Huck 2502 User manual

November 25, 2015
HK837
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
INSTRUCTION MANUAL
2502 & A2502
HYDRAULIC INSTALLATION TOOLS

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
EU Declaration of Conformity
Manufacturer:
Huck International Inc., Installation Systems Division, 85 Grand Street, Kingston, NY, 12401, USA
Description:
Model number 2400 series fastener installation tools
Model number 2500 series fastener installation tools
Model number 2600 series 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 Pattendon, 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: Renno Budziak
Position: Vice President of Engineering, Installation Systems Division
Place: Kingston, New York, USA
Date: May, 1996
Huck Model Series 2400, 2500 and 2600 (families)
Sound Level
SEL = 75.8 dB (A)
peak value = 108.2 dB (C)
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent noise level (Leq) of
66 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.
Huck Model Series 2400, 2500 and 2600 (families)
Vibration Level
For an eight hour work day, installing 3000 typical Huck
fasteners will result in an equivalent weighted RMS
vibration level (Aeq) of 12.50m/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 Huck International, Inc., Kingston, NY, USA. Vibration
measurements are frequency weighted in accordance with ISO 8041 (1990).

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
CONTENTS
EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–5
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–7
ASSEMBLY DRAWING SECTIONAL VIEW I. . . . . . . . . . . . . . . . . . . . . . . . . . .8
PRINCIPLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10–11
ASSEMBLY OF NPTF THREADED COMPONENTS. . . . . . . . . . . . . . . . . . . . .11
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
ASSEMBLY DRAWING SECTIONAL VIEW II . . . . . . . . . . . . . . . . . . . . . . . . .14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
ASSEMBLY DRAWING ELECTRIC/AIR CONTROLS AND HYDRAULIC HOSES . . . .16
ASSEMBLY DRAWING PISTON DISASSEMBLY / ASSEMBLY TOOL . . . . . . . . . .17
ASSEMBLY DRAWING PISTON DISASSEMBLY DETAIL . . . . . . . . . . . . . . . . . .18
ASSEMBLY DRAWING PISTON ASSEMBLY DETAIL . . . . . . . . . . . . . . . . . . . .19
ASSEMBLY DRAWING AIR TRIGGER & HOSE ASSEMBLY . . . . . . . . . . . . . . .20
ASSEMBLY DRAWING 2502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
ASSEMBLY DRAWING A2502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
ASSEMBLY DRAWING A2502-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ASSEMBLY DRAWING 8-A2502-500-2 . . . . . . . . . . . . . . . . . . . . . . . . . .24
ASSEMBLY DRAWING A2502-625-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ASSEMBLY DRAWING 2502-625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ASSEMBLY DRAWING 8-2502-625-25. . . . . . . . . . . . . . . . . . . . . . . . . . .27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
KITS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SPECIFICATIONS FOR STANDARD PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .29
FASTENER SELECTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
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. ReadMSDSSpecificationsbeforeservicingthetool.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 without
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...
SAFETY INSTRUCTIONS
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.

