Arconic BobTail User manual

January 13, 2017
HK1098
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
Instruction Manual
BTT25
BobTail®Hydraulic Installation Tool
Declaration of Conformity
2
Safety Instructions
3-4
Principle of Operation
5
Program Cycle
5
Operating Instructions
6
Specifications
6-7
Optional Equipment
7
Maintenance
7-8
Set-up Using 918 Powerig®
9-10
Components Drawings
10-15
Puller Wear and
Replacement
16
Limit Switch Adjustment
17
Wiring Instructions
18

2
BTT25 BobTail® Hydraulic Installation Tool (HK1098)

3
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
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 underline: emphasize a specific
instruction.
WARNINGS: Must be understood to avoid
severe personal injury.
CAUTIONS: Show conditions that will damage
equipment or structure.
Safety Instructions

4
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can
experience discomfort in the hands, arms, shoulders, neck
or other parts of the body.
2. When using tool, the operator should adopt a comfortable
posture while maintaining a secure footing and avoid
awkward or off balanced postures.
3. The operator should change posture during extended tasks
to help avoid discomfort and fatigue.
4. If the operator experiences symptoms such as persistent
or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or stiffness, these warnings
should not be ignored. The operator should tell the employer
and consult a qualified health professional.
V. ACCESSORIES HAZARDS:
1. Disconnect tool from energy supply before changing inserted
tool or accessory.
2. Use only sizes and types of accessories and consumables
that are recommended. Do not use other types or sizes of
accessories or consumables.
VI. WORKPLACE HAZARDS:
1. Be aware of slippery surfaces caused by use of the tool and
of trip hazards caused by the air line or hydraulic hose.
2. Proceed with caution while in unfamiliar surroundings; there
could be hidden hazards such as electricity or other utility
lines.
3. The assembly power tool is not intended for use in potentially
explosive environments.
4. Tool is not insulated against contact with electrical power.
5. Ensure there are no electrical cables, gas pipes, etc., which
can cause a hazard if damaged by use of the tool.
VII. NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent, disabling
hearing loss and other problems such as tinnitus, therefore
risk assessment and the implementation of proper controls
is essential.
2. Appropriate controls to reduce the risk may include actions
such as damping materials to prevent workpiece from
‘ringing’.
3. Use hearing protection in accordance with employer’s
instructions and as required by occupational health and
safety regulations.
4. Operate and maintain tool as recommended in the instruction
handbook to prevent an unnecessary increase in the noise
level.
5. Select, maintain and replace the consumable / inserted tool
as recommended to prevent an unnecessary increase in
noise.
6. If the power tool has a silencer, always ensure that it is in
place and in good working order when the tool is being
operated.
VIII. VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the
nerves and blood supply to the hands and arms.
2. Wear warm clothing when working in cold conditions and
keep hands warm and dry.
3. If numbness, tingling, pain or whitening of the skin in the
fingers or hands, stop using the tool, tell your employer and
consult a physician.
4. Support the weight of the tool in a stand, tensioner or
balancer in order to have a lighter grip on the tool.
X. HYDRAULIC TOOL SAFETY INSTRUCTIONS:
1. 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 (continued)
WARNINGS:
Do not exceed maximum pull or return settings
on tool.
Be sure all hose connections are tight. All tool
hoses must be connected.

5
BTT25 BobTail® Hydraulic Installation Tool (HK1098)




 






















































The operator pushes the Tool’s Nose over the end
of the fastener until the Tool’s Puller bottoms on the
fastener. When the Tool’s Limit Switch Rod makes
contact with the end of the fastener, the Limit Switch in
the back of the Tool is activated. This sends an input
signal to the tool control. When the operator presses the
Trigger on the Tool, an input is sent to the tool control.
When both conditions are met, the tool control will turn
on the hydraulic pump, PULL pressure, for fastener
installation. The Piston moves back to start the swaging
process.
A Pressure Transmitter on the Relief Valve assembly
sends a signal to the control to indicate the “pressure
set point” has been reached and the “hold timer” can
start. The “hold timer” will keep the hydraulic pump,
PULL pressure, on until the timer times out. An external
Relief Valve will control the amount of pull pressure that
can be reached.
After the “hold timer” times out, the hydraulic pump
shifts to RETURN pressure and the Tool’s Anvil is
ejected off of the collar and the Tool is released from
the fastener.
PrinciPle of oPeration
Program cycle

