Huck ALCOA BOBTAIL BTT25-ST User manual

October 29, 2014
HK1120
INSTRUCTION MANUAL
BOBTAIL®INSTALLATION SYSTEM
BTT57-ST
BTT57-ST
BTT57R-ST
BTT57R-ST
BTT25-ST
BTT25-ST
BTT35-ST
BTT35-ST

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
2

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
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EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TOOL TO POWERIG SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PRESSURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STICKER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
WRENCHING-UP OF PIPE THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
HYDRAULIC COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
TOOL ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
C
CONTENTS ONTENTS

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
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I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with qualified per-
sonnel is recommended before using Huck equipment.
2. Huck equipment must be maintained in a safe working con-
dition 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 pro-
cedures.
3. For multiple hazards, read and understand the safety instruc-
tions 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 fas-
tener 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 trig-
gers 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 manufac-
turer.
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 rele-
vant European directives.
-READ MANUAL prior to using this equipment.
-EYE PROTECTION IS REQUIRED while using this equip-
ment.
-HEARING PROTECTION IS REQUIRED while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specific instruction.
S
SAFETY AFETY I INSTRUCTIONS NSTRUCTIONS
CAUTIONS: show conditions that will
damage equipment and or structure.
WARNINGS: Must be understood to avoid
severe personal injury.

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
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IV. REPETITIVE MOTION HAZARDS:
1. When using assembly power tool, the operator can experi-
ence 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 awk-
ward 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 poten-
tially 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, dis-
abling hearing loss and other problems such as tinnitus,
therefore risk assessment and the implementation of prop-
er 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 instruc-
tion 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 bal-
ancer 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 over-
heating.
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.
WARNING: Do not exceed maximum pull or
return settings on tool.
S
SAFETY AFETY I INSTRUCTIONS NSTRUCTIONS ( (CONTINUED CONTINUED) )

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
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S
SPECIFICATIONS
PECIFICATIONS
Power Source: Huck POWERIG Hydraulic Unit
Hose Kits: Use only genuine HUCK Hose Kits rated at
10,000 psi working pressure.
Hydraulic Fluid: Hydraulic fluid shall meet DEXRON
III, DEXRON VI, MERCON, Allison C-4 or equivalent
ATF specifications.
Fire resistant fluid may be used if it is an ester based
fluid such as Quintolubric HFD or equivalent. Water
based fluid shall NOT be used as serious damage to
equipment will occur.
Max Operating Temp: 125 ° F ( 51.7 ° C)
Max Flow Rate: 2 gpm ( 7.6 l/m)
Max Inlet Pull Pressure:
BTT57 ONLY
BTT57 ONLY = 9,000 psi, ( 621 bar)
Max Inlet Return Pressure:
BTT57 ONLY
BTT57 ONLY = 8,000 psi, ( 552 bar)
Pull Capacity: BTT25-ST BTT25-ST = XX,XXX lbf ( XXX kN)
BTT35-ST
BTT35-ST = XX,XXX lbf ( XXX kN)
BTT57-ST
BTT57-ST = 62,550 lbf ( 278 kN)
Return Capacity:
BTT57-ST
BTT57-ST = 30,500 lbf ( 136 kN)
Stroke: BTT25-ST
BTT25-ST = 1.63 inches (4.14 cm)
BTT35-ST
BTT35-ST = 1.63 inches (4.14 cm)
BTT57-ST
BTT57-ST = 2.20 inches (5.59 cm)
Weight: BTT25-ST
BTT25-ST = 8.5 lbs (3.8 kg)
BTT35-ST
BTT35-ST = 11 lbs (5 kg)
BTT57-ST
BTT57-ST = 22.3 lbs (10.1 kg)
BTT57R-ST
BTT57R-ST