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can
experience discomfort in the hands, arms, shoulders, neck
or other parts of the body.
2. When using tool, the operator should adopt a comfortable
posture while maintaining a secure footing and avoid
awkward or off balanced postures.
3. The operator should change posture during extended tasks
to help avoid discomfort and fatigue.
4. If the operator experiences symptoms such as persistent
or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or stiffness, these warnings
should not be ignored. The operator should tell the
employer and consult a qualified health professional.
V. ACCESSORIES HAZARDS:
1. Disconnect tool from energy supply before changing
inserted tool or accessory.
2. Use only sizes and types of accessories and consumables
that are recommended. Do not use other types or sizes of
accessories or consumables.
VI. WORKPLACE HAZARDS:
1. Be aware of slippery surfaces caused by use of the tool
and of trip hazards caused by the air line or hydraulic hose.
2. Proceed with caution while in unfamiliar surroundings;
there could be hidden hazards such as electricity or other
utility lines.
3. The assembly power tool is not intended for use in
potentially explosive environments.
4. Tool is not insulated against contact with electrical power.
5. Ensure there are no electrical cables, gas pipes, etc., which
can cause a hazard if damaged by use of the tool.
VII. NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent,
disabling hearing loss and other problems such as tinnitus,
therefore risk assessment and the implementation of
proper controls is essential.
2. Appropriate controls to reduce the risk may include
actions such as damping materials to prevent workpiece
from ‘ringing’.
3. Use hearing protection in accordance with employer’s
instructions and as required by occupational health and
safety regulations.
4. Operate and maintain tool as recommended in the
instruction handbook to prevent an unnecessary increase
in the noise level.
5. Select, maintain and replace the consumable / inserted
tool as recommended to prevent an unnecessary increase
in noise.
6. If the power tool has a silencer, always ensure that it is in
place and in good working order when the tool is being
operated.
VIII. VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the
nerves and blood supply to the hands and arms.
2. Wear warm clothing when working in cold conditions and
keep hands warm and dry.
3. If numbness, tingling, pain or whitening of the skin in the
fingers or hands, stop using the tool, tell your employer
and consult a physician.
4. Support the weight of the tool in a stand, tensioner, or
balancer in order to have a lighter grip on the tool.
IX. HYDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Carry out a daily check for damaged or worn hoses or
hydraulic connections and replace if necessary.
2. Wipe clean all couplers 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.
SAFETY INSTRUCTIONS (continued)
WARNING: Do not exceed the maximum
PULL or RETURN settings on tool.
WARNING: Be sure all hose connections
are tight. All tool hoses must be connected.

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
DESCRIPTION
MAX OPERATING TEMP: 125° F (51.7° C)
MAX PULL PRESSURE: 5700 psi (393.02 bar)
MAX RETURN PRESSURE: 2400 psi (165.48 bar)
POWER SOURCE: Huck POWERIG®Hydraulic Unit
COMPATIBLE FASTENERS: See TABLE 3 -
FASTENER SELECTION CHART
HOSE KITS: Use only genuine HUCK Hose Kits rated
@ 10,000 psi (689.5 bar) 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.
DEXRON is a registered trademark of General Motors Corp.
MERCON is a registered trademark of Ford Motor Corp.
Quintolubric is a registered trademark of Quaker Chemical Corp.
SPECIFICATIONS
Huck’s 2502 and A2502 series of Hydraulic Installation
Tools installs a wide range of Huck Blind Fasteners
and HUCKBOLT®Fasteners. These mini-tools are
lightweight and compact, which make them ideal for
installing fasteners in limited-clearance applications.
The 2502 tool series is designed to be powered by a
Huck POWERIG®Hydraulic Unit (or equivalent hydraulic
unit) with maximum operating pressures of:
• RETURN: 2400 psi (165.48 bar) and
• PULL: 5700 (see NOTE) psi (393.02 bar)
NOTE: The PULL pressure must be set at 8400
psi (579.18 bar) to install -12 diameter fasteners
in MG, GP, and LGP only.
Model 2502 has an electric switch and should be used
with POWERIG models 918, 918-5, 940, and 943-913.
Model A2502 has an air trigger and is suitable for use
with POWERIG models 942 and 970-3. NOTE: Model
970-3 may be used when lower PULL and RETURN
pressures are sufficient.
Each tool is complete with 12 ft. hydraulic hoses and
couplings, an electric switch and cord (2502) or an
air trigger and tubing (A2502). The tool is basically
a cylinder and piston assembly. An unloading valve,
designed to relieve the hydraulic pressure at the end of
the PULL stroke, is situated near the piston. The end of
the piston rod is threaded, and a retaining nut and stop
are included for attaching nose assemblies†.
When the hydraulic hoses and trigger control are
connected to the POWERIG, an air or electric trigger
controls the PULL and RETURN strokes of the tool. The
trigger is pressed and hydraulic pressure is directed to
the PULL side of the piston; fastener installation begins.
When fastener installation is completed, the trigger is
released. Hydraulic pressure is directed to the RETURN
side of the piston, moving it forward. The tool and nose
assembly are pushed off the installed fastener.
At end of the PULL stroke, the piston uncovers flats of
the unloading valve, and the pressure is unloaded by
allowing the fluid to flow back to the POWERIG.
†Nose assemblies must be ordered separately.
A distinct nose assembly is required for each
fastener, based on type and size. Contact your Huck
representative for the appropriate Nose Assembly
Selection Chart and the various Huck Fastener
Selection Chart for more specific information on fastener
type and sizing.
TABLE 1 - TOOL SPECIFICATIONS
MODEL LENGTH
Inch (cm) WIDTH Inch (cm) HEIGHT Inch (cm) WEIGHT lbs (kg)
Entire Series 8.0 (20.4) 2.0 (5.0) 6.0 (15.2) 4.5 (2.04)
NOTE: Length and weight do not include nose assemblies.
CAUTION: The PULL pressure must be
set to 8400 psi (579.18 bar) to install -12
diameter fasteners in MG, GP, & LGP only.

