RETURNED)
SHEET LINE
SPENT PINTAIL EJECTION
DANGER ZONE
KEEP HANDS AND FOREIGN OBJECTS
CLEAR DURING OPERATION.
TOOL ANVIL WILL ADVANCE TO SHEET
LINE WHEN TRIGGER IS PRESSED.
KEEP THIS
AREA CLEAR
THIS AREA MUST BE FREE
OF FIXED OBSTRUCTIONS.
TOOL MOVES FORWARD
DURING FASTENER
INSTALLATION.
MAX DISTANCE MOVED =
TOOL STROKE.
SEE MANUAL FOR TOOL
STROKE LENGTH.
Figure 3
WARNING:
Note tool
danger
zones in
Figure 3,
and heed
intstuctions.
GENERAL ARRANGEMENT OF FASTENING SYSTEM COMPONENTS
HEED WARNING AND DANGER ZONE INSTRUCTIONS
Tool shown with
electric trigger.

2480 & 2481 series Hydraulic Installation Tools (HK970)
7
Preparation for Use
1. Rub Slic-Tite® TEFLON® thread compound, or
equivalent, on pipe threads to prevent leaks and for ease
of assembly.
2. Use Huck Powerig® Hydraulic Power Source®, or
equivalent, that has been prepared for operation per
instruction manual. Check both PULL and RETURN
pressures, and ensure they are adjusted to pressures
given in SPECIFICATIONS of this manual. See both
hydraulic unit instruction manual and T-124883CE
instruction manual before and during checking
procedure. Visually inspect for leaks and to verify that
End Cap is installed correctly.
3. First, turn hydraulic unit to OFF; then disconnect power
supply from hydraulic unit. Disconnect trigger control
system from hydraulic unit.
4. Connect tool hoses to hydraulic unit. If required, adjust
position of trigger assembly on return pressure hose.
Connect trigger control system to hydraulic unit.
5. 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.
6. Select the appropriate nose assembly for the fastener to
be installed. Disconnect hydraulic unit from power
supply. Disconnect tool’s trigger control system from
hydraulic unit. Attach nose assembly to tool.
7. Reconnect tool’s trigger control system to hydraulic unit;
reconnect unit to power supply. Check operation of nose
assembly. Install fasteners in test plate of correct
thickness with proper size holes. Inspect installed
fasteners. If fasteners do not pass inspection, see
TROUBLESHOOTING section of this manual to locate
and correct malfunction.
8. Operator should receive training on proper use of Huck
equipment from qualified personnel.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.
CAUTIONS:
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.
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.)
WARNINGS:
Correct PULL and RETURN pressures are
required for operator safety and for
installation tool function. Gauge p/n
T-124883CE is available for checking pressures.
See Tool specifications and gauge instruction
manual. Failure to verify pressures may result
in severe personal injury.
Be sure to connect Tool’s hydraulic hoses to
Powerig® Hydraulic Power Source before
connecting Tool’s switch control cord to unit. If
not connected in this order, severe personal
Injury may occur.