6
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
1. Push the tool’s nose over the end of the fastener until it
bottoms out.
2. Press and hold the trigger until the collar is swaged and
the tool’s Anvil is ejected off the collar and the tool is
released from the fastener.
Operating Instructions
Specifications
10.4
(26.5)
5.2
(13.3)
2.0
(5.1)
2.4
(6.3)
figure 1
Model BTT25
OPERATING TEMPERATURE RANGE: 32–125° F (0–51.7° C)
STROKE: 1.63 in. (4.1 cm)
WEIGHT: 8 lbs. (3.62 kg)
INCHES
(cm)
WARNINGS:
- To avoid pinch point, never place hand
between nose assembly and work piece.
- Only use compatible equipment with this
tool.
Service Kit - BTT25KIT
Teon Stick - 503237
Loctite® 242 - 505016
Anti-seize Lubricant - 508183
CE Compatible
Pump/Controller - HK432BT
Hose Cable
Extension Assembly - 128461-(length)
Test Plates:
12mm Small - 128484
12mm Large - 128483
14mm Small - 128467
14mm Large - 128466
16mm Small - 128465
16mm Large - 128464
20mm Small - 128486
20mm Large - 128485
Load Cell Assembly - 128433
(shown below)
Loctite is a registered trademark of Henkel Corporation, U.S.A.
TEFLON is a registered trademark of E. I. du Pont de Nemours and
Company.
To maintain CE conformity, only CE compatible equipment should be used with these tools. Installation tools
and nose assemblies are the only CE components, unless otherwise noted. Controls and other hardware
shown in the manual are for domestic use only.
Optional Equipment

7
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
Specifications (continued)
1.6
(4.1)
1.3
(3.3)
2.3
(5.9)
4.4
(11.3)
5.7
(14.5)
Apply Locte 242
(P/N 505016) or
equivalent–per
manufacturer’s
instrucons–to these
threaded joints.
Apply Locte 243
Threadlocker (P/N
508567) or
equivalent–per
manufacturer’s
instrucons–to
setscrew threads.
128759
Anvil Assembly
128758
Anvil Holder
501920
Setscrew (3)
128757
Puller
501736
Setscrew (1)
Apply An-seize Lubricant
(P/N 508183) or
equivalent–per
manufacturer’s
instrucons–to outside of
Puller and inside of Anvil.
* Locte is a trademark of Henkel Corporaon, U.S.A.
99-7850 nose
assembly
INCHES
(cm)
12 mm
figure 2
Maintenance
Carefully handle individual parts; examine them for
damage and wear. Replace parts when required.
Always replace O-rings and Back-up Rings when
the tool is disassembled.
• Theefciencyandlifeofyourtooldependsonproper
maintenance. Read this section completely before
proceeding with maintenance and repair. Use proper
hand tools in a clean and well-lighted area. Only
standard hand tools are required in most cases. Where
a special tool is required, the description and part
number are given.
• While clamping tool 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 vise with soft jaws greatly reduces
possibility of damaging tool. Remove components in a
straight line without bending, cocking or undue force.
Re-assemble tool with the same care.
•Consult TroubleshooTing in this manual if a
malfunction occurs, and then see the appropriate
Assembly and Assembly Drawings.
SEALANTS, LUBRICANTS, HYDRAULIC FLUID, &
SERVICE KITS
• Use Automatic Transmission Fluid DEXRON®III or
equivalent.Fireresistanthydraulicuidmustbeused
to comply with OSHA regulation 1926.302 paragraph
(d).Anoptionalreresistanduidthatmaybeused
is Quintolubric®822-220. Fluid viscosity 300 SUS @
100°F (37.7° C) and 50 SUS at 210°F (98.8° C) is
recommended for ambient temperatures 0° to 130° F
(-17.7–54.4° C).
• Apply Parker Threadmate®, Loctite®567, or Slic-Tite®
(per manufacturer’s instructions) to pipe plug threads
andquickconnectttings.
• Smear LUBRIPLATE®130-AA (P/N 502723) or
equivalent on O-rings and mating surfaces to aid
assembly and prevent damage to O-rings.
CAUTIONS:
- Keep dirt and other material out of
hydraulic system (tool, hoses, couplers,
and Powerig).
- Keep separated parts away from dirty
work surfaces. Dirt in hydraulic system
causes valve failure in hydraulic unit.
WARNING: Inspect tool for damage and
wear before each use. Do NOT operate if
damaged or worn; severe personal injury
may occur.
CAUTION: Do NOT use Teon®tape on pipe
threads. Tape can shred and break free into
uid lines, resulting in malfunctions.
continued...

