Huck BTT35 User manual

10-06-2008
HK1086
INSTRUCTION MANUAL
BOBTAIL INSTALLATION SYSTEM
BTT35
BTT35
BTT35R
BTT35R

BTT35 series Bobtail Installation System Alcoa Fastening Systems
2
EC Declaration of Conformity
Manufacturer:
Alcoa Fastening Systems, Industrial Products Group, 1 Corporate Drive, Kingston, NY,
12401, USA
Description of Machinery:
BTT25, 35, 57 family of fastener installation tools
Relevant provisions complied with:
Council Directive related to Machinery (98/37/EC)
Council Directive related to EMC/EMI (2004/108/EC)
European Representative:
Rob Pattenden, Huck International, Ltd. Unit C Stafford Park 7, Telford Shropshire TF3 3BQ,
England, United Kingdom
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment specified above conforms to the
above Directive(s) and Standard(s).
Signature: ___________________________________
Full Name: Tom Kingsbury
Position: Product Engineer
Installation Systems Division
Place: Kingston, New York, USA
Date: July, 2008
Sound Levels
Models: BTT25, 35, 57 family
To calculate equivalent noise level for other quantities of fas-
teners in an eight hour period, use the formula:
Leq = SEL + 10 log (n/28,800)
where n= number of fasteners in eight hours.
Vibration Levels
Models: BTT25, 35, 57 family
For an eight hour work day, installing 500 typical Huck fas-
teners will result in an equivalent weighted RMS vibration
level A(8) of:
.121 m/s2
To calculate equivalent vibration level for other quantities of
fasteners in an eight hour period, use the formula:
Equivalent Vibration Level, A8 (m/s2) = (n/480) x .116
where n= number of fasteners in eight hours,
and .116(m/s2)= Aeq for 60 seconds.
Test data to support the above information is on file at Alcoa Fastening Systems, Industrial Products Group, Kingston
Operations, Kingston, NY, USA. Vibration measurements are frequency weighted in accordance with ISO 8041 (2005).
SEL
dB (A)
Peak Value
dB (C)
Leq
dB (A)
68.8 94.8 67.0
Leq reflects the equivalent noise level result of
installing 500 typical Huck fasteners for an eight
hour work day.

BTT35 series Bobtail Installation System Alcoa Fastening Systems
3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SPECIFICATIONS
BTT35 and BTT35R Tool Assembly . . . . . . . . . . . . . . . . . . . . . . . .6
99-7851 Nose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SERVICING THE TOOL
Good Service Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SET-UP USING 918 POWERIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
WRENCHING-UP OF PIPE THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
128441-3 3-TOOL CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
BTT35 ASSEMBLY DRAWINGS
BTT35 Tool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
128283 Tool Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
128401 Trigger & Terminal Box Assembly . . . . . . . . . . . . . . . . . . .14
128398 Limit Switch Housing Assembly . . . . . . . . . . . . . . . . . . . .14
BTT35 ASSEMBLY PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
BTT35R ASSEMBLY DRAWINGS
BTT35R Tool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
128412 Cylinder Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .17
128429 Handle & Housing Assembly . . . . . . . . . . . . . . . . . . . . . .18
128423 Switch Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . .18
128428 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
PULLER WEAR EVALUATION AND REPLACEMENT . . . . . . . . . . . . . . . .19
ADJUSTING THE LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
C
CONTENTS
ONTENTS