2480 & 2481 series Hydraulic Installation Tools (HK970)
8
Operating Instructions
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 workpiece.) Hold
pin and push nose assembly onto pin protruding through
collar until nose anvil touches collar. Depress trigger and
hold until collar is swaged and pintail breaks. Release
trigger. Tool will go into RETURN stroke. Tool and nose are
ready for next installation cycle.
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 and
hold trigger until fastener is installed and pintail breaks.
Release trigger. Tool will go into its return stroke. Tool/nose
are ready for next installation cycle.
CAUTIONS:
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.
Do not use TEFLON® tape on pipe threads.
Pipe threads may cause tape to shred resulting
in tool malfunction. (Threadmate™ is available
from Huck in a 4oz. tube as part number
508517.)
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.
BOM blind fasteners jam in nose assembly if
pulled when not in workpiece.
To avoid structural and tool 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.
WARNINGS:
Read full manual before using tool.
Inspect tool for damage or wear before each
use. Do not operate if damaged or worn, as
severe personal injury may occur.
A half-hour training session with qualified
personnel is recommended before using Huck
equipment.
When operating Huck installation equipment,
always wear approved eye protection.
Be sure there is adequate clearance for the
operator’s hands before proceeding.
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.
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.
This tool is shipped with an attached regulator and a 1/4” inside diameter air hose (Huck p/n 115436), with a plastic plug
in the air inlet connector. An air supply capable of 6.3 CFM at a pressure greater than 10 psi greater than the installed
regulator set point (Figure 16)must be available. Air supply should be equipped with a filter-regulator-lubricator unit.
Do NOT pull a
fastener with the
collar upside down.
CORRECT CORRECT
Bead UP Flange DOWN
Do NOT install a fastener without a
workpiece (structure to be fastened), a
pin, and a properl oriented collar in place.

2480 & 2481 series Hydraulic Installation Tools (HK970)
9
Maintenance
GOOD SERVICE PRACTICES
The efficiency and life of an installation tool depends upon
proper maintenance and good service practices. Read this
entire page before proceeding with maintenance/repair.
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.
Use proper hand tools in a clean well lit area for
maintenance and/or repair. Always be careful to keep dirt
and 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 half-inch 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, and
reassemble tool with the same care.
Consult Troubleshooting section of this manual if a
malfunction occurs. 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 AND LUBRICANTS
Coat hose fitting threads with a non-hardening TEFLON®
thread compound such as Threadmate™, which is available
from HUCK in a 4oz. tube as part number 508517.
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 is available from HUCK in a
tube as part number 502723.)
SERVICE PARTS KIT
Service parts kit 2480KIT contains perishable parts for both
the 2480 and 2481 family of tools. For convenience, and as
experience indicates, keep extra kits (O-rings, back-up
rings, and other standard items) and tool parts on hand.
Inspect tool daily. Check hoses, fittings and disconnects for
leaks or damage.
Preventive Maintenance
SYSTEM INSPECTION
Operating efficiency of the tool is directly related to
performance of the complete system, including tool and
nose assembly, hydraulic hoses, control trigger assembly
and the Powerig® Hydraulic Unit. 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 POWER SOURCE
Maintenance and repair instructions are in applicable
Powerig Hydraulic Unit Instruction Manual.
Tool and 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, and replace parts as necessary. On any assembly
with UNITIZED™ Jaws, clean all parts in mineral spirits or
isopropyl alcohol only. Under no circumstances should 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 embedded particles from the pull grooves
of the jaws.
CAUTION: Do not use TEFLON®tape on pipe
threads. Pipe threads may cause tape to shred
resulting in tool malfunction.
5 4438 O-ring 5 11 2 Back-up Ring
110439
Female
Connector
110438
Male
Connector
Use a fine India stone to remove any nicks or burrs from
these areas to prevent damage to O-ring of Female Connector.
Figure 5

