Howmet Aerospace BobTail BTT25-ST User manual

7
Table of Contents
2
3-4
Safety Instructions
Principle of Operation
7
6
5
5
Declaration of Conformity
HK1120
Instruction Manual
BobTail®
Hydraulic Installation Tool Models
BTT57-ST
BTT25-ST
BTT57R-ST
BTT35-ST
Specifications
Preparation for Use
Tool to Powerig Setup
Limit Switch Adjustment
Operating Instructions
Maintenance
Components Drawings
and Parts List
Wiring Diagram
Limited Warranty 17
8
8
9
10-16
16
August 3, 2020

3
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
I. GENERAL SAFETY RULES:
1. Ahalfhourlonghands-ontrainingsessionwithqualied
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qualied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qualied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Specicationsbeforeservicingthetool.MSDS
specications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deectors.
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
efciency,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xed.
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uids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xedtoasuspensiondevice,
makesurethatxationissecure.
9. Beware of the risk of crushing or pinching if nose
equipmentisnottted.
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qualiedhealthprofessional.
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 underline:emphasizeaspecic
instruction.
WARNINGS: Must be understood to avoid
severe personal injury.
CAUTIONS: Show conditions that will damage
equipment or structure.

4
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
V. ACCESSORIES HAZARDS:
1. Disconnect tool from energy supply before changing
inserted tool or accessory.
2. Use only sizes & types of accessories & 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 &
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 & other problems such as tinnitus,
therefore risk assessment & 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 & as required by occupational health & safety
regulations.
4. Operate & maintain tool as recommended in instruction
handbook to prevent unnecessary increase in noise level.
5. Select, maintain & replace the consumable/inserted tool as
recommended to prevent an unnecessary increase in noise.
6. If the tool has a silencer, always ensure that it is in place &
in good working order when the tool is being operated.
VIII. VIBRATION HAZARDS:
1. Exposure to vibration can cause disabling damage to the
nerves & blood supply to the hands & arms.
2. Wear warm clothing when working in cold conditions &
keep hands warm & dry.
3. If numbness, tingling, pain or whitening of the skin in the
ngersorhands,stopusingthetool,tellyouremployer&
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 & replace if necessary.
2. Wipe all couplers clean before connecting. Failure to do
so can result in damage to the quick couplers & cause
overheating.
3. Ensure that couplings are clean & correctly engaged before
operation.
4. Useonlycleanoil&llingequipment.
5. Powerunitsrequireafreeowofairforcoolingpurposes
& 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 & cause
overheating.
Where trade names are used in this manual, note:
DEXRON is a registered trademark of General Motors Corporation.
Loctite is a registered trademark of Henkel Corporation, U.S.A.
LUBRIPLATE is a registered trademark of Fiske Brothers Rening Co.
Quintolubric is a registered trademark of Quaker Chemical Corp.
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.
Threadmate is a registered trademark of Parker Intangibles LLC.
TRUARC is a trademark of TRUARC Co. LLC.
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
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
POWER SOURCE:
Huck POWERIG Hydraulic Unit
HOSE KITS:
Use only genuine HUCK Hose Kits rated @
10,000 psi working pressure.
HYDRAULIC FLUID:
HydraulicuidshallmeetDEXRONIII,DEXRON
VI, MERCON, Allison C-4 or equivalent ATF
specications.Fireresistantuidmaybeused
ifitisanesterbaseduidsuchasQuintolubric
HFDorequivalent.WaterbaseduidshallNOT
be used as serious damage to equipment will
occur.
MAX OPERATING TEMP: 125°F (51.7°C)
MAX FLOW RATE: 2 gpm (7.6 l/m)
STROKE:
BTT25-ST = 1.63 inches (4.14 cm)
BTT35-ST = 1.63 inches (4.14 cm)
BTT57-ST = 2.2 inches (5.59 cm)
BTT57R-ST = 2.2 inches (5.59 cm)
WEIGHT:
BTT25-ST = 8.5 lbs (3.8 kg)
BTT35-ST = 11 lbs (5 kg)
BTT57-ST = 22.3 lbs (10.1 kg)
MAX PULL PRESSURE: 8,400 psi (580 bar)
MAX RETURN PRESSURE: 6,500 psi (450 bar)
TOOL CAPACITY:
TOOL PULL RETURN
BTT25-ST: 25,000lbf (111 kN) 11,200lbf (50 kN)
BTT35-ST: 25,000lbf (111 kN) 11,200lbf (50 kN)
BTT57-ST: 58,400lbf (260 kN) 24,600lbf (109 kN)
BTT57R-ST: 58,400lbf (260 kN) 24,600lbf (109 kN)
The operator pushes the Tool Nose over the end of the
fastener until the Tool 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.
When the trigger is pressed, the powerig receives a signal
to swage the fastener.
The Piston moves back to start the swaging process.
After the fastener is fully swaged, the operator must
release the trigger, at which point the Tool’s Anvil is
ejected off of the collar and the Tool is released from the
fastener.
Principle of Operation
Specications
C
DE
C
D
BTT57R-ST
BTT35-ST
ØB
ØA
ØB
ØA
C
D
BTT25-ST and BTT57-ST
ØB
ØA
inches (cm) Ø A Ø B C D E
BTT25-ST 2.25 (5.71) 1.80 (4.57) 3.61 (9.16) 6.83 (17.34) n/a
BTT35-ST 2.62 (6.65) 2.38 (6.05) 5.49 (13.93) 8.92 (22.67) n/a
BTT57-ST 3.54 (8.99) 3.00 (7.62) 7.16 (18.19) 13.62 (34.59) n/a
BTT57R-ST 3.54 (8.99) 3.00 (7.62) 7.16 (18.19) 12.84 (32.61) 6.54 (16.61)
Figure 1