BTT35 series Bobtail Installation System Alcoa Fastening Systems
4
S
SAFETY
AFETY
This instruction manual must be read,
with particular attention to the following
safety guidelines, by any person servic-
ing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood to avoid
severe personal injury.
CAUTIONS - show conditions that will damage
equipment and or structure.
Notes - are reminders of required procedures.
Bold, Italic type and underlining - empha-
sizes a specific instruction.
2. A half hour long hands-on training session with
qualified personnel is recommended before using
Huck equipment.
3. Huck equipment must be maintained in a safe
working condition at all times. Tools and hoses
should be inspected on a regular basis for damage
or wear. Any repair should be done by a qualified
repairman trained on Huck procedures.
4. Repairman and Operator must read manual prior to
using equipment. Warning and Caution stick-
ers/labels supplied with equipment must be under-
stood before connecting equipment to any primary
power supply. As applicable, each of the sections
in this manual have specific safety and other infor-
mation.
5. Read MSDS Specifications before servicing the
tool. MSDS Specifications are available from the
product manufacturer or your Huck representative
or is included with your tool.
6. When repairing or operating Huck installation
equipment, always wear approved eye protection.
Where applicable, refer to ANSI Z87.1 - 2003
7. Disconnect primary power source before doing
maintenance on Huck equipment.
8. Tools and hoses should be inspected for leaks at
the beginning of each shift/day. If any equipment
shows signs of damage, wear, or leakage, do not
connect it to the primary power supply.
9. Mounting hardware should be checked at the
beginning of each shift/day.
10. Make sure proper power source is used at all
times.
11. Never remove any safety guards or pintail deflec-
tors.
12. Never install a fastener in free air. Personal injury
from fastener ejection may occur.
13. When using an offset nose, always clear spent
pintail out of nose assembly before installing the
next fastener.
14. If there is a pinch point between trigger and work
piece, use remote trigger. (Remote triggers are
available for all tooling).
15. 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 impor-
tant factor in maintaining tool efficiency, eliminat-
ing downtime, and in preventing an accident
which may cause severe personal injury.
16. Never place hands between nose assembly and
work piece. Keep hands clear from front of tool.
17. Tools with ejector rods should never be cycled
with out nose assembly installed.
18. When two piece lock bolts are being used always
make sure the collar orientation is correct. See
fastener data sheet of correct positioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

BTT35 series Bobtail Installation System Alcoa Fastening Systems
5
P
PRINCIPLE
RINCIPLE OF OF O
OPERATION
PERATION
Start
Pull & Hold Trigger
AND
Limit Switch Tripped
Cycle Does Not Start Energi e Combination Valve
Start 10 Second Timer TD-1
Pressure Setting Attained
Start Adjustable (0-3 sec)
Delay Timer TD-2
TD-2 Timed Out
De-energi e Combination Valve
Start Adjustable (.25-3.75 Sec)
Timer TD-3
TD-3 Timed Out
End of
Program Cycle
NOTES:
- Trigger is the go signal.
- If trigger is released, cycle backs out.
- Li it switch ay be ade before trigger is pulled and cycle will still start.
- Li it switch ust be ade for .1 seconds after cycle starts; then progra no
longer looks for li it switch during cycle.
- If hydraulic cycle is started/proceeding when trigger is released, the co bination
valve is de-energized (released output), then continue to back out of cycle.
(The Pressure-Not-Reached light will turn on.)
- Exception: If hydraulic pressure set-point is reached and TD-2 is ti ed out,
the operation ay release trigger and the progra will finish nor ally.
N
Y
Y
Y
Y
TD-1 Timed Out
N
Y
N
Y
N
The LED on the tool is
turned on until the next
installation has reached
the pressure setting.
Then the LED turns off.
Timer Ranges
TD-1: 10 sec
TD-2: Adjustable 0-3 sec
TD-3: Adjustable .25-3.75
TD-4: 1 sec
TD-5: 1/2 sec
Timer Uses
TD-1: Stop hydraulics from
staying on too long in
case a hydraulic leak
occurs
TD-2: Time to hold hydraulics
after pressure is met
TD-3: Time to eject or release
hydraulics
N
P
PROGRAM
ROGRAM
C
CYCLE
YCLE
Operating Temperature Range: 32-125F (0-51.7C)
The operator pushes the Tool's Nose over the end of the fas-
tener 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 oper-
ator 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.
O
OPERATING
PERATING I
INSTRUCTIONS
NSTRUCTIONS:
:
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 fas-
tener.
!
WARNING: Only use compat-
ible equipment with this tool.
!
WARNING: To avoid pinch
point, never place hand
between nose assembly and
work piece

BTT35 series Bobtail Installation System Alcoa Fastening Systems
6
8.55
217.3
3.12
79.2
2.87
72.8
2.38
60.4
Ø
Ø
S
SPECIFICATIONS
PECIFICATIONS BTT35
BTT35
• Stroke: 1.625 in
• Weight: Approximately 13 lbs.
INCHES
mm
BTT35 Tool Assembly
Figure 1
12.03
305.6
2.87
72.8
2.38
60.4
Ø
Ø
5.49
139.3
INCHES
mm
BTT35R Tool Assembly
• Stroke: 1.625 in
• Weight: Approximately 13 lbs.

