Huck 2480 SERIES User manual

05-20-2014
HK970
INSTRUCTION MANUAL
MODELS 2480 & 2481 SERIES
HYDRAULIC INSTALLATION TOOLS

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
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2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
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CONTENTS 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

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
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I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with qualified personnel is recom-
mended 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 proce-
dures.
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 down-
time, 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 nor-
mal 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 maintain-
ing a secure footing and avoid awkward or off balanced postures.
3. The operator should change posture during extended tasks to help avoid discom-
fort 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 recommend-
ed. 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 haz-
ards such as electricity or other utility lines.
3. The assembly power tool is not intended for use in potentially explosive environ-
ments.
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 mate-
rials 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 work-
ing 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 rele-
vant 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.
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SAFETY AFETY I INSTRUCTIONS NSTRUCTIONS
CAUTIONS: show conditions that will
damage equipment and or structure.
WARNINGS: Must be understood to avoid
severe personal injury.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
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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 com-
pact tools are particularly adapted to installing fasten-
ers 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.
D
DESCRIPTION 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.
S
SPECIFICATIONS PECIFICATIONS ( (ALL ALL MODELS 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)

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
6
S
SPECIFICATIONS PECIFICATIONS ( (CONTINUED CONTINUED) )

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
7
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.
P
PRINCIPLE RINCIPLE OF OF O OPERATION PERATION ( (SEE SEE FIGURE FIGURE 2) 2)

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
8
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.
P
PREPARATION REPARATION FOR FOR U USE SE
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 SPECIFI-
CATIONS 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 con-
trol 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.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
9
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 reduc-
ing 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.
O
OPERATING PERATING I INSTRUCTIONS 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 pin-
tail 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 dam-
aged.
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 person-
nel.
WARNING: Do not pull on a pin with-
out 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 work-
piece.
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.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
10
CAUTION:
- Keep dirt and other material out of hydraulic sys-
tem.
- 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 pro-
ceeding with maintenance/repair.
Use proper hand tools in a clean well-lighted area for-
maintenance/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 materi-
als 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 bend-
ing, 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 SEC-
TIONAL 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 SERV-
ICE PARTS KIT
Rub SLIC-TITE TEFLON thread compound, or equiv-
alent, 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 nick-
ing/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 568-
number): material and durometer. For additional infor-
mation/specifications on O-rings and back-up rings,
see NOTES AND SPECIFICATlONS FOR STAN-
DARD PARTS.
Inspect tool daily. Check hoses, fittings and discon-
nects for leaks or damage.
M
MAINTENANCE AINTENANCE

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
11
PREVENTIVE MAINTENANCE
System Inspection
Operating efficiency of the Tool is directly
related to performance of complete sys-
tem, including tool/nose assembly,
hydraulic hoses, control trigger assembly
and the POWERIG® Hydraulic Unit
Therefore, an effective preventive mainte-
nance 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 trig-
ger 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 reg-
ular 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, pis-
ton and rod/extension, and unloading
valve for scored surfaces, excessive wear
or damage — replace parts as necessary.
On any assembly with UNITIZEDTM Jaws,
clean all parts in mineral spirits or iso-
propyl alcohol only — under no circum-
stances let jaws come in contact with
other solvents — also, do not let jaws
soak; dry the jaws immediately after
cleaning; dry other parts before assem-
bling. 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.
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MAINTENANCE AINTENANCE ( (CONTINUED CONTINUED) )

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
12
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 trig-
ger 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.
T
TROUBLESHOOTING ROUBLESHOOTING

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
13
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)
S
SPARE PARE P PARTS ARTS S SERVICE ERVICE K KIT IT
S
STICKER TICKER L LOCATIONS 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.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
14
The following procedure is for complete
disassembly - - disassemble only sub-
assemblies 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 han-
dle 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.
D
DISASSEMBLY 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.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
15
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
D
DISASSEMBLY ISASSEMBLY ( (CONTINUED CONTINUED) )

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
16
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
D
DISASSEMBLY ISASSEMBLY ( (CONTINUED CONTINUED) )

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
17
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 length-
wise, 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
D
DISASSEMBLY ISASSEMBLY ( (CONTINUED CONTINUED) )

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
18
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
A
ASSEMBLY 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 assem-
bled 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.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
19
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
A
ASSEMBLY SSEMBLY ( (CONTINUED CONTINUED) )
CAUTION: To avoid damaging dump
valve, do not use arbor press.

2480 & 2481 series Tooling (HK970) Alcoa Fastening Systems
20
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
A
ASSEMBLY SSEMBLY ( (CONTINUED CONTINUED) )