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
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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.
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 eject‐
ed off of the collar and the Tool is released from the fas‐
tener.
1. Attach proper Nose Components to Tool as applicable.
2. Use Huck POWERIG Hydraulic Unit, or equivalent, that
has been prepared for operation per instruction manu-
al. Check both PULL and RETURN pressures and, if
required, adjust to pressures given in P PRESSURE
RESSURE
S
SETTINGS ETTINGS section of this manual.
3. First, turn hydraulic unit to OFF. Then disconnect power
supply from hydraulic unit. Disconnect trigger control
system from hydraulic unit.
4. Connect PULL pressure hose, with coupler nipple, into
port “P” of tool. Use only with HUCK supplied hoses
rated at 10,000 psi or greater. Check trigger assembly
for apparent damage or wear. If required, adjust posi-
tion of trigger assembly on hose. Connect trigger con-
trol system to hydraulic unit.
5. Connect hydraulic unit to power supply (air or electric).
Turn hydraulic unit to ON. Depress trigger a few times
to cycle tool and to circulate hydraulic fluid. Observe
action of Tool and check for leaks.
P
PREPARATION REPARATION FOR FOR U USE SE
WARNINGS:
Read full manual before using tool.
A half-hour training session with qualified
personnel is recommended before using
Huck equipment.
When operating Huck installation equip-
ment, always wear approved eye protec-
tion.
Be sure there is adequate clearance for
the operator’s hands before proceeding.
CAUTION: Do not use TEFLON®* tape on
pipe threads. Pipe threads may cause tape to
shred resulting in tool malfunction.
(Threadmate™ is available from Huck in a
4oz. tube as part number 508517.)
WARNING: Correct PULL and RETURN
pressures are required for operator’s
safety and for Installation TooI’s function.
Gauge T-124833CE is available for check-
ing pressures. See P PRESSURE
RESSURE S SETTINGS ETTINGS
and Gauge Instruction Manual. Failure to
verify pressures may result in severe per-
sonal injury.
WARNING: Be sure to connect Tool’s
hydraulic hoses to POWERIG Hydraulic
Unit before connecting Tool’s switch con-
trol cord to unit. If not connected in this
order, severe personal Injury may occur.
WARNING: Huck recommends that only
Huck Powerig Hydraulic Units be used as
a 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 SPECIFICAL-
LY NOT RECOMMENDED AND MAY BE
DANGEROUS.
P
PRINCIPLE RINCIPLE OF OF O OPERATION PERATION
Threadmate is a registered trademark of Parker Intangibles LLC.
TEFLON is a registered trademark of E. I. du Pont de Nemours and Company
CAUTION: Do not let disconnected hoses
and couplers contact a dirty floor. Keep
harmful material out of hydraulic fluid. Dirt in
hydraulic fluid causes valve failure In Tool
and In POWERIG Hydraulic Unit.
CAUTION: 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.

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
8
* Two digit number after dash indicates hose length in feet.
(Example: 1183 9-12 is 12 foot hose assembly.)
BTT57R-ST
Optional
Tool
Balancer
Nose
Assembly
918
Powerig
Shown To primary power source
1183 9-*
Hose Assembly
1289 4
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
T
TOOL
OOL
TO
TO P
POWERIG
OWERIG S
SETUP
ETUP
NOTE: To decrease Relief Valve pressure, turn
the Relief Valve handle gradually counterclock-
wise; 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 on Powerig and
Relief Valve using Huck Gage 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 flange. At least one dim-
ple should be marked by the anvil.
WARNING: To prevent tripping hazard,
suspend tools and route hoses off of
floors.
WARNING: Only use compatible equip-
ment with this tool.
P
PRESSURE RESSURE S SETTINGS ETTINGS
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
Table 1
Figure 3