8
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
maintenance (continued)
• Each Service Kit contains perishable parts for your
specictool.Asforeseeableusemayindicate,keep
extra kits (O-rings, Back-up Rings, other standard
items) and tool parts in stock. When stock is depleted,
you can get kit items from any regular retailer of
these items. See kit parts list for: O-ring size (AS568-
number); material; durometer. For kit parts lists and
related information, see generAl noTes.
PREVENTIVE MAINTENANCE
SYSTEM INSPECTION
Operatingefciencyofthetoolisdirectlyrelatedtothe
performance of the complete system, including the tool
with nose assembly, hydraulic hoses, trigger and control
cord, and POWERIG. Therefore, an effective preventive
maintenance program includes scheduled inspections of
the system to detect and correct minor troubles. At the
beginning of each shift/day:
• Inspect tool and nose assembly for external damage.
• Verifythathydraulichosettings,couplings,and
electrical connections are secure.
• Inspect hydraulic hoses for damage and deterioration.
Do not use hoses to carry tool. Replace hoses if
damaged.
• Observe tool, hoses, and hydraulic unit during
operation to detect abnormal heating, leaks, or
vibration.
• Max contamination level: NAS 1638 class 9, or ISO
CODE 18/15, or SAE level 6.
POWERIG MAINTENANCE
Refer to the applicable POWERIG instruction manual.
TOOL MAINTENANCE
Whenever disassembled and at regular intervals
(depending on severity and length of use), replace all
seals, wipers, and back-up rings in tool. Service Kits,
hoses, and extra parts should be kept in stock. Inspect
cylinder bore, pistons, and piston rods for scored surfaces
and excessive wear or damage. Replace as necessary.
NOSE ASSEMBLY MAINTENANCE
Clean nose assembly often. Dip in mineral spirits or
similar solvent to clean puller and wash away metal chips
and debris. At regular intervals, as experience shows,
disassemble nose and use a sharp “pick” to remove
imbedded particles from grooves of puller.
DEXRON is a registered trademark of General Motors Corporation.
Quintolubric is a registered trademark of Quaker Chemical Corp.
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.
Teon is a registered trademark of E. I. du Pont de Nemours and
Company.
LUBRIPLATE is a registered trademark of Fiske Brothers Rening
Co.
CAUTION: Replace all seals, wipers, and
rings when the tool is disassembled
for any reason, and at regular intervals,
depending on severity and duration of use.

9
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
setuP using the 918 Powerig



 














 
















 
 


 
 
 
 
 
figure 3
1. With the Nose Assembly in place on the installation
tool, begin setup. First connect the hydraulic hoses
to the Powerig.
2. Connect the Relief Valve to the other end of the
Powerig hydraulic hoses.
3. Connect 125926 Hose Assembly to the Transducer
(PULL pressure) and Relief Valve (RETURN
pressure).
4. Connect 118308 Cord Assembly from the Controller
to the Powerig labeled TOOL 1.
5. Connect 128457 Cable Assembly from the
Controller to the Transducer.
6. Connect the 125926 Hose Assembly to the
installation tool.
7. Connect the 128418 Cord Assembly to the
installation tool.
8. a. Connect the other end of 128418 Cord
Assembly to the Controller at TOOL 1.
b. Connect optional 128461-* Hose/Cable
Assembly.
9. Connect the electrical plug from the Controller to a
120 VAC 15amp power.
WARNING:
- To prevent tripping hazard, suspend tools
and route hoses off oors.
- Only use compatible equipment with this
tool.
continued...