6
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
POWER SOURCE CONNECTIONS
1. Coathosettingthreadswithanon-hardening
TeonTM thread compound such as Parker Threadmate,
Loctite 567, or Slic-tite stick to male pipe threads per
manufacturer’s instructions.
2. Use only a HUCK Powerig that is recommended or
equivalent that has been prepared for operation per
applicable instruction manual. Check both PULL and
RETURN pressures with gauge part number
T-124833CE, and adjust as necessary to match
installation tool.
3. Turn Powerig® to “OFF” and couple tool hoses to
Powerig® hoses.
4. Turn Powerig® to “ON” and depress and release
triggerafewtimestocirculatehydraulicuid.Observe
actionoftool.Checkforuidleaks.
5. Attach the proper Nose Assembly to the tool.
Preparation for Use
WARNINGS:
Read full manual before using tool.
A half-hour training session with qualied
personnel is recommended before using Huck
equipment.
When operating Huck installation equipment,
always wear approved eye protection.
Be sure there is adequate clearance for the
operator’s hands before proceeding.
Correct PULL and RETURN pressures are
required for operator safety and for TooI
function. Gauge T-124833CE is available for
checking pressures. See Tool SpecificationS and
Gauge Instruction Manual. Failure to verify
pressures may result in severe personal injury.
Be sure to connect hydraulic tool hoses to
Powerig® Hydraulic Unit before connecting
Tool switch control cord to unit. If not
connected in this order, severe personal Injury
may occur.
CAUTIONS:
Do not use TEFLON®tape on pipe threads. Pipe
threads may cause tape to shred resulting in
tool malfunction.
Do not let disconnected hoses and couplers
contact a dirty oor. Keep harmful material out
of hydraulic uid. Dirt in hydraulic uid causes
valve failure In Tool and In Powerig® Hydraulic
Unit.
Hose couplers must be completely joined
together to insure that ball checks in both
nipple and body are completely open.
Improperly assembled couplers will cause
overheating and malfunctions in both tool and
Powerig. Hand tighten couplers. Do NOT use a
pipe wrench.
Huck recommends that only HUCK Powerig®
Hydraulic Unit be used as the power source for
Huck installation equipment. Hydraulic power
units that deliver high pressure for both PULL
and RETURN, and are not equipped with relief
valves are specically not recommended, and
may be dangerous.