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
SPECIFICATIONS (CONTINUED)
8.0
20.4
5.2
13.3 3.0
7.7
2.0
5.0
1.2
3.2
1.5 3.8
6.0
15.2
FIGURE 1
INCHES
cm

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
ASSEMBLY DRAWING: SECTIONAL VIEW I
FIGURE 2

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
PRINCIPLE OF OPERATION
When the hydraulic hoses and trigger control are
connected to the POWERIG®Hydraulic Unit, an air or
electric trigger controls the PULL and RETURN strokes
of tool. The trigger is pressed and hydraulic pressure
is directed to the PULL side of the piston. Fastener
installation begins.
When fastener installation is completed, the trigger is
released. Hydraulic pressure is directed to the RETURN
side of the piston, moving it forward. The tool and nose
assembly are pushed off the installed fastener. At the
end of the PULL stroke, the piston uncovers flats of
the unloading valve, and the pressure is unloaded by
allowing the fluid to flow back to the POWERIG.
WARNING: Huck recommends that a Huck
POWERIG® be used to power Huck tools.
(Only use the POWERIG as indicated in
its instruction manual.) Hydraulic power
units that deliver high PULL and RETURN
pressures—but which are NOT equipped
with RELIEF VALVES—are specifically NOT
RECOMMENDED and may be dangerous.
Set the PULL and RETURN pressures
as specified in Specifications. Failure to
properly set these pressures could result in
serious personal injury.
Use Huck Pressure Gauge (P/N T-124883CE)
as indicated in its instruction manual.
Improper pressure settings may result in
severe personal injury.
WARNINGS:
- Read entire manual before using tool.
- A 30-minute training session with
qualified personnel is recommended
before using Huck equipment.
- When operating Huck equipment,
always wear approved eye and hearing
protection.
- Be sure there is adequate clearance for
the operator’s hands before proceeding.
- Connect the tool’s hydraulic hoses to
the POWERIG®Hydraulic Unit before
connecting the tool’s switch control cord
to it. If not connected in this order, severe
personal injury may occur.
PREPARATION FOR USE
CHECKING & ADJUSTING OUTPUT PRESSURES
NOTE: Before starting this procedure, review the
CAUTIONs in DESCRIPTION and Figure 3.
Use a Huck POWERIG®Hydraulic Unit, or equivalent,
that has been suitably prepared for operation.
NOTE: Review all WARNINGs on this page.
1. Turn OFF the POWERIG and disconnect its power
supply. Connect the tool hoses to the POWERIG.
2. Connect tool’s control switch electrical cord to the
POWERIG.
3. Connect the POWERIG to the power supply (air
or electric). Turn ON the POWERIG. Press and
hold the tool trigger for 30 seconds; then press the
trigger a few times to cycle the tool and circulate the
hydraulic fluid. Observe the action of the tool and
check for leaks. Turn OFF the POWERIG.
4. Disconnect the tool’s control switch electrical
cord from the POWERIG. Select the correct nose
assembly for the fastener to be installed (see
Nose Assembly Selection Chart). Attach the nose
assembly to the tool as instructed in Nose Assembly
Data Sheet.
5. Re-connect the POWERIG to the power supply.
Reconnect the tool’s trigger control system to the
POWERIG. Check the operation of nose assembly;
install fasteners in a test plate of correct thickness
with proper size holes. Inspect installed fasteners.
If fasteners do not pass inspection, see TROUBLESHOOTING
to investigate possible causes.
Threadmate is a registered trademark of Parker Intangibles LLC.
Loctite is a registered trademark of Henkel Corporation, U.S.A.
Slic-Tite is a registered trademark of LA-CO Industries, Inc.
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CAUTION: Keep disconnected hoses,
couplers and hydraulic fluid free of foreign
matter. Contaminated fluid can cause valve
failures.
1 Turn OFF the POWERIG and disconnect its power
WARNING: Connect the tool’s hydraulic
hoses to the POWERIG before connecting
tool’s trigger control system to the
POWERIG. If not connected in this order,
severe personal injury may occur.
POWERIG
.
CAUTION: Apply Parker Threadmate®,
Loctite®567, or Slic-Tite®to male pipe
threads (per manufacturer’s instructions) to
prevent leaks and to ease assembly.