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
9
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.
TO INSTALL A BOBTAIL FASTENER:
1. Check work and remove excessive gap. (Gap is the
space between sheets. Gap is excessive if not
enough pintail sticks through the collar for the nose
assembly puller to grab onto).
2. Put BOBTAIL pin in hole.
3. Slide BOBTAIL collar over pin. (The flanged end of
the collar must be towards the pieces being fastened.)
4. Push nose assembly onto the pin until the nose
assembly puller stops against the pin. Tool and nose
assembly must be held at right angles (90 degrees) to
the work.
5. Depress tool trigger to start installation cycle.
6. When forward motion of nose assembly anvil stops,
release trigger. Tool will go into its return stroke and
push off the installed fastener.
7. The tool and nose assembly are ready for the
next installation cycle.
O
OPERATING PERATING I INSTRUCTIONS NSTRUCTIONS
For safe operation. Please read completely
WARNING: To avoid severe personal injury,
wear approved eye and ear protection.
Ensure adequate clearance for Operator’s
hands before proceeding with fastener
installation.
WARNING: Do not pull on a pin without
placing fastener/collar in a workpiece. 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.
CAUTION: Remove excess gap from between
the sheets. This permits enough pintail to
emerge from collar for ALL puller teeth to
engage with pintail. If ALL teeth do not
engage properly, jaws will be damaged.
WARNING: To avoid pinch point, never place
hand between nose assembly and work
piece.
WARNING: Only use compatible equipment
with this tool.
Refer to Figure BB, Switch Housing Assembly Drawing
on page 12 for identification of Lockdown Screw and
Limit Switch Adjustment Screw. NOTE: It is important
to ensure that the face of the micrometer is firmly
against the Puller Head, and the micrometer depth
pin is in contact with the Actuator Rod when meas-
uring.
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 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 specification of .485”. You will
notice the Light Box light will come on once the
switch has been made.
5. Tighten the Lockdown Screw. NOTE: After tighten-
ing 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 during
tightening the Lockdown Screw.
6. Once adjusted to the specification of .480”-.490”, dis-
connect the Light Box and reconnect the system. The
tool is now ready to drive fasteners.
TOOLS NEEDED: • Controller or Light Box • Depth Micrometer • Allen Wrench
Light Box
Light Box
(Styles
(Styles
may vary)
may vary)
Hold micrometer face
Hold micrometer face
firmly to Puller face when
firmly to Puller face when
measuring.
measuring.
L
LIMIT IMIT S SWITCH WITCH A ADJUSTMENT DJUSTMENT

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
10
M
MAINTENANCE AINTENANCE
•The efficiency and life of your tool depends on proper
maintenance. Please 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 compo‐
nents in a straight line without bending, cocking or
undue force. Reassemble tool with the same care..
Sealants, Lubricants, Service Kits
•See S SPECIFICATIONS PECIFICATIONS for fluid type. Dispose of fluid
in accordance with local environmental regulations.
Recycle steel, aluminum, and plastic parts in accor-
dance with local lawful and safe practices.
•Rub pipe plug threads and quick connect fittings
with PTFE thread compound.
•Smear LUBRIPLATE®13OAA*, or equivalent lubri-
cant, on O-Rings and mating surfaces to aid assem-
bly and to prevent damage to O-Rings.
(LUBRIPLATE 13O-AA is available in a tube as
Huck P/N 502723.)
•Each Service Kit contains perishable parts for your
specific 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 deplet-
ed, you can get kit items from any regular retailer of
these items.
PREVENTIVE MAINTENANCE
System Inspection
Operating efficiency of the tool is directly related to the
performance of the complete system, including the tool
with nose assembly, hydraulic hoses, trigger and con‐
trol cord, and POWERIG. Therefore, an effective pre‐
ventive 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 dam-
age.
• Verify that hydraulic hose fittings, couplings, and
electrical connections are secure.
• Inspect hydraulic hoses for damage and deteriora-
tion. Do not use hoses to carry tool. Replace hoses
if damaged.
• Observe tool, hoses, and hydraulic unit during oper-
ation to detect abnormal heating, leaks, or vibration.
• Max hydraulic fluid 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, 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 Corp.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Threadmate is a registered trademark of Parker Intangibles LLC..
TEFLON is a registered trademark of DuPont Corp.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
CAUTIONS:
- Consult MSDS before servicing tool.
- Keep dirt and other material out of
hydraulic system.
- Separated parts most be kept away from
dirty work surfaces.
- Dirt/debris in hydraulic fluid causes failure
in POWERIG® Hydraulic Unit’s valves.
CAUTION: Do not use TEFLON®* tape on pipe
threads. Pipe threads may cause tape to
shred resulting in tool malfunction.
(Threadmate™ is available from Huck in a
4oz. tube as part number 508517.)
CAUTION: Always replace seals, wipers,
and back-up rings when tool is disassem-
bled for any reason.
WARNING: Inspect tool for damage or
wear before each use. Do not operate if
damaged or worn, as severe personal
injury may occur.