10
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
To decrease
the Relief Valve
pressure, gradually
turn the Relief
Valve handle
counterclockwise;
turn clockwise to
increase pressure.
Relief
Valve
Trigger
Switch
Load
Cell
Test
Fastener
Tool Force
Reading
setuP (continued)
10. Set the PULL and RETURN pressures
on the Powerig using Huck Gauge P/N
T-124833CE and TABLE 1.
11. Using a load cell (PhoTo A) or a skidmore,
and a test fastener in the tool, energize
the Powerig using a trigger switch. Adjust
the Relief Valve (PhoTo B) so the tool
generates 12,000–13,000 lbs. force. This
is a direct force reading, not pressure. It
equals approximately 4,250 psi (293 bar)
Powerig pressure.
NOTE: It is important to release the
trigger while adjusting the pressure,
then re-energizing to re-check pressure.
Otherwise, the reading on the pressure
display may be incorrect. When the
desired pressure is achieved, reconnect
the Controller Cord.
12. Tool #2 and Tool #3: Set up the same way
as Tool 1.
13. After the system is set up, install a test
fastener. Verify that the fastener is
installed correctly. This can be checked by
inspectingthedimplesonthecollarange;
at least one dimple should be marked by
the anvil. If not, add time to Timer #2 (Hold
Timer) in the Controller box, and test with
fasteners until the proper installation is
achieved. See “Set Point Adjustments” in
the ConTroller section of this manual to
adjust timer.
TABLE 1 - PRESSURE SETTINGS
FAsTener
size Tool
Powerig Pull
Pressure
seTTing (Psi)
Powerig
reTurn
Pressure seTTing
(Psi)
ConTroller
Pressure
seTTing (Psi)
12 mm BTT25
7500 psi
(517 bar)
(minimum)
6500 psi
(448 bar)
4200 psi
(289 bar)
Photo A
Photo B
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nger-tightcondition.
3)Wrenchtightento2-3turnspastnger-tightcondition.
4) Final thread engagement can be checked (optional)
bymeasuringthedimensionfromtheangeofmale
ttingtotheendofthethreadbeforeassembly
andsubtractingthedistanceundertheange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)

11
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
128441-3 controller
UL & Serial
No. Sticker
Instructions &
Wiring Diagram
Digital
Display
PLC Arrow
Buttons
Command
Buttons
ESC - MENU - ENT
3-Position
Mode
Switch
1.Move the 3-Position Mode Switch on the PLC to
“STOP” (right-most position).
2.Press the MENU Command Button to enter the
“Monitor” menu.
3.Press the ENT Command Button to select “Data
Monitor”. Press ENT again to select “V” data type.
4.Enter the address button of the value you need to
alter.Usetheleft(◄)andright(►)buttonsto
positioncursor,andtheup(▲)anddown(▼)
buttons to change individual digits. Press the ENT
CommandButtonwhennished.
5.Press the ENT Command Button to enter the
“Change” menu.
6.Use the arrow buttons again to enter the new value.
Press ENTwhennished.
7.Press the ESC Command Button 5 times to exit.
8.Move the Mode Switch back to “RUN” (left-most
position).
9.Check the continuously scrolling display for your new
value before using the Tool again.
“V“
ADDRESS DESCRIPTION RANGE DEFAULT UNITS
07411 T1 Press. SetPt 1000-9999 4200 psi
07412 T2 Press. SetPt 1000-9999 4200 psi
07413 T3 Press. SetPt 1000-9999 4200 psi
07421 T1 Hold Timer 0-3000 500 msec
07422 T2 Hold Timer 0-3000 500 msec
07423 T3 Hold Timer 0-3000 500 msec
07431 T1 Eject Timer 250-3750 600 msec
07432 T2 Eject Timer 250-3750 600 msec
07433 T3 Eject Timer 250-3750 600 msec
SET POINT ADJUSTMENTS
The active set points are displayed continuously while the Controller is in RUN mode. Stopping the Controller (which
also stops Tool sequencing) allows the user to enter the Controller menu to make adjustments. Do not begin this
procedure if any of the tools are still in use.
M 3 : D A T A T Y P E V
A D D R E S S 0 0 0 0 0
M 3 : >D A T A M O N I T O R
> B I T M O N I T O R
M 3 : D A T A V 0
C H G = 0000 0000
AsshiPPed:
Controller Pressure:
4200 psi
Hold Timer:
500 (.50 seconds)
Eject Timer:
600 (.60 seconds)
figure 4