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
The operating efficiency of your tool is directly related
to performance of the entire system, including the
tool and nose assembly, hydraulic hoses, control
trigger assembly, and the POWERIG®Hydraulic Unit.
Therefore, an effective preventive maintenance program
includes scheduled inspections of the system to detect
and correct minor troubles.
NOTE: Where a part number (P/N) is given, Huck
sells that part.
SYSTEM INSPECTION
- Inspect the tool daily. Check hoses, fittings, and
couplings for leaks and damage. Clear air-lines of dirt
and water.
- Service the tool in a clean, well-lighted area. Take
special care to prevent contamination of pneumatic
and hydraulic systems.
- Carefully handle all parts and components. Before
reassembly, examine them for damage and wear;
replace when necessary. Replace O-rings and
Back-up rings when the tool is disassembled for any
reason.
- Have available all necessary hand tools (standard and
special); a half-inch brass drift and wood block; an
arbor press; and a soft-jaw vise. Unsuitable hand tools
could cause tool damage. See KITS & ACCESSORIES.
- Follow the disassembly and assembly procedures in
this manual. If Huck recommended procedures are
not followed, the tool could be damaged.
- Disassemble and assemble tool components in a
straight line. Do NOT bend, twist, or apply undue
force.
- Apply continuous steady pressure to disassemble a
component. An arbor press provides steady pressure
to press a component into or out of an assembly.
- Never force a component if it is misaligned. Reverse
the procedure to correct misalignment and start over.
FLUID MAINTENANCE
See SPECIFICATIONS for fluid type. For fluid maintenance,
refer to NAS 1638 class 9, ISO CODE 18/15, or SAE
level 6. Dispose of fluid in accordance with local
environmental regulations. Recycle steel, aluminum, and
plastic parts in accordance with local lawful and safe
practices.
STANDARD SEALANTS, LUBRICANTS
- Apply Parker Threadmate®, Loctite®567, or Slic-Tite®
to male pipe threads per manufacturer’s instructions (to
ease assembly and to prevent leaks).
- Smear LUBRIPLATE®130-AA or SUPER-O-LUBE®
on rings and mating parts to ease assembly and to
prevent nicking/pinching rings on rough/tight spots.
PREVENTIVE MAINTENANCE
Huck recommends that you:
- Inspect the tool and nose daily for damage and wear.
Inspect the tool before each use for leaks.
- Verify that hoses, fittings, and trigger connections are
secure and free of leaks.
- Inspect hydraulic hoses for signs of damage. Replace
if necessary.
- Inspect the tool, hoses, and POWERIG during
operation to detect abnormal heating, leaks, or
vibration.
For supplementary information, see TROUBLESHOOTING,
the DISASSEMBLY and ASSEMBLY procedures, and the
ASSEMBLY DRAWINGS in this manual.
POWERIG MAINTENANCE
Maintenance instructions and repair procedures are in
the appropriate POWERIG Instruction Manual.
TOOL MAINTENANCE
Whenever disassembled, and at regular intervals,
depending on use, replace all O-rings and Back-up
rings. Tool-specific Spare Parts Service Kits should be
kept on hand. Inspect cylinder bore, piston, piston rod,
and unloading valve for scored surfaces, excessive
wear, and damage; replace as necessary.
MAINTENANCE
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CAUTIONS:
- Consult the Material Safety Data Sheet
(MSDS) before servicing tool.
- Keep foreign matter out of the hydraulic
system. Keep separated parts away from
dirty work surfaces.
- Dirt and debris in hydraulic fluid causes
valve failures in tool and POWERIG®.
- Check the Assembly Drawings in this
manual for the proper direction of the
flats on the dump valve.
CAUTION: Do not use TEFLON®tape
on pipe threads. Tape can shred and
break free into fluid lines, resulting in
malfunctions.
continued...