7
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
To primary power source
Optional Hose Assembly
Powerig
918 Shown
118309-* Hose Assembly
*Two digit number after dash
indicates hose length in feet.
(Example: 118309-12 is a
12-foot hose assembly.)
Optional Tool Balancer
Installation Tool
BTT57R-ST shown
Nose
Assembly
128904 Relief Valve
TOOL 1
TOOL 1
CAUTION
CAUTION
ON
OFF
POWERIG HYDRAULIC UNIT
CAUTIO N
TOOL 2 15 VAC
24 VAC
TOOL 2
CAUTIO N
CAUTIO N
CAUTIO N
CAUTIO N
CAUTIO N
Fastener
Size
Fastener
Grade
Powerig PULL
Pressure Setting, psi
Powerig RETURN
Pressure Setting, psi
128904 Relief
Valve Setting, psi
20mm 10.9 7500 min 4500 4650
7/8 (-28) 5 7500 4500 4500
3/4” 5 7500 2800 3000
1” 5 7500 4500 5000
1” 8 7500 5500 6700
TABLE 1: Pressure Settings
WARNINGS:
To prevent tripping hazard, suspend tools and route
hoses off of oors.
Only use compatible equipment with this tool.
Tool to Powerig Setup
NOTE: To decrease Relief Valve pressure, turn the
Relief Valve handle gradually counterclockwise;
turn clockwise to increase pressure.
1. With the Nose Assembly in place on the Installation
Tool, begin setup.
First connect the Hydraulic Hoses to the Powerig.
2. Connect Relief Valve 128904 to the other end of the
Powerig Hydraulic Hoses.
3. Connect 118309- Hose Assy to the Relief Valve (Tool
Side).
4. Connect the other end of the 118309- Hose Assy to
the installation tool.
5. Connect the Power Cord from the Tool to the
118309- Hose Assembly.
6. Connect the Power Cord from the Hose Assembly to
the Powerig.
7. Set Pull and Return pressures of Powerig and Relief
Valve using Huck Gauge p/n T-124833CE and Table
1.
8. Once the system is set up, install test fastener. Check
to be sure 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.
Figure 2

8
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
1. Push the tool’s nose over the end of the fastener until it
bottoms out.
2. Press the trigger and hold 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
Limit Switch Adjustment
WARNINGS:
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.
Do NOT attempt to install a pin without placing the fastener and collar in
the work piece (structure to be fastened).
Do NOT attempt to install a pin without a properly oriented collar in
place.
The collar ange must be against work piece.
If these safety measures are not followed, the fastener could eject with
great velocity and cause severe personal injury.
This condition can cause pin to eject with great velocity and force if the
pintail breaks off or teeth/grooves strip. This may cause severe personal
injury.
To avoid pinch point, never place hand between nose assembly and work
piece.
Only use compatible equipment with this tool.
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
damaged.
FOR SAFE OPERATION, THIS SECTION MUST BE READ AND UNDERSTOOD.
Do NOT pull a fastener
with the collar upside
down.
CORRECT CORRECT
 
Do NOT install a fastener without a
workpiece (structure to be fastened), a pin,
and a properly oriented collar in place.
Note: In certain situations, it may be
permissible to use a BobTail tool and
fastener without a collar to remove
sheet gap prior to full installation
with a collar. Consult qualied
Huck engineering personnel before
attempting this operation.
TOOLS NEEDED
Controller or Light Box
Depth Micrometer
Allen Wrench
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. Using an Allen wrench, loosen the Lock-down 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.485”.Youwill
notice the Light Box light will come on once the switch
has been made.
5. Tighten the Lock-down Screw. NOTE: After tightening
the Lock-down 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 during tightening the Lock-
down Screw.
6. Onceadjustedtothespecicationof.480”-.490”,
disconnect the Light Box and reconnect the system. The
tool is now ready to drive fasteners.
Light Box
(styles may vary)
Hold micrometer face
rmlytopullerface
when measuring.
Figure 3