12
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
590059
HUCK Scker
590259 CAUTION Keep Clear Scker
590189-5 CAUTION Pressure Scker
128772 Actuator Rod
508308
Spring
128752 Limit Switch Rod Guide
128750 Limit Switch Rod
128700 Tool Assembly (see Figure 7)
128781 Trigger & Terminal Box Assembly (see Figure 8.1)
128745 Limit Switch Housing Assembly (see Figure 8.2)
VIEW B-B
SECTION A-A
(Enlarged)
BTT25 Tool Assembly
CAUTION Sckers
figure 5
btt25 tool assembly

13
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
128700 tool subassembly
128706 Rear Piston Shield
125902 Locater Buon (2)
507473 Retaining Ring (2)
128702 Suspension Sleeve
128788 Hydraulic Hose (2)
503431
Reducing Bushing (2)
110438
Male Coupler
110439
Female Coupler
128701
Locking Screw
Actuator Hole
128694 Piston Assembly (see Figure 7)
128698 Main Housing Assembly (see Figure 7)
128708 Forward Gland Assembly
(see Figure 7)
128696 Rear Piston Assembly
(see Figure 7)
figure 6

14
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
128700 subassemblies
128694 Piston Assembly
128698 Main Housing Assembly
128708 Forward Gland Assembly
128696 Rear Piston Assembly
128707
Forward Gland
506064
Wiper Seal
501148
Back-up Ring
506080
O-Ring
501142
Back-up Ring
506078
O-Ring
501108
Back-up Ring (3)
500814
O-Ring (2)
505917
Polyseal
128697
Rear Piston
501148 Back-up Ring (2)
128695
Piston
506080
O-Ring
507635
Pipe Plug (2)
128699
Main Housing
121343
Lockscrew
506077
O-Ring
501138
Back-up Ring (2)
figure 7

15
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
128781 & 128745 assemblies
128778
Trigger Box
128756
Trigger Assembly
128780
Trigger Box Cover
505344-3
Strain Relief
124379
Terminal Strip
505879
Screw
128416
Cable Assembly
128779
Trigger Box Clamp
502472
Screw (2)
506358
Strain Relief
128786
Switch Cable
505588
Screw
501050
Self-locking
Nut
128785 Tension
Cable Assembly
502468
Screw (4)
508310
LED Lamp
500048
Cap Screw
500166
Flat Washer (2)
507570
Buon-head
Cap Screw (2)
128749
Switch Plate
508360
Spring
500166
Flat Washer (2)
128747
Limit Switch
Upper Housing
128746
Limit Switch
Lower Housing
500063
Screw (2)
500051
Cap Screw
508307
Spring
128748
Actuator
Lever
501342
Dowel
500057
Cap Screw (4)
506038
Microswitch
* Locte is a trademark of Henkel Corporaon, U.S.A.
Dimple for
Limit Switch
Rod
Apply Locte 242
or equivalent, per
manufacturer’s
instrucons. *
Secon A-A
Secon A-A
A
A
A
A
128781 Trigger & Terminal Box Assembly
128745 Limit Switch Housing Assembly
figure 8.1
figure 8.2