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2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
MAINTENANCE (CONTINUED)
NOSE ASSEMBLY MAINTENANCE
Clean nose assemblies in mineral spirits to clear jaws
and rinse metal chips and dirt. For a more thorough
cleaning, disassemble the nose assembly. Use a
pointed “pick” to remove imbedded particles from the
pull grooves of the jaws
Clean all parts of any assembly with UNITIZEDTM Jaws
in mineral spirits or isopropyl alcohol only; do not let
jaws come in contact with other solvents. Do not let
jaws soak; dry them immediately after cleaning. Huck
recommends drying other parts before re-assembling.
For additional information, see the appropriate Nose
Assembly Data Sheet.
SPARE PARTS SERVICE KITS
Spare Parts Service Kits contain perishable parts
(O-rings, Back-up rings, and other standard items) for
your tool (see KITS & ACCESSORIES). For convenience,
and as experience indicates, keep extra kits 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 information
and specifications on O-rings and Back-up rings, see
SPECIFICATIONS FOR STANDARD PARTS.
Loctite is a registered trademark of Henkel Corporation, U.S.A.
Threadmate is a registered trademark of Parker Intangibles LLC.
Slic-tite is a registered trademark of LA-CO Industries, Inc.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co
SUPER-O-LUBE is a registered trademark of Parker Hannifin Corp.
Teflon is a registered trademark of E. I. du Pont de Nemours and
Company.
CAUTION: Damaged jaw teeth, or debris
packed between teeth, will result in
fastener not being installed or being
improperly installed.
ASSEMBLY OF NPTF THREADED COMPONENTS
AIR FITTINGS
1) Apply TEFLON®stick to male threads which do
not have pre-applied sealant per manufacturer’s
recommendations. (Proceed to All Fittings step 2)
HYDRAULIC FITTINGS
1) Apply Threadmate™ to male and female threads
which do not have pre-applied sealant per
manufacturer’s recommendations. (Proceed to All
Fittings step 2)
ALL FITTINGS:
2) Tighten to finger-tight condition.
3) Wrench tighten to 2-3 turns past finger-tight condition.
4) Final thread engagement can be checked (optional)
by measuring the dimension from the flange of male
fitting to the end of the thread before assembly
and subtracting the distance under the flange after
assembly.
THREAD SIZE FINAL THREAD ENGAGEMENT AT FULL MAKE-UP
1/8-27 NPTF .235 inch (.59 cm)
1/4-18 NPTF .339 inch (.86 cm)
3/8-18 NPTF .351 inch (.89 cm)