2480 & 2481 series Hydraulic Installation Tools (HK970)
10
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 subassemblies.
1. Read WARNING. Disconnect tool’s electrical connector
from the hydraulic unit; then uncouple tool’s hydraulic
hoses and drain into a container.
2. Remove tool retaining nut using 1-1/16 open-end
wrench. Slide nose assembly anvil away from tool.
Unscrew collet from tool piston.
3. Unscrew four screws from handle assembly. Remove the
screws and nuts, and separate handle halves. (Figure 6)
4. (Optional) Unscrew hydraulic hoses from tool.
NOTE: Do not remove hydraulic hoses from tool
unless replacing them.
5. Remove quick disconnects from hoses, and push
rearward on piston until remaining hydraulic fluid is
drained into container, and discard fluid.
6. Electric Trigger Models: Lift trigger switch assembly
from handle half. Pull control cord out of built-in handle
strain relief. Pull both bullet connectors apart. (Figure X)
Air Trigger Models: Lift air trigger assembly from
handle half. Pull air hose out of handle’s built-in strain
relief. (Figure 10)
7. Electric Trigger Models: Disassemble switch and cord
assembly as instructed in Figure 7.
Air Trigger Models: Disassemble air trigger and hose
assembly as instructed in Figure 8.
Disassembly Procedure
WARNING: Disconnect tool control trigger
system from Powerig® Hydraulic Unit before
disconnecting tool hydraulic hoses from unit. If
not disconnected in this order, severe personal
injury may occur.
Trigger
Switch Assembly
Bullet
Connectors
Left Half
of Handle
Screws (4)
Nut (4)
Cylinder
Head Assembly
Right Half
of Handle
Hose Assy (2)
Control Cord
Figure 6 TOOL FRONT -HANDLE HALVES SEPARATED
508593
Setscrew
124877
Button
124878
Trigger
Housing
124885
Switch
Assembly
Disassembl Procedure:
1. Loosen Setscrew using
5/64 hex key.
2. Remove Button.
3. Unscrew Switch from
Housing.
Figure 7 ELECTRIC TRIGGER ASSEMBLY
124887
Trigger Housing
500773
O-Ring
124888
Air Hose
113021
Quick
Disconnect
500777
O-Ring
126339
Trigger
Body
112555
Trigger
Stem
Disassembl Procedure
NO E: When removing air hose
from either fitting, slice hose
lengthwise, at fitting, just
enough to remove easily. hen,
cut hose squarely across to be
ready for assembly.
1. Unscrewing nut from quick
disconnect body; then cut
and remove Air Hose.
2. Remove Air Hose from Air
Trigger Housing.
3. Unscrew Trigger Body from
Housing.
4. Remove O-ring from
Trigger Stem, and pull Stem
out.
5. Remove O-ring from
Housing.
Figure 8 AIR TRIGGER AND HOSE ASSEMBLY

2480 & 2481 series Hydraulic Installation Tools (HK970)
11
DISASSEMBLE CYLINDER ASSEMBLY
1. Place spacer over threaded end of piston; then thread
piston assembly tool onto the piston. If the cylinder
contains fluid, push the piston rearward and drain the
fluid into a container. Discard the fluid.
2. Remove pintail deflector from end cap by twisting and
pulling in one motion.
3. With a 1-5/16 open-end wrench, unscrew end cap.
4. Using optional Piston Assembly Tool, press piston, with
unloading valve, and end cap/rear gland out through
the rear of the tool. (Figure 9)
5. Slide end cap and unloading valve from piston; then
remove piston insertion tool and spacer.
6. Use a small diameter pointed rod to remove all seals,
wipers, O-rings and back-up rings from components
and discard them. Do not re-use any seals. Clean parts,
including O-ring grooves. Examine all components for
wear or defects, and replace as required.
Disassembly Procedure
Remove Pintail Deflector and unscrew End Cap.
Press piston assembly with remaining components
through the back of the tool, and remove them in
the order shown (1-5).
Remove and discard all seals from subassemblies.
345 1
2
Front
Gland
Assembly
PRESS
123111-2 Piston
Assembly Tool
123112-2
Spacer End Cap
Pintail Deflector
Unloading Valve
Rear
Gland
Assembly
Piston
Figure 9 TOOL SHOWN WITH HANDLE HALVES REMOVED AND PISTON ASSEMBLY TOOL INSTALLED