BTT35 series Bobtail Installation System Alcoa Fastening Systems
7
Apply
Anti-seize Lubric nt
P/N 508183 to
Outside of Puller
and inside of Anvil
Apply
Loctite 242
P/N 505016
to these
threaded joints
501736
Setscrew
(Qty. 1)
500648
Setscrew
(Qty. 3)
128376
Anvil Holder
128389
Puller
128379
Anvil Assy
1.75
44.45
Ø
4.28
108.7
5.84
148.3
S
SPECIFICATIONS
PECIFICATIONS 99-7851
99-7851
99-7851 Nose Assembly
5/8 Inch, 16mm
INCHES
mm
Figure 2

BTT35 series Bobtail Installation System Alcoa Fastening Systems
8
GOOD SERVICE PRACTICES
CAUTION: Keep dirt and other harmful material out of
hydraulic system, which includes tool, hoses, couplers
and POWERIG Hydraulic Unit. Parts must be kept away
from unclean work surfaces. Dirt in hydraulic system
causes valve failure in hydraulic unit.
Individual parts must be handled carefully and examined
for damage or wear. Replace parts where required.
Always replace O-rings and Back-up Rings when tool is
disassembled for any reason.
•The efficiency and life of your tool depends on prop-
er maintenance. Using the manual will help give a
clear understanding of the tool and basic mainte-
nance procedures. Please read this section com-
pletely 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.
•Consult TROUBLESHOOTING section of this manual if a
malfunction occurs and then see appropriate
ASSEMBLY and/or component illustration sections.
Sealants, Lubricants, Hydraulic Fluid & Service Kits
•Use automatic transmission fluid DEXRON®*III or
equivalent. Fire resistand hydraulic fluid must be
used to comply with OSHA regulation 1926.302
paragraph (d). An optional fire resistand fluid that may
be used is Quintolubric®*822-220. Fluid viscosity 300
SUS @ 100°F and 50 SUS at 210°F is recommended
for ambient temperatures 0° to 130° F.
•Rub Slic-Tite®* with PTFE thread compound, or equiv-
alent, on pipe plug threads and quick connect fitting.
CAUTION: Do not use TEFLON®* tape on pipe
threads. Pipe threads may cause tape to shred
resulting in tool malfunction. (Slic-Tite is available
in stick form as Huck P/N 503237.)
•Smear LUBRIPLATE®13OAA*, or equivalent lubri-
cant, on O-Rings and mating surfaces to aid assembly
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. See kit parts list for: O-ring size
(AS568- number); material; durometer. For kit parts
lists and related information, see General Notes.
*DEXRON is a registered trademark of General Motors Corporation.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Slic-Tite is a registered trademark of LA-CO Industries, Inc.
TEFLON is a registered trademark of DuPont Corp.
LUBRIPLATE is a registered trademark of Fiske Brothers Refining
Co.
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 switch and
control cord, and POWERIG Hydraulic Unit. Therefore,
an effective preventive maintenance program includes
scheduled inspections of the system to detect and cor-
rect minor troubles. At the beginning of each shift/day:
• Inspect tool and nose assembly for external damage.
• 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 opera-
tion to detect abnormal heating, leaks, or vibration.
• Max contamination level: NAS 1638 class 9, or ISO
CODE 18/15, or SAE level 6.
POWERIG Hydraulic Unit Maintenance
Refer to the applicable 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 sur-
faces and excessive wear or damage. Replace as nec-
essary. Always replace seals, wipers, and back-up
rings, and always grease gears whenever the tool is
disassembled for any reason.
Nose Assembly Maintenance
Clean nose assembly often. Dip in mineral spirits or sim-
ilar 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.
!
WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged
or worn, as severe personal injury may occur
S
SERVICING
ERVICING THE THE T
TOOL
OOL

BTT35 series Bobtail Installation System Alcoa Fastening Systems
9
118308-*
Cord Assy
(2-Wire)
* Two digit number after das indicates ose lengt in feet.
(Example: 118308-12 is 12 foot ose assembly.)
BTT35
99-7581
Optional
Tool
Balancer
918 Powerig
To primary
power source
128441-3
3-Tool Controller
115 VAC
15A Plug
128418-*
Cord Assy 128457-*
Cable Assy
(Pressure
Transmitter)
125926-*
Hose Assy
128415
Relief
Valve
Transducer
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
Figure 3
S
SETUP
ETUP U
USING
SING THE THE 918 P
918 POWERIG
OWERIG
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 Assy to the Transducer
(PULL pressure) and Relief Valve (RETURN pres-
sure).
4. Connect 118308 Cord Assy from the Controller to
the Powerig labeled TOOL 1.
5. Connect 128457 Cable Assy from the Controller to
the Transducer.
6. Connect the 125926 Hose Assy to the installation
tool.
7. Connect the 128418 Cord Assy to the installation
tool.
8. a. Connect the other end of 128418 Cord Assy to
the Controller at TOOL 1.
b. Connect optional 128461-* Hose/Cable Assy.
9. Connect the electrical plug from the Controller to a
120 VAC 15amp power.
continued
!
WARNING: To prevent tripping hazard, sus-
pend tools and route hoses off of floors.
!
WARNING: Only use compatible equipment
with this tool.