9
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
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.
Reassemble tool with the same care.
STICKER LOCATIONS: HUCK tools come with stickers which
contain important safety and pressure settings information.
Stickers must remain on the tool and easily read. If a sticker
becomes damaged, worn, unreadable, or missing; or
when replacing Cylinder, the sticker(s) must be ordered
and placed in the location shown.
HUCK/Year of Manufacture Sticker 590517
CE and PRESSURES WARNING Sticker 590512-15
SEALANTS, LUBRICANTS, SERVICE KITS: See SpecificationS
foruidtype.Disposeofuidinaccordancewithlocal
environmental regulations. Recycle steel, aluminum, and
plastic parts in accordance with local lawful and safe
practices. Coathosettingthreadswithanon-hardening
TeonTM thread compound such as ThreadmateTM (available
from Huck in a 4oz. tube as p/n 508517.) Lubricate o-rings
and mating surfaces with LUBRIPLATE®13OAA* (available in
a tube as Huck p/n 502723), or equivalent to aid assembly
and prevent damage to o-rings. Each Service Kit contains
perishablepartsforyourspecictool.Keepextrakits
(o-rings, back-up rings, other standard items) and tool parts
in stock.
PREVENTIVE MAINTENANCE
SYSTEM INSPECTION: An effective preventive maintenance
program includes scheduled inspections of the tool with
nose assembly, hydraulic hoses, trigger, control cord,
and Powerig 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, and
replace if necessary. Do not use hoses to carry tool.
• Observe tool, hoses, and hydraulic unit during operation to
detect abnormal heating, leaks, or vibration.
•Maxhydraulicuidcontaminationlevel:NAS1638class9,
or ISO CODE 18/15, or SAE level 6.
POWERIG MAINTENANCE: Maintenance instructions and
repair procedures are in the appropriate Powerig Instruction
Manual.
TOOL MAINTENANCE: Whenever disassembled, and also 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,
disassemble nose and use a sharp “pick” to remove particles
from grooves of puller.
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged or
worn, as severe personal injury may occur.
CAUTIONS:
Consult MSDS before servicing tool.
Keep dirt and other material out of hydraulic
system.
Separated parts must be kept away from dirty
work surfaces.
Dirt/debris in hydraulic uid causes failure in
Powerig® Hydraulic Unit’s valves.
Do not use TEFLON®tape on pipe threads. Pipe
threads may cause tape to shred resulting in tool
malfunction.
Always replace seals, wipers, and back-up rings
when tool is disassembled for any reason.
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)
Hydraulic Couplings
TIP: Use a ne India stone to remove nicks and burrs from
diameter A and leading edge to prevent damage to O-ring.
O-ring (P/N 504438)Back-up ring (P/N 501102)

10
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Components Drawing BTT25-ST, BTT35-ST, BTT57-ST
B
15 (See Figure 8)
13
A A
SECTION A-A (Enlarged)
17 (See Figure 9)
18 19 20 21
C
C
VIEW B-B
SECTION C-C
(Enlarged)
22
23 Apply Loctite 242
HUCK p/n 505016 per manufacturer’s instructions.
24 25, 26
4b
2d 2c
(2)
4a 4e 4f
4c 4d 1c
(2)
1d
6
(2)
5
3c
(3)
3a
8
7
(2)
9
1b
2a
1a
3d
3b
12 10(2)
27(2)
3e
28
Figure 4
BTT25-ST_revE BTT35-ST_revD BTT57-ST_revD

11
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Parts List
ITEM DESCRIPTION BTT25-ST
Part Number
BTT35-ST
Part Number
BTT57-ST
Part Number QTY
1Main Housing Assembly contains: 128698 121981 128716 1
1a Main Housing 128699 119018 128725 1
1b Lock screw 121343 121343-35 121343-57 1
1c O-Ring 506077 506078 506079 1
1d Back-up Ring 501138 501142 501144 2
2Piston Assembly contains: 128694 128282 128717 1
2a Piston 128695 128014 128727 1
2b Pipe Plug (not shown) 507635 503703 503703 2
2c Back-up Ring 501148 501151 502855 2
2d O-Ring 506080 506089 506085 1
3Rear Piston Assy contains: 128696 128281 128718 1
3a Rear Piston 128697 128590 128726 1
3b Polyseal 505917 505918 505919 1
3c Back-up Ring 501108 501112 501144 3
3d O-Ring 500814 500818 500850 1
3e O-Ring 500814 503808 500850 1
4Forward Gland Assy contains: 128708 121890 121891 1
4a Forward Gland 128707 121878 121879 1
4b Wiper 506064 506065 506066 1
4c Back-up Ring, inner 501142 501144 503610 1
4d O-Ring, inner 506078 506079 506082 1
4e Back-up Ring, outer 501148 501151 501155 1
4f O-Ring, outer 506080 506089 506090 1
5Rear Piston Shield 128706 125903 128721 1
6Locater Button 125902 125902 125902-1 2
7Retaining Ring 507473 507474 503448 2
8Suspension Sleeve 128702 128430 128722 1
9Piston Locking Screw 128701 128440 128701 1
10 Hydraulic Hose 128788 118944-2 123749-2 2
12 Male Coupler 110438 110438 110438 1
13 Female Coupler 110439 110439 110439 1
15 Trigger & Terminal Box Assy
See Figure 8 129074 129070 129075 1
17 Switch Housing Assy See Figure 9 128745 129069 129372 1
18 Actuator Rod 128772 128397 128754 1
19 Limit Switch Rod Guide 128752 128396 128755 1
20 Spring 508308 508308 508308 1
21 Limit Switch Rod 128750 128395 128753 1
22 Adapter Plate n/a n/a 128751 1
23 Screw n/a n/a 504284 4
24 Huck Sticker 590059 590059 590059 1
25 CAUTION Trademark & Year Sticker 590517 590517 590517 1
26 CAUTION Pressure Sticker 590512-15 590512-15 590512-15 1
27 Reducer Bushing 503431 503431 n/a 2
28 Tubing n/a 504173 n/a 1