2480 & 2481 series Hydraulic Installation Tools (HK970)
12
Clean out O-ring grooves and reinstall perishable parts (seals,
etc.) using service kit 2480KIT. NOTE: The small inner ring
insert of polyseals 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 Parker SUPER O-LUBE, or equivalent, on seals
and mating surfaces. Note the orientation of all O-rings,
back-up rings, wipers, and polyseals of piston, front
gland, and rear gland, and install them accordingly.
(Figure 10)
2. Thread piston assembly tool onto piston. Lubricate all
mating surfaces. Press evenly against gland cap to slide
front gland assembly over piston assembly tool and into
piston. Slide wiper onto piston as shown. Install unloading
valve into piston. NOTE: The long flats of the unloading
valve must be oriented toward the rear of the tool.
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 in a soft vise,
press assembled piston and components into cylinder.
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.
6. Press wiper into groove of end cap. Thread end cap into
cylinder and tighten. Install deflector.
7. Assemble hoses to cylinder head assembly. Use Slictite®
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 for Electric or Air Trigger.
9. Assemble handle assembly to tool.
ASSEMBLING HANDLE TO TOOL
1. Electric Trigger Models:
a. Screw switch into housing.
b. Slide button onto switch.
c. Tighten setscrew using 5/64 hex key.
Air Trigger Models:
NOTE: To ease assembly, heat ends of hose before pushing
onto fittings. When using a new disconnect, remove and
discard plastic ferrule from nut before attaching air hose.
a. Push O-ring over threads of air trigger body.
b. Push stem through body. Stretch O-ring over stem and
into groove.
c. Screw trigger into housing.
d. Screw hose fitting into housing. Push hose onto fitting.
e. Slide nut over hose. Push hose onto quick disconnect.
Tighten nut.
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 handle. Tighten screws.
Assembly Procedure
CAUTION: Do not use TEFLON®tape on pipe
threads. Pipe threads may cause tape to shred
resulting in tool malfunction.
Piston Insertion Tool
Piston
Front Gland Assembl
Note orientation of all seals!
Rear Gland Assembl
Note orientation of all seals!
Unloading
Valve
Vise
C linder Head
Piston Assembl Tool
Figure 10
GLANDS, PISTON, AND VALVE ASSEMBLY

2480 & 2481 series Hydraulic Installation Tools (HK970)
13
See Figure 13 for Electric Trigger, Hoses, and Cord part numbers.
See Figure 14 for Air Trigger and Hoses part numbers.
12 588
Stop
111795
Retaining
Nut
Handle
See able at right
for part number.
124876 End Cap
Unloading Valve
See able below for part number.
Cylinder
See able below
for part number.
Piston (not sold separately)
12421 Deflector
Front Gland (not sold separately)
5 64 Screw (4)
5 71 7 Locknut (4)
5 5843 Front Wiper
12487 Gland Cap
5 5818 Polyseal
(note orientation)
5 111 Back-up Ring
5 816 O-ring
5 111 Back-up Ring
5 5849 O-ring
Rear Gland (not sold separately)
5 71 8 Rear Wiper
5 11 4 Back-up Ring
5 81 O-ring
5 111 Back-up Ring
5 816 O-ring
124871 Front Gland Assembl Piston Assembl (Note 1)
See able below for part number. 124873 Rear Gland Assembl
Trigger Switch
Assembl
(Figures7 & 13
for Electric;
Figures 8 & 13
for Air.)
Notes:
1. Piston lengths var
depending on which tool
is used. Some pistons
protrude from the front of
the tool. The piston shown
in this picture is the
standard 2480 tool piston.
2480 series Components
Figure 11
Tool
Number
Piston
Assembly Cylinder Unloading Valve Handle
2480
124883
124862 124868
124867
2480-2
2480-17
2480-25
2480-30
2480L 124875
2480L-1 124875-2
2480L-2 124875-3
2480LS 128148 128138 128140
2480LSL 128435
2480XL 124875-1
124862 124868
A2480
124883A2480-6
131625A2480-30
A2480LS 128148 128138 128140