BTT35 series Bobtail Installation System Alcoa Fastening Systems
10
Load
Cell
Trigger
Switch
Test
Fastener
PHOTO - A
PHOTO - B
Tool Force
Tool Force
Reading
Reading
To decrease
Relief Valve pres-
sure, turn the
Relief Valve han-
dle gradually
counterclockwise;
turn clockwise to
increase pressure.
Relief
Relief
Valve
Valve
Fastener
Size
Tool Powerig
PULL Pressure
Setting, psi
Powerig
RETURN Pressure
Setting, psi
Controller
Pressure
Setting, psi
5/8(16mm) BTT25 7500 min. 6500 4200
Table 1 - Pressure Settings
S
SETUP
ETUP (CONTINUED)
8. Set Pull and Return pressures on Powerig
using Huck Gage P/N: T-124833CE and
Table 1.
9. Using a load cell (see PHOTO-A) or a skid-
more, and a test fastener in the tool, energize
the Powerig using a trigger switch. Adjust the
Relief Valve (see PHOTO - B)so the tool
generates 20,500-21,000 lbs. force. This is a
direct force reading, not pressure. It equals
approximately 4,950 psi Powerig pressure.
NOTE: It is important to Release the
Trigger while adjusting 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.
10. Tool #2 and Tool #3 - Set up the same way as
Tool 1.
11. Once the system is set up, Install test fasten-
er. 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 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 CONTROLLER sec-
tion of this manual to adjust timer.
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

Figure 4
BTT35 series Bobtail Installation System Alcoa Fastening Systems
11
128441-3 C
128441-3 CONTROLLER
ONTROLLER
UL & Serial
No. Sticker
Instructions &
Wiring Diagram
Digital
Display
PLC Arrow
Buttons
Command
Buttons
ESC - MENU - ENT
3-Position
Mode
Switch
ASSHIPPED:
Controller Pressure:
4200 psi.
Hold Timer:
500 (.50 seconds).
Eject Timer:
600 (.60 seconds).
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 the cursor. Use the up ( ▲ ) and down
( ▼ ) buttons to change individual digits. Press
the ENT Command Button when finished.
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 finished.
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 = 00 0 0 0 0 0 0

BTT35 series Bobtail Installation System Alcoa Fastening Systems
12
B
VIEW B-B
SECTION A-A
(Enlarged)
1.366
Make/Break coarse
adjustument for
Limit Switch
15 (See Figure 8.1)
16
17 (See Figure 8.2)
18 19 20
21
1-14 128283 Too Assemb y (See Figure 7)
A A
BTT35 Tool Assembly Refer to Parts List for individual part numbers.
Figure 6

BTT35 series Bobtail Installation System Alcoa Fastening Systems
13
R
P
1a
1b
1c
1d
2a
2b
2c 2d
3a
3d
3b 3c
4a
4b
4c 4d
4e 4f 2c
77
5
6
(qty 2)
8
1d 3c 3e
9
14
11
13
12
10
128283 Tool Assembly Refer to Parts List for individual part numbers.
Actuator
Hole
1c
1d 1d 3c 3e 3d 3c
Figure 7

BTT35 series Bobtail Installation System Alcoa Fastening Systems
14
15a
15b 15c 15d 15e
15f
15g
15h15 j
Section A-A
A
A15k(4)
Figure 8.1 - 128401 Trigger & Terminal Box Assembly
Refer to Parts List for individual part numbers.
Figure 8.2 - 128 98 Limit
Switch Housing Assembly
Refer to Parts List for individual part numbers.
AA
17a
17b 17c
17d 17e
17f17g17h
17 j 17k 17m 17n 17p
17q17r
Section A-A
Actuator
Lever
Dimple for
Limit Switch
Rod
Apply Loctite 242
or equivalent, per
manufacturer s
instructions*
* Loctite is a trademark of Henkel Corporation, U.S.A.
Figure 8