12
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Components Drawing BTT57R-ST
A
A
Section A-A
14 15
2a 16 17
1b
4b
4c 4d 4e 4f 2c 2d 2c
1d
1c
1d 3c 3b 3c
3d
3c
3d
4a 1a 7(2) 3a
6(2) 5 18
9
20(5)
10
8
21b(4)
21c
13
12
11
19
21a
21d
21f
21h
21g
21e(4) 22
23
Figure 5
BTT57R-ST_revD

13
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Parts List BTT57R-ST
Item Description Part
Number Qty.
1Main Housing Assembly contains: 128716 1
1a Cylinder 128725 1
1b Lockscrew 121343-57 1
1c O-Ring 506079 1
1d Back-up Ring 501144 2
2Piston Assembly contains: 128717 1
2a Piston 128727 1
2b Pipe Plug (not shown) 503703 2
2c Back-up Ring 502855 2
2d O-Ring 506085 1
3Rear Piston Assy contains: 129343 1
3a Rear Piston 129342 1
3b Polyseal 505919 1
3c Back-up Ring 501144 3
3d O-Ring 500850 2
4Forward Gland Assy contains: 121891 1
4a Forward Gland 121879 1
4b Wiper 506066 1
4c Back-up Ring 503610 1
4d O-Ring 506082 1
4e Back-up Ring 501155 1
4f O-Ring 506090 1
5Rear Piston Shield 128721 1
6Locater Button 125902-1 2
7Retaining Ring 503448 2
8Suspension Sleeve 128722 1
9Piston Locking Screw 128701 1
10 Hydraulic Hose 123749-2 2
11 Cable Assembly 129072 1
12 Male Coupler 110438 1
13 Female Coupler 110439 1
14 Actuator Rod 128754 1
15 Limit Switch Rod Guide 128755 1
16 Spring 508308 1
17 Limit Switch Rod 129348 1
18 Pinch Guard 129349 1
19 Switch Housing Assy
See Figure 10 129372 1
20 Screw 502468 5
21 Handle Assembly contains: 128428 1
21a Handle Flange 128424 1
21b Button Head Screw 502468 4
21c Handle Cover 128427 1
21d 1/4-20 Screw 500069 1
21e 10-32 Screw 500101 4
21f 5/16-18 Screw 500077 1
21g Handle 128426 1
21h Trigger Assy 120361 1
Item Description Part
Number Qty.
22 Terminal Strip 124379 1
23 Socket Head Screw 505879 1
24 Huck Sticker 590059 1
25 CAUTION Trademark & Year
Sticker 590517 1
26 CAUTION Pressure Sticker 590512-15 1

14
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Trigger and Terminal Box Assembly
129072 Cable Assy
Trigger Box Clamp
128779 (BTT25-ST & BTT57-ST only)
128404 (BTT35-ST)
502472
Button Head Screw (2)
Flat Head Screw
505588 (BTT25-ST & BTT57-ST only)
501050 Self-Locking Nut
(BTT25-ST & BTT57-ST only)
128785 Tension Cable Assy
(BTT25-ST & BTT57-ST only)
128786
Switch Cable
506358
Strain
Relief
Trigger Box
128778 (BTT25-ST & BTT57-ST only)
128652 (BTT35-ST)
120361 Trigger Assy
(505231 Wire BTT35-ST only) Trigger Box Cover
128780 (BTT25-ST & BTT57-ST) 128653 (BTT35-ST)
505642 Socket Head Screw
124379 Terminal Strip
505344-3 Strain Relief
502468 Button Head Screw
508310 LED Lamp (BTT57-ST only)
Figure 6
129074_revB 129070_revA 129075_revB