2480 & 2481 series Hydraulic Installation Tools (HK970)
14
2481 series Components
H draulic hose with
female connector end
H draulic hose with
male connector end
Power Cord
See Figure 13 for Hoses, and Cord part numbers.
12 588
Stop
111795
Retaining
Nut
124867
Handle
124876 End Cap
124868 Unloading Valve
124886 Cylinder
Piston (not sold separately)
12421 Deflector
Front Gland (not sold separately)
5 64 Screw (4)
5 71 7 Locknut (4)
5 5843 Wiper
12487 Gland Cap
5 5818 Polyseal
(note orientation)
5 111 Back-up Ring
5 816 O-ring 5 111 Back-up Ring
5 5849 O-ring
Rear Gland (not sold separately)
5 71 8 Wiper
5 11 4 Back-up Ring
5 581 O-ring
5 111 Back-up Ring
5 816 O-ring
124871 Front Gland Assembl
124883 Piston Assembl (2481)
124875-2 Piston Assembl (2481L-1)
See Note 1
124873 Rear Gland Assembl
Trigger
Switch
Assembl
(See Figures
7 & 13
for details.)
Notes:
1. The piston shown in this
picture is the standard
2481 tool piston. The
2481L-1 piston protrudes
from the front of the tool.
Figure 12

2480 & 2481 series Hydraulic Installation Tools (HK970)
15
Hydraulic Hoses
See Table above for individual tools
124879 Trigger
Switch Assembly
(See Figure 7)
503431 Reducing Bushing
110438 Male Connector
110439 Female Connector
Control Cord Assembly*
See Table above for individual tools
(Contains cord with connecter, plug, and
receptor attached)
Hydraulic Hoses and Electric Trigger and Cord
Figure 13
Tool
Number
Hose
Number
Hose
Length
Control Cord
Assembly Number
Cord
Length
2480 HPHX12-AA10 12 ft. 124880 13 ft.
2480-2 HPHX2-AA10 2 ft. 124880-3 3 ft.
2480-17 HPHX17-AA10 17 ft. 124880-4 2 ft.
2480-25 HPHX25-AA10 25 ft. 124880-2 17 ft.
2480-30 HPHX30-AA10 30 ft. 124880-5 25 ft.
2480L
124881-1 12 ft. 124880 13 ft.
2480L-1
2480L-2
2480LS
2480LSL
2480XL
2481
2481L-1

2480 & 2481 series Hydraulic Installation Tools (HK970)
16
Hydraulic Hoses*
See Table above for individual tools
503431 Reducing Bushing
110438 Male Connector
110439 Female Connector
Air Trigger and
Hose Assembly*
(See Figure 8)
* Tools are shipped standard with 12 ft. hoses and cord. For other lengths available, see OPTIONAL EQUIPMENT.
Air Hoses and Trigger and Cord
Figure 14
Tool
Number
Hose
Number
Hose
Length
Air Hose
Assembly Number
Air Hose
Length
A2480 124881-1 12 ft. 124889 13 ft.
A2480-6 124881-2 6 ft. 124889-1 6.5 ft.
A2480-30 HPHX30-AA10 30 ft. 124889-2 31 ft.
A2480LS 124881-1 12 ft. 124889 13 ft.