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
11
W
WRENCHING RENCHING- -UP UP OF OF P PIPE IPE T THREADS HREADS
The following table pertains to 1/8, 1/4, and 3/8 NPTF joints in this product. All turn counts listed are beyond
hand-tight. Teflon stick or equivalent (NOT tape) must be used without exception.
Pipe Thread Size Number of Turns
1/8 NPTF 2 - 2 1⁄4
1/4 NPTF 1 1⁄2 - 1 3⁄4
3/8 NPTF 1 1⁄2 - 1 3⁄4
Table 2 - Wrenching-up of Pipe Threads
This tool comes labeled with important stickers that contain safety and pressure settings information. It is
necessary that these stickers remain on the tools and are easily read. If stickers become damaged or worn, or if
they have been removed from the tool, they must be replaced. The part numbers are shown in the tool assembly
drawings on pages 12 and 13 of this manual.
S
STICKER TICKER L LOCATIONS OCATIONS
H
HYDRAULIC YDRAULIC C COUPLINGS OUPLINGS

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
12
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
UCK 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 6

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
13
P
PARTS ARTS L LISTS ISTS FOR FOR BTT25-ST, BTT35ST, & BTT57-ST BTT25-ST, BTT35ST, & BTT57-ST
Refer to Figures 6, & 8-12 for Tool Assembly item numbers.
Item
note
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 Lockscrew 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 Keep Clear Sticker 590259 590259 590259 1
26 CAUTION Pressure Sticker 590189-5 590189-5 590189-5 1
27 Reducer Bushing 503431 503431 n/a 2
28 Tubing n/a 504173 n/a 1

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
14
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 7

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
15

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
16

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
17

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
18
O
OPTIONAL PTIONAL E EQUIPMENT QUIPMENT
TEFLON®Stick -503237
TEFLON®Sealant -620012
Loctite®243 -508567
Anti-seize Lubricant - 508183
LUBRIPLATE®130-AA - 502723
Threadmate™ (4oz. tube) - 508517
Hose Cable Extension Assy - 118309-(length)
Swage Gage - HG-S-MBT20 (20mm)
HG-S-BT24 (3/4”)
Pressure Gage - T124833CE
Service Kit - SF32KIT
DEXRON is a registered trademark of General Motors Corp.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Threadmate is a registered trademark of Parker Intangibles LLC..
TEFLON is a registered trademark of DuPont Corp.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
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.

BTT-ST family of BobTail® Hydraulic Tools (HK1120) Alcoa Fastening Systems
19
L
LIMITED
IMITED W
WARRANTIES
ARRANTIES
TOOLING WARRANTY:
Huck warrants that tooling and other items (excluding
fasteners, and hereinafter referred as "other items")
manufactured by Huck shall be free from defects in
workmanship and materials for a period of ninety (90)
days from the date of original purchase.
WARRANTY ON "NON STANDARD OR CUSTOM
MANUFACTURED PRODUCTS":
With regard to non-standard products or custom man-
ufactured products to customer's specifications, Huck
warrants for a period of ninety (90) days from the date
of purchase that such products shall meet Buyer's
specifications, be free of defects in workmanship and
materials. Such warranty shall not be effective with
respect to non-standard or custom products manufac-
tured using buyer-supplied molds, material, tooling
and fixtures that are not in good condition or repair
and suitable for their intended purpose.
THERE ARE NO WARRANTIES WHICH EXTEND
BEYOND THE DESCRIPTION ON THE FACE
HEREOF. HUCK MAKES NO OTHER WAR-
RANTIES AND EXPRESSLY DISCLAIMS ANY
OTHER WARRANTIES, INCLUDING IMPLIED
WARRANTIES AS TO MERCHANTABILITY OR AS
TO THE FITNESS OF THE TOOLING, OTHER
ITEMS, NONSTANDARD OR CUSTOM MANUFAC-
TURED PRODUCTS FOR ANY PARTICULAR PUR-
POSE AND HUCK SHALL NOT BE LIABLE FOR
ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, ARISING FROM THE USE OF SUCH
TOOLING, OTHER ITEMS, NONSTANDARD OR
CUSTOM MANUFACTURED PRODUCTS OR
BREACH OF WARRANTY OR FOR ANY CLAIM
FOR INCIDENTAL OR CONSEQUENTIAL DAM-
AGES.
Huck's sole liability and Buyer's exclusive remedy for
any breach of warranty shall be limited, at Huck's
option, to replacement or repair, at FOB Huck's plant,
of Huck manufactured tooling, other items, nonstan-
dard or custom products found to be defective in
specifications, workmanship and materials not other-
wise the direct or indirect cause of Buyer supplied
molds, material, tooling or fixtures. Buyer shall give
Huck written notice of claims for defects within the
ninety (90) day warranty period for tooling, other
items, nonstandard or custom products described
above and Huck shall inspect products for which such
claim is made.
TOOLING, PART(S) AND OTHER ITEMS NOT MANU-
FACTURED 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 CONDI-
TION, DESIGN, OPERATION, MERCHANTABILITY
OR FITNESS FOR USE OF ANY TOOL, PART(S),
OR OTHER ITEMS THEREOF NOT MANUFAC-
TURED BY HUCK. HUCK SHALL NOT BE LIABLE
FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDI-
RECTLY, ARISING FROM THE USE OF SUCH
TOOLING, PART(S) OR OTHER ITEMS OR
BREACH OF WARRANTY OR FOR ANY CLAIM
FOR INCIDENTAL OR CONSEQUENTIAL DAM-
AGES.
The only warranties made with respect to such tool,
part(s) or other items thereof are those made by the
manufacturer thereof and Huck agrees to cooperate
with Buyer in enforcing such warranties when such
action is necessary.
Huck shall not be liable for any loss or damage result-
ing from delays or nonfulfillment 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 discontin-
ue 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 Office, see
back cover.
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 Tools Kits and Nose Assemblies. Please con-
tact your Huck Representative or the nearest Huck
office listed on the back cover for the ATSC in your
area.