15
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Switch Housing Assemblies BTT25-ST and BTT57-ST
129372 Switch Housing Assembly (BTT57-ST)
500051
Screws(3)
500108
Mounting
Screws (4)
Limit Switch
Adjustment
Screw
508309
Adjuster Spring
129351
Mounting
Plate Assy
500047
Screw
129345
Switch
Housing
505344-3
Cord Grip
508313
Washer
Lock-down
Screw
128745 Switch Housing Assembly (BTT25-ST)
128746
Lower Housing
128747
Upper Housing
500063
Cap Screws (2)
508307
Spring
128748
Lever
500047
Cap Screw (4)
501342 Dowel
506038 Switch
507570 Screws (2)
508371
Screw
500166
Flat Washer
128749 Switch Plate
508360 Spring
500051
Cap Screw
500166
Flat Washer
Figure 7
128745_revC
129372_revA

16
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
Switch Housing Assembly BTT35-ST
Wiring Diagram 129071
129069 Switch Housing Assembly (BTT35-ST)
+24VAC LS1
NOT USED TRIGGER
To
Powerig
From
Powerig
BLACK - 1
BLACK - 2
BLACK - 3
BLACK - 2
BLACK - 3 BLACK
WHITE - 1 WHITE
129072
Cord
Assembly
110686
Connector
BLACK BLACK
BLACK
BLACK
506038
Switch
LS1 - NC
120361
Trigger
110686 Connector
120361
Trigger
506038
Switch
LS1 - NC
505231
Wire
Figure 8
Figure 9
129069_revA
129071_revA

17
BTT25,35,57 -ST series Hydraulic Installation Tools (HK1120)
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dened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
tness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-fulllmentofordersowingtostrikes,
res,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specications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ofceslisted
below.
Eastern
One Corporate Drive Kingston, New York 12401-0250
Telephone(845)331-7300FAX(845)334-7333
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.

Howmet 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 y, drive, build and power.
Through the ingenuity of our people and cutting-edge advanced
manufacturing, we deliver these products at a quality and
eciency that ensures customer success and shareholder value.
CERTIFIED
MANAGEMENT
SYSTEM
ISO 9001-2015
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© 2018 Howmet Aerospace, Inc.
Howmet Fastening Systems
Kingston Operations
1 Corporate Drive, Kingston, NY 12401
Tel: [phone] • Fax: [phone]
www.afsHowmet.net/us
INDUSTRIAL NORTH AMERICA
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
Tel: [phone]
Fax: [phone]
[email protected]
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1925 North MacArthur Drive
Tracy, CA 95376
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PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
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Fax: [phone]
[email protected]
INDUSTRIAL GLOBAL
Kolkata Operations
Unit No. 28, 2nd Floor,
55/1, Chowringhee Road,
Kolkata 700071, West Bengal, India
Tel: [phone]
Tel: [phone]
Fax [phone]
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1508 Centre Road
Clayton, Victoria
Australia 3168
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215126 China
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Unit C, Staord Park 7
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England TF3 3BQ
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[email protected]
Tokyo Operations (Japan and Korea)
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Chiyoda-ku, Tokyo
100-0011 Japan
Tel: [phone]
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AEROSPACE NORTH AMERICA
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
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[email protected]
Simi Valley Operations
3990A Heritage Oak Court
Simi Valley, CA 93063
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F-95611 Cergy Pontoise
France
Tel: [phone]
Fax: [phone]
Hong Kong Operations
27th Floor, 88 Hing Fat Street
Causeway Bay
Hong Kong, China
Tel: [phone]
Howmet Fastening Systems Tooling Support Locations
Howmet provides technical assistance
regarding the use and application of
Howmet 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 Howmet’s written quotations, acknowledgments, and/
or purchase orders. It is recommended that the user secure
specic, up-to-date data and information regarding each
application and/or use of such products.