16
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
TOOLS NEEDED
1. Interchangeable Anvil Micrometers or Dial Calipers
2. Depth Micrometers
3. Allen Wrenches
Puller wear and/or rePlacement
1. Using Dial Calipers or an interchangeable Anvil
Micrometer, measure the Puller to determine if it is
worn out or new. (The Puller does not have to be
removed from the tool to be measured.)
2. Remove the setscrews from the anvil holder, and
unscrew the anvil holder from the tool.
3. Unscrew the setscrews from the Puller, then
unscrew the Puller from the piston.
4. After the Puller has been unscrewed from the
Piston, remove and clean all its components.
NOTE: To add life to the Puller, always clean
components upon changing or checking Puller.
a) Insert the spring into the piston.
b) Insert the actuator rod into the piston.
c) Insert the rod guide into the piston.
d) Screw the puller onto the piston.
5. Reinstall the components before screwing a NEW
Puller onto the Piston.
6. Apply Loctite Anti-Seize or
an equivalent lubricant to
the Puller to keep it from
wearing against the Anvil
duringtherstseveral
drives.
7. a) Bottom the anvil holder
on the piston.
b) Back off the anvil holder until a groove is visible
through the setscrew hole.
c) Install the setscrew.
8. Check the Limit Switch setting using the Controller
or a Light Box and the depth micrometers. Adjust
withinthespecicationof.430”–.435”.SeelimiT
swiTCh AdjusTmenT on the next page.
Spring
Limit Switch Rod
Puller
Rod Guide
Piston

17
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
TOOLS NEEDED
1. Controller or Light Box
2. Depth Micrometers
3. Allen Wrench
limit switch adjustment
NOTE: It is important to ensure that the face of the
micrometer is rmly against the Puller Head, and
the micrometer depth pin is in contact with the
Actuator Rod when measuring.
1. Check to see where the Limit Switch is set using
the Light Box and the Depth Micrometer.
2. Use an Allen wrench to loosen the Lockdown
Screw.
3. To increase the switch setting, turn the Limit Switch
Adjustment Screw counterclockwise; to decrease it,
turn it clockwise.
4. Adjusttheswitchtothespecicationof.430”–.435”.
You will notice the Light Box light will come on after
the switch has been made.
5. Tighten the Lockdown Screw.
NOTE: After tightening the Lockdown Screw,
verify the adjustment again by measuring with
the depth micrometer. In some cases, because
of the tight tolerance, it is possible for the
adjustment to be jarred when the Lockdown
Screw is tightened.
6. Afterithasbeenadjustedtothespecication
of .430”–.435”, disconnect the Light Box and
reconnect the system.
The tool is now ready to drive fasteners. Limit Switch
Adjustment
Screw
Lockdown
Screw
Light Box
(Styles
may vary)
Hold micrometer face
rmly to Puller face when
measuring.

18
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
wiring instructions












   




     








      








 









 
               
  
 







figure 9

19
BTT25 BobTail® Hydraulic Installation Tool (HK1098)
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
Powerigs®manufactured after 12/1/2016 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 and Rings world-wide locations:
AMERICAS
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800-278-4825
845-331-7300
FAX: [phone]
Carson Operations
900 Watson Center Rd.
Carson, CA 90745
800-421-1459
310-830-8200
FAX: [phone]
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: [phone]
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: [phone]
Acuña Operations
Hidalgo #120
Parque Industrial Amistad
26220 Acuña Coahuila
Mexico
FAX: [phone]
TELEX: 1173530 LUKSME
EUROPE
Telford Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: [phone]
Us Operations
BP4
Clos D’Asseville
95450 Us par Vigny
France
33-1-30-27-9500
FAX: [phone]
FAR EAST
Melbourne Operations
11508 Centre Road
Clayton, Victoria
Australia 3168
03-764-5500
Toll Free: 008-335-030
FAX: [phone]








Huck is Forever, For the Long Haul, The
Future of Fastening Technology, The Future of
Assembly Technology, The Future of Tooling
Technology, and Tools of Productivity are
service marks of Huck International. Huck
provides technical assistance regarding the use
and application of Huck 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.
© 2017 Huck International, Inc.
1 Corporate Drive, Kingston, NY 12401 • Tel: [phone] • Fax: [phone]