Americas
Alcoa Fastening Systems
Aerospace Products
Tucson Operations
3724 East Columbia
Tucson, AZ 85714
800‐234‐4825
520‐747‐9898
FAX: 520‐748‐2142
Alcoa Fastening Systems
Aerospace Products
Carson Operations
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800‐421‐1459
310‐830‐8200
FAX: 310‐830‐1436
Alcoa Fastening Systems
Industrial Products
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714‐8117
800‐388‐4825
254‐776‐2000
FAX: 254‐751‐5259
Alcoa Fastening Systems
Industrial Products
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
800‐278‐4825
845‐331‐7300
FAX: 845‐334‐7333
Alcoa Fastening Systems
Industrial Products
Latin America Operations
Avenida Parque Lira. 79‐402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: 525‐515‐1776
TELEX: 1173530 LUKSME
Far East
Alcoa Fastening Systems
Industrial Products
Australia Operations
14 Viewtech Place
Rowville, Victoria
Australia 3178
03‐764‐5500
Toll Free: 008‐335‐030
FAX: 03‐764‐5510
Europe
Alcoa Fastening Systems
Industrial Products
United Kingdom Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952‐290011
FAX: 0952‐290459
Alcoa Fastening Systems
Aerospace Products
France Operations
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33‐1‐30‐27‐9500
FAX: 33‐1‐34‐66‐0600
A Global Organization
Alcoa Fastening Systems (AFS) maintains
company offices throughout the United States
and Canada, with subsidiary offices in many
other countries. Authorized AFS distributors
are also located in many of the world’s
Industrial and Aerospace centers, where they
provide a ready source of AFS fasteners,
installation tools, tool parts, and application
assistance.
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 fasten‐
ers and tooling.
NOTICE: The information contained in this publi‐
cation 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, acknowledge‐
ments, and/or purchase orders. It is recommend‐
ed that the user secure specific, up‐to‐date data
and information regarding each application
and/or use of such products.
HWB898 1003‐5M
© 2003 Alcoa Fastening Systems
1 Corporate Drive, Kingston, NY 12401 • Tel: 800‐431‐3091 • Fax: 845‐334‐7333 • www.alcoafasteningsystems.com
Certified to
ISO 14 1:2 4
Indus rial
Produc s
Certified to
ISO 9 1:2 8
Indus rial
Produc s
One Great ConnectionSM
Alcoa Fastening Systems world-wide locations:
For the Long Haul™
®