12
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
OPERATING INSTRUCTIONS
Review all CAUTIONs and WARNINGs prior to
installing fasteners. If the tool malfunctions, consult the
TROUBLESHOOTING section before attempting any repairs.
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.
• Reasonable care of tools by operators is an
important factor in maintaining efficiency and
reducing downtime.
TO INSTALL A HUCKBOLT® FASTENER:
1. Place a pin in the workpiece and place the collar
over the pin.
NOTE: If the collar has one tapered end, that end
must be out toward tool; not next to the sheet.
2. Hold the pin in the hole and push the nose
assembly onto the pin protruding through the collar
until the nose anvil touches the collar. Hold the tool
at a right-angle (90 degrees) to the work.
3. Move hands away from pin and structure. Keep
hands away from front of tool during operation. Tool
anvil advances forward.
4. Press and hold the trigger until the collar is swaged
and the pintail breaks. Release the trigger; the tool
will perform its RETURN stroke.
The pressure is re-directed; the piston moves forward;
and the tool is pushed off the fastener and ready for the
next installation cycle.
TO INSTALL A HUCK BLIND FASTENER:
1. Place a fastener in the workpiece or in the end of
the nose assembly.
NOTE: The tool or nose assembly must be
held against, and at a right angle (90°) to, the
workpiece.
2. Press and hold the trigger until the fastener is
installed and the pintail breaks. Release the trigger;
the tool will perform its RETURN stroke.
The pressure is re-directed; the piston moves forward;
and the tool is pushed off the fastener and ready for the
next installation cycle.
R i ll CAUTION d WARNING i t
WARNINGS:
• Wear approved eye and hearing
protection.
• Ensure adequate clearance for
operator’s hands before installing
fasteners.
• Be sure that pintail deflector is attached
to the tool and directed away from all
personnel.
• Do not pull on a pin without placing a
fastener/collar in a workpiece. Make sure
that the collar chamfer is out, toward the
tool. Pins eject with great velocity when
pintails break off or teeth/grooves strip,
which could cause serious injury.
WARNING: Do not pull on a pin without
placing fastener in a workpiece; fastener
will eject with velocity and force when
pintail breaks off or teeth/grooves strip;
this may cause severe personal injury.
CAUTIONS:
• BOM blind fasteners will jam in the nose
assembly if they are pulled when not in
workpiece.
• To avoid structural and tooI damage, be
sure there is sufficient clearance for the
nose assembly at full stroke.
• Do not abuse the tool by dropping
it, using it as a hammer or otherwise
causing unnecessary wear and tear.
• Remove excess gap from between
the sheets to permit proper fastener
installation and prevent jaw damage.
ALL jaw teeth must engage the pintail to
avoid damaging the teeth.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.

13
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
DISASSEMBLY
This procedure is for complete disassembly of the
tool. Disassemble only those components necessary
to replace damaged rings and worn or damaged
components. Always replace seals, wipers, O-rings, and
Back-up rings of disassembled components. Always use
a soft-jaw vise to avoid damaging the tool.
For component identification, see the Assembly
Drawings in this manual.
TO DISASSEMBLE THE TOOL:
1. Disconnect the tool’s electric trigger control cord
or air trigger control hose, and then uncouple the
hydraulic hoses.
2. Remove the nose assembly from the tool.
3. Unscrew both couplers (nipple & body) from the
hoses, and drain the hoses into a container.
4. Push rearward on the piston until the remaining
hydraulic fluid is drained into a container. Discard
the fluid.
NOTE: Do NOT remove hydraulic hoses from
tool unless replacing them.
5. Remove the protective hose sleeve from the hoses.
To reach the hose fittings, slide back the plastic
shrouds.
6. Model 2502: Loosen the strain relief grommet.
Remove the switch; loosen the set screw and
carefully pry out the switch with a small screw
driver. Loosen the two wires at rear of the switch
and remove it from the cord. Pull out the cord and
remove the grommet. Disassemble the electrical
connector to replace connector, or to rewire it.
Model A2502: Unscrew the air trigger assembly.
Loosen the air fitting. Pull out the air trigger hose.
Loosen the air quick disconnect and remove it.
7. Remove the deflector from the end cap. Remove
the socket-head cap screw from the cap.
8. Hold a spanner wrench in the slots of the retaining
ring; loosen and remove the ring.
9. Press the piston, with unloading valve, and the end
cap out of the tool. (Figure 6 - Piston Disassembly/
Assembly Tool and Figure 7 - Piston Disassembly
Detail)
10. Slide the end cap and the unloading valve from the
piston.
11. Use a small, dull pointed “pick” to remove all
seals, wipers, O-rings and Back-up rings from
components.
The tool has been properly disassembled. Store all
re-usable parts (screws and disassembled components)
in a clean, dry area.
TO
TO
TO
O
D
D
D
S
IS
IS
IS
S
AS
AS
AS
S
SE
SE
SE
MB
MB
MB
LE
LE
LE
T
T
T
HE
HE
HE
T
T
T
OO
OO
OO
OO
L
L
L:
WARNING: Disconnect the tool control
trigger system from the POWERIG®
Hydraulic Unit before disconnecting the
hydraulic hoses from it. If not disconnected
in this order, serious personal injury may
occur.