BTT35 series Bobtail Installation System Alcoa Fastening Systems
15
Item
note
Description Part
Number
Qty.
1Main Housing Assembly contains: 121981 1
1a Main Housing 119018 1
1b Lockscrew 121343-35 1
1c O-Ring 506078 1
1d Back-up Ring 501142 2
2Piston Assembly contains: 128282 1
2a Piston 128014 1
2b Pipe Plug 503703 2
2c Back-up Ring 501151 2
2d O-Ring 506089 1
3Rear Piston Assy contains: 128281 1
3a Rear Piston 128590 1
3b Polyseal 505918 1
3c Back-up Ring 501112 2
3d O-Ring 500818 1
3e O-Ring 503808 1
4Forward Gland Assy contains: 121890 1
4a Forward Gland 121878 1
4b Wiper 506065 1
4c Back-up Ring 501151 1
4d O-Ring 506089 1
4e Back-up Ring 501144 1
4f O-Ring 506079 1
5 Shield 125903 1
6Locater Button 125902 2
7Retaining Ring 507474 2
8Suspension Sleeve 128430 1
9Locking Screw 128440 1
10 High Pressure Hose 118944-2 2
11 Reducer 503431 2
12 Male Coupler 110438 1
13 Female Coupler 110439 1
14 Cable Tie 505839 1
Item
note
Description Part
Number
Qty.
15 Trig./Term. Box Assy contains: 128401 1
15a Trigger & Terminal Box 128652 1
15b Trigger Assembly 120361 1
15c Trigger. & Terminal Box Cover 128653 1
15d Screw 505642 1
15e Terminal Strip 124379 1
15f Strain Relief 505344-3 1
15g Cable Assembly 128416 1
15h Trigger & Terminal Box Plate 128404 1
15j Screw 502472 2
15k Screw 502468 4
16 Tubing 504173 7in.
17 Switch Housing Assy contains: 128398 1
17a Cap Screw 500049 1
17b Lower Switch Housing 128392 1
17c Cap Screw 500109 4
17d Cap Screw 500051 1
17e 1/8 NPT - 1/4 Tube Fitting 506268 1
17f Cap Screw 500050 1
17g Upper Switch Housing 128391 1
17h LED Lamp 508310 1
17j Limit Switch Actuator Lever 128393 1
17k Microswitch 506038 1
17m Button Head Cap Screw 507570 2
17n Limit Switch Plate 128394 1
17p Spring 508309 1
17q Spring 508307 1
17r Dowel 501343 1
17s Black Wire (not shown) 505231 4ft.
17t Wire Marker Cartrg. (not shown) 506660 .05
18 Actuator Rod 128397 1
19 Limit Switch Rod Guide 128396 1
20 Spring 508308 1
21 Limit Switch Rod 128395 1
Refer to Figures 6, 7, and 8 on the following pages for Tool Assembly Item numbers.
BTT35 T
BTT35 TOOL
OOL A
ASSEMBLY
SSEMBLY P
PARTS
ARTS L
LIST
IST

BTT35 series Bobtail Installation System Alcoa Fastening Systems
16
110439
Coupler
Body
128397
Actuator
Rod
118944-2 High Pressure Hoses
128412 Tool Assembly
(See Figure 10)
BTT35R Tool Assembly
128396
Limit Switch
Rod Guide
508308
Spring
128395-1
Limit Switch
Rod
128425
Pinch
Guard
502468
Screw
128429
Handle
503431 Reducing Bushings
110438
Coupler
ipple
Figure 9

4d
4b 4c
3b 2b 2c
3c
3d
1c 1d
2d 2e 2f 1c 3d 4c 4e
128412 Cylinder Assembly Refer to Parts List for individual part numbers.
1a
2a 3a 8
5
6
4a
9
7
Figure 10
BTT35 series Bobtail Installation System Alcoa Fastening Systems
17
Item
note
Description Part
Number
Qty.
1Piston Assembly contains: 128282 1
1a Piston 128014 1 1b Pipe Plug (not shown) 503703 2
1c Back-up Ring 501151 2
1d O-Ring 506089 1
2Forward Gland Assy contains: 121890 1
2a Forward Gland 121878 1 2b Back-up Ring 501151 1
2c O-Ring 506089 1
2d Wiper 506065 1
2e Back-up Ring 501144 1
2f O-Ring 506079 1
3Main Housing Assembly contains: 121981 1
3a Main Housing 119018 1
3b Lockscrew 121343-35 1
3c O-Ring 506078 1
3d Back-up Ring 501142 2
Item
note
Description Part
Number
Qty.
4Rear Piston Assy contains: 128413 1
4a Rear Piston 128591 1
4b Polyseal 505918 1
4c Back-up Ring 501112 2
4d O-Ring 500818 1 4e O-Ring 503808 1
4f Pipe Plug (not shown) 503703 2
5Suspension Sleeve 128430 1
6Retaining Ring 507474 2 7 Shield 125903 1
8Locater Button 125902 2 9Locking Screw 128440 1