2480 & 2481 series Hydraulic Installation Tools (HK970)
17
Optional Equipment
Pressure Gauge T-124833CE
Service Parts Kit 2480KIT
(Includes all perishable seals,
O-rings, and Back-up rings.
A spare Service Parts Kit
should be kept on hand at
all times.)
Pintail Bottle Assembly 128017
(To convert tool to 2480B)
Piston Assembly Tool Kit 123110-2 (Standard)
Includes:
Piston Assembly Tool - 123111-2
Spacer - 123112-2
Polyseal Insertion Tool - 121694-202
Piston Assembly Tool Kit 123110-4 (L / XL)
Includes:
Piston Assembly Tool - 123111-4
Spacer - 123112-3
Polyseal Insertion Tool - 121694-202
Control Cord Assembly Cord Length Part No.
(Contains cord with - 2.5 ft 124880-6
connector, plug, and - 3.5 ft 124880-1
receptor attached) - 4.5 ft 124880-9
- 13.3 ft 124880-8
- 17.75 ft 124880-4
- 26 ft 124880-2
- 30.75 ft 124880-5
- 39 ft 124880-10
Hose and Cord Kits Hose Length Part No.
(Contains control cord - 6 ft 118309-6
assembly and both - 12 ft 118309-12
hydraulic hoses with male - 26 ft 118309-26
and female quick connect - 38 ft 118309-38
fittings at each end) - 52 ft 118309-52
Individual Hoses Hose Length Part No.
- 2 ft HPHX02-AA10
- 6 ft HPHX06-AA10
- 12 ft HPHX12-AA10
- 17 ft HPHX17-AA10
- 25 ft HPHX25-AA10
- 30 ft HPHX30-AA10
- 38 ft HPHX38-AA10
- 40 ft HPHX40-AA10
- 50 ft HPHX50-AA10
TEFLON® Stick - 503237
TEFLON® Sealant - 620012
Loctite® 243 - 508567
Never-Seez® NS-160 - 505565
(anti-seize and lubricating compound)
LUBRIPLATE® 130-AA - 502723
Threadmate™ (4oz. tube) - 508517
Sticker Locations
The 2480 and 2481 series tools
come labeled with:
Safety and pressure sticker,
part number 590424
This sticker 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 Placement
Figure 4
8400 580
3200 220
PLACEMENT OF CE, CAUTION, AND WARNING STICKER
590424 Sticker
NOTES:
1. These hoses do not have
reducing bushings or
quick connect fittings at
each end.
2. These hoses are directly
interchangeable with the
124881 series hoses.

2480 & 2481 series Hydraulic Installation Tools (HK970)
18
Troubleshooting
1. 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 coupling
e. Unloading valve not installed in tool
2. Tool operates in reverse:
a. Reversed hydraulic hose connections between
Powerig and tool
3. Tool leaks hydraulic fluid:
a. Defective Tool O-rings or loose hose connections at
tool
4. Hydraulic couplers leak fluid:
a. Damaged or worn O-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 Powerig instruction manual
6. Tool operates erratically; fastener not installed
properly:
a. Low or erratic hydraulic pressure — air in system
b. Damaged or worn piston O-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. Grooves on fastener pintail stripped during PULL
stroke:
a. Operator not sliding anvil completely onto fastener
pintail
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
swaged:
a. Improper tool operation — see Trouble 6
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
fastener:
a. Improper Tool operation — see Trouble 6
b. RETURN pressure too low
c. Nose assembly not installed correctly
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 possi-
ble, substitute known good parts for suspected defective parts. Use Trouble Shooting Chart as an aid for lo-
cating and correcting trouble.

2480 & 2481 series Hydraulic Installation Tools (HK970)
19
Limited Warranties
Limited Lifetime Warranty on BobTail® Tools:
Huck International, Inc. warrants to the original purchaser
that its BobTail® installation tools manufactured after
12/1/2016 shall be free from defects in materials and
workmanship for its useful lifetime. This warranty does not
cover special order / non-standard products, or part failure
due to normal wear, tool abuse or misapplication, or user
non-compliance with the service requirements and
conditions detailed in the product literature.
Two Year Limited Warranty on Installation Tools:
Huck International, Inc. warrants that its installation tools
and Powerig® hydraulic power sources manufactured after
December 1, 2016 shall be free from defects in materials
and workmanship for a period of two years from date of
purchase by the end user. This warranty does not cover
special order / non-standard products, or part failure due
to normal wear, tool abuse or misapplication, or user non-
compliance with the service requirements and conditions
detailed in the product literature.
90 Day Limited Warranty on Nose Assemblies and
Accessories:
Huck International, Inc. warrants that its nose assemblies
and accessories shall be free from defects in materials and
workmanship for a period of 90 days from date of purchase
by the end user. This warranty does not cover special
clearance noses, or special order / non-standard product, or
part failure due to normal wear, abuse or misapplication, or
user non-compliance with the service requirements and
conditions detailed in the product literature.
Useful lifetime is defined as the period over which the
product is expected to last physically, up to the point when
replacement is required due to either normal in-service
wear, or as part of a complete overhaul. Determination is
made on a case-by case basis upon return of parts to Huck
International, Inc. for evaluation.
Tooling, Part(s) and Other Items not manufactured 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.
Huck shall not be liable for any loss or damage resulting
from delays or non-fulfillment 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 [phone] FAX [phone]
Outside USA and Canada
Contact your nearest Huck International location (see
reverse).
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 Tool
Kits and Nose Assemblies. Please contact your Huck
Representative or the nearest Huck International location
(see reverse) for the ATSC in your area.