14
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
ASSEMBLY DRAWING SECTIONAL VIEW II
FIGURE 3

15
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
This section details the re-assembly of the tool. For
component identification, see the Assembly Drawings in
this manual. Before re-assembling the tool:
• Inspect components for scoring, excessive
wear, and damage; replace as necessary. Clean
components in mineral spirits or other solvent
compatible with O-ring seals. Clean O-ring grooves.
• Replace all O-rings, Quad-rings, and Back-up rings.
See Assembly Drawings for guidance on positioning
these rings. Take care not to damage rings. Use
the rings that are supplied in Spare Parts Service
Kit 2502/2503KIT. Smear LUBRIPLATE®130-AA or
SUPER-O-LUBE®on rings and mating parts to ease
assembly.
• Apply Parker Threadmate®, Loctite®567, or Slic-
Tite®to male pipe threads per manufacturer’s
instructions.
TO RE-ASSEMBLE THE TOOL:
1. See Figure 8 - Piston Assembling Detail and follow
instructions carefully.
2. Slide unloading valve through hole in piston - - the
valve flats must be to the rear of the tool.
3. Push end cap assembly over piston extension.
4. Screw in retaining ring - - tighten with spanner
wrench. Install socket head cap screw in end cap.
5. Push pintail deflector over end cap - - it engages
ribs on cap.
6. Apply Parker Threadmate®, Loctite®567, or Slic-
Tite®to hose threads. Screw the hoses into the
handle. Slide shrouds over fittings.
7. Model 2502: Assemble electrical cord to connector.
Screw strain relief grommet into handle. Push cord
through grommet. Attach cord to trigger switch.
Press switch into handle and tighten set screw
against switch. Pull excess cord down through
handle and grommet. Tighten strain relief grommet.
Model A2502: Thread air fitting into handle. Attach
quick disconnect to air line. Attach air line to
handle’s air fitting. Screw air trigger assembly into
handles trigger fitting and tighten set screw against
fitting.
8. Slide protective hose sleeve onto assembled hoses
and control cord/air hose.
9. Apply Parker Threadmate®, Loctite®567, or Slic-
Tite®to PULL and RETURN pressure hose threads.
Screw coupling nipple onto PULL pressure hose
(from “P” port of tool). Screw coupling body onto
RETURN pressure hose.
10. Install nose assembly per applicable instructions on
Nose Assembly Data Sheet.
11. Connect hydraulic hoses to the POWERIG.
12. Connect the trigger connector/disconnect to the
POWERIG.
NOTE: See PREPARATION FOR USE before operating the
tool.
If all test results are good, the tool is ready to return to
service.
ASSEMBLY
WARNING: Do not omit any seals during
servicing or re-assembly; leaks will result
and serious personal injury can occur.
CAUTION: When re-assembling the tool,
always replace damaged and defective
parts, and all seals, wipers, and rings of
sub-assemblies.
CAUTION: Do not use TEFLON®tape on
pipe threads. Tape can shred, resulting in
malfunctions.
WARNING: Connect the tool’s hydraulic
hoses to the POWERIG®Hydraulic Unit
before connecting the (air or electric)
trigger assembly to it. If not connected in
this order, serious personal injury could
occur.
TO
TO
TO
O
R
R
R
E
E
E-
S
AS
AS
AS
S
SE
SE
SE
MB
MB
MB
LE
LE
LE
T
T
T
HE
HE
HE
T
T
T
OO
OO
OO
OO
L
L
L:
CAUTION: Do not use TEFLON®tape on
pipe threads. Tape can shred, resulting in
malfunctions.

16
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
ELECTRIC/AIR CONTROLS AND HYDRAULIC HOSES
FIGURE 5

17
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
PISTON DISASSEMBLY / ASSEMBLY TOOL
FIGURE 6

18
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
PISTON DISASSEMBLY DETAIL
FIGURE 7

19
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
PISTON ASSEMBLY DETAIL
FIGURE 8

20
2502 & A2502 Series Hydraulic Installation Tools (HK837) Alcoa Fastening Systems & Rings
AIR TRIGGER &HOSE ASSEMBLY
FIGURE 9