BTT35 series Bobtail Installation System Alcoa Fastening Systems
18
128423 Switch
Housing Assembly
508309
Adjuster
Spring
128422
Mounting
Plate Assy
500047
Screw
500051
Screws(3)
500108
Mounting
Screws (4)
128414
Switch
Housing
508310
Red LE
505344-3
Cord Grip
508313
Washer
508310
Red LE
128423 Switch
Housing Assembly
508309
Adjuster
Spring
128422
Mounting
Plate Assy
500047
Screw
500051
Screws(3)
500108
Mounting
Screws (4)
128414
Switch
Housing
508310
Red LE
505344-3
Cord Grip
508313
Washer
508310
Red LE
128428 Han le Assembly
128427
Handle
Cover
502468
Screws (4)
128424
Handle
Flange
500077
Screw
500101
Screws (4)
500069
Screw
120361
Trigger
Assembly
128426
Handle
128428 Han le Assembly
128427
Handle
Cover
502468
Screws (4)
128424
Handle
Flange
500077
Screw
500101
Screws (4)
500069
Screw
120361
Trigger
Assembly
128426
Handle
128416-1
Cable
Assembly
124379
Wiring
Bridge
128423
Switch Housing
Assembly
128429 Han le & Housing Assembly
505879
Screw
128428
Handle
Assembly
502467
Screw(4)
Figure 11

BTT35 series Bobtail Installation System Alcoa Fastening Systems
19
P
PULLER
ULLER W
WEAR
EAR AND AND/
/OR
OR R
REPLACEMENT
EPLACEMENT
1. Using Dial Calipers or 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.) A new Puller
will measure .261-.262 inches. A worn Puller will
measure around .250 inches or will begin to strip
fasteners.
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. Once unscrewed from the Piston, remove and
clean all the components from the Puller. Note:
To add life to the Puller, always clean compo-
nents upon changing or checking Puller.
a) Insert Spring into Piston
b) Insert Actuator Rod into Piston
c) Insert Rod Guide into Piston
d) Screw Puller onto Piston
5. Reinstall the components before screwing a NEW
Puller onto the Piston.
6. Apply Loctite Anti-Seize
or some other form of
lubricant to the Puller to
keep it from wearing
against the Anvil during
the first several drives.
7. a) Bottom Anvil Holder on Piston.
b) Back off Anvil Holder until a groove is visible
through Setscrew hole.
c) Install Setscrew.
8. Check the Limit Switch setting using the Controller
or a Light Box and the depth micrometers. Adjust
within the specification of .430”-.435”. (See LIMIT
SWITCH ADJUSTMENT on the next page.)
TOOLS NEEDED
1. Interchangeable Anvil Micrometers or Dial Calipers
2. Depth Micrometers
3. Allen Wrenches
Spring
Spring
Limit Switch Rod
Limit Switch Rod
Puller
Puller
Rod Guide
Rod Guide
Piston
Piston

BTT35 series Bobtail Installation System Alcoa Fastening Systems
20
L
LIMIT
IMIT S
SWITCH
WITCH A
ADJUSTMENT
DJUSTMENT
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 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 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 .430”-
.435”. You will notice the Light Box light will come
on once 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 during tightening the
Lockdown Screw.
6. Once adjusted to the specification of .430”-.435”,
disconnect the Light Box and reconnect the sys-
tem. The tool is now ready to drive fasteners.
TOOLS NEEDED
1. Controller or Light Box
2. Depth Micrometer
3. Allen Wrench
Limit Switch
Adjustment
Screw Lockdown
Screw
Where a Light Box is mentioned in these instructions, the Controller may be used instead when convenient.
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.
SERVICE NOTES