Arconic Inc. (NYSE: ARNC) creates breakthrough products
that shape industries. Working in close partnership with our
customers, we solve complex engineering challenges to
transform the way we fly, drive, build and power.
Through the ingenuity of our people and cutting-edge
advanced manufacturing, we deliver these products at a
quality and efficiency that ensures customer success and
shareholder value.
Arconic Fastening Systems Tooling Support Locations
Huck provides technical assistance
regarding the use and application of Huck
fasteners and tooling. NOTICE: The
information contained in this publication 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, acknowledgments, and/or
purchase orders. It is recommended that the user secure
specific, up-to-date data and information regarding each
application and/or use of such products.
CERTIFIED
MANAGEMENT
SYSTEM
ISO 9001-2015
ISO 14001-2015
© 2018 Huck International, Inc.
Arconic Fastening Systems
Kingston Operations
1 Corporate Drive, Kingston, NY 12401
Tel: [phone] • Fax: [phone]
www.afshuck.net/us
INDUSTRIAL NORTH AMERICA
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
Tel: [phone]
Fax: [phone]
[email protected]
Tracy Operations (IDG)
1925 North MacArthur Drive
Tracy, CA 95376
Tel: [phone]
Fax: [phone]
[email protected]
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
Tel: [phone]
Fax: [phone]
[email protected]
INDUSTRIAL GLOBAL
Kolkata Operations
Unit No. 28, 2nd Floor,
55/1, Chowringhee Road,
Kolkata 700071, West Bengal, India
Tel: [phone]
Tel: [phone]
Fax [phone]
Melbourne Operations
1508 Centre Road
Clayton, Victoria
Australia 3168
Tel: [phone]
Fax: [phone]
[email protected]
São Paulo Operations
Rodovia Anhanguera, s/n, KM 17
Parque São Domingos - Complexo
Anhanguera - Galpão 1 Seção III
(Módulo III) Box 11
CEP 05112-000 São Paulo – SP Brazil
Tel: [phone]
Suzhou Operations
58 Yinsheng Road,
SIP Suzhou, Jiangsu
215126 China
Tel: [phone]-8888
Telford Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
Tel: [phone]
Fax: [phone]
[email protected]
Tokyo Operations (Japan and Korea)
1013 Hibiya U-1 Bldg.
Uchisaiwai-cho 1-1-7
Chiyoda-ku, Tokyo
100-0011 Japan
Tel: [phone]
Fax: [phone]
AEROSPACE NORTH AMERICA
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
Tel: [phone]
Fax: [phone]
[email protected]
Simi Valley Operations
3990A Heritage Oak Court
Simi Valley, CA 93063
Tel: [phone]
Fax: [phone]
www.afs-simivalley.com
AEROSPACE GLOBAL
Aichach Operations
Robert-Bosch Str. 4
Aichach 86551
Germany
Tel: [phone]
[email protected]
Cergy Operations
15 Rue du Petit Albi
F-95611 Cergy Pontoise
France
Tel: [phone]
Fax: [phone]
Hong Kong Operations
27th Floor, 88 Hing Fat Street
Causeway Bay
Hong Kong, China
Tel: [phone]