Huck Howmet Aerospace BobTail BTT25 User manual

June 9, 2023
HK1098
BobTail®Hydraulic
Installation Tool
Instruction Manual
BTT25 Table of Contents
EC/UKCA Declaration of Conformity 2
Safety Instructions 3 - 5
Description 5
Principle of Operation 6
Program Cycle 6
Tool Specifications 6 - 7
Spare Parts and Accessories 7 - 8
Maintenance 8 - 9
Tool Disassembly 9
Tool Assembly 10
Preparation for Use 10
Operating Instructions 11
Hydraulic Couplings 11
Sticker Locations 11
Tool-to-Powerig®Setup 12
Assembly of NPTF Threaded
Components 13
128441-3 Controller 13
Component Drawings 14 - 16
Wiring Instructions 16
Puller Wear and/or Replacement 17
Limit Switch Adjustment 17
Nose Assembly Installation and
Removal 18
Troubleshooting 18
Warranties 19

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
2
EC Declaration of Conformity
Manufacturer:
Huck International, LLC, Industrial Products Group,
1 Corporate Drive, Kingston, NY, 12401, USA
Description of Machinery:
Models BTT25, 35, 57, and BT 60 families of hydraulic
installation tools and specials based on their design (e.g.
PR####).
Relevant provisions complied with:
• Council Directive related to Machinery (2006/42/EC)
• British Standard related to hand held, non-electric
power tools (ISO 11148-1:2011)
Representatives:
EU: Lutz Baumann
Hildesheim Operations
Fairchild Fasteners Europe - VSD GmbH
Steven 3
31135 Hildesheim
Germany
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment
specied above conforms to the above
Directive(s) and Standard(s).
Signature:
Full Name: Nicholas Gougoutris
Position: Engineering Manager
Location: Huck International, LLC d/b/a
Howmet Fastening Systems
Kingston, New York, USA
Date: 5/12/23 May 12, 2023
UKCA Declaration of Conformity
Manufacturer:
Huck International, LLC, Industrial Products Group,
1 Corporate Drive, Kingston, NY, 12401, USA
Description of Machinery:
Models BTT25, 35, 57, and BT 60 families of hydraulic
installation tools and specials based on their design (e.g.
PR####).
Relevant provisions complied with:
• British Standard related to hand held, non-electric
power tools (ISO 11148-1:2011)
• Supply of Machinery (Safety) Regulations 2008
Representatives:
UK: Paul Carson
Huck International, Ltd.
Unit C
Staord Park 7
Telford, Shropshire
England TF3 3BQ, United Kingdom
Authorized Signature/date:
I, the undersigned, do hereby declare that the equipment
specied above conforms to the above
Directive(s) and Standard(s).
Signature:
Full Name: Nicholas Gougoutris
Position: Engineering Manager
Location: Huck International, LLC d/b/a
Howmet Fastening Systems
Kingston, New York, USA
Date: 5/12/23 May 12, 2023
Test data to support the above information is on file at: Howmet Fastening Systems, Kingston Operations, Kingston, NY, USA.
Declared dual number noise emission values in accordance with ISO 4871
A weighted sound power level, LWA: 79 dB (reference 1 pW) Uncertainty, KWA: 3 dB
A weighted emission sound pressure level at the work station, LpA: 68 dB (reference 20 µPa) Uncertainty, KpA: 3 dB
C-weighted peak emission sound pressure level, LpC, peak: 96 dB (reference 20 µPa) Uncertainty, KpC: 3 dB
Values determined according to noise test code ISO 15744, using as basic standards ISO 3744 and ISO 11203. The sum of a
measured noise emission value and its associated uncertainty represents an upper boundary of the range of values which is likely
to occur in measurements.
Declared vibration emission values in accordance with EN 12096
Measured Vibrations emission value, a: .32m/s2Uncertainty, K: .06 m/s2
Values measured and determined according to ISO 28662-1, ISO 5349-2, and EN 1033

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
3
DANGER - IMPORTANT
DO NOT EXCEED HOSE MINIMUM BEND RADIUS
Failure to heed the warnings below could lead to a damaged hose, damaged tool,
damaged property, personal injury, or death.
• This high pressure hose is not to be used other than assembled in a genuine HUCK
tool or hose assembly or used as a replacement hose of a genuine HUCK tool or
hose assembly.
• Improper use of this product can cause property damage, personal injury, and
death, including but not limited to electrocution, fluid injection or loss of limb
caused by high pressure leak, dangerously whipping hose or contact with
suddenly moving or falling objects.
• Do not exceed rated working pressure (700 bar/10150 psi) or minimum bend
radius (see chart below). Do not use in temperatures less than -40°C (-40°F) or
greater than +100°C (+212°F). Do not exceed fluid working temperature of +70°C
(+158°F).
• Do not use if hose is kinked, abraded, cut, bulged or leaking. Do not attempt to
repair hose.
• Do not carry tool by hoses. • Store hose assemblies in a clean dry area.
• Refer to a HUCK hydraulic tool manual for hose inspection & maintenance intervals.
Hose Type Minimum Bend Radius
126107 Series 2.76 Inches 70 mm
118944 and 124881 Series 2.17 Inches 55 mm
HA and HPH Series 1.97 Inches 50 mm
Glossary of Terms and Symbols
Product complies with
requirements set forth by the
relevant UK and European
directives.
NOTES Notes are reminders of required
procedures.
Read manual before using
equipment. FONT STYLING Bold, italic type and underline:
emphasize a specific instruction.
Hearing protection is required
while using this equipment. WARNINGS Must be understood to avoid severe personal injury.
Eye protection is required
while using equipment. CAUTIONS Show conditions that will damage equipment or structure.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
4
I. GENERAL SAFETY RULES:
1. A half hour long hands-on training session with
qualied personnel is recommended before using
Howmet equipment.
2. Howmet 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 Howmet 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 eectiveness of safety measures and increase
operator risk.
6. Do not discard safety instructions; give to operator.
7. Do not use assembly power tool if it is 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 Howmet representative.
11.Only genuine Howmet 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
e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. The operator should adopt a comfortable posture,
maintain a secure footing and avoid awkward or o
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
stiness, these warnings should not be ignored.
The operator should tell the employer and consult a
qualied 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.
Safety Instructions

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
5
DEXRON is a registered trademark of General Motors Corporation.
GLYD Ring is a registered trademark of Trelleborg Sealing Solutions
Germany GmbH
Loctite is a registered trademark of Henkel IP & Holding GmbH
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
MERCON is a registered trademark of Ford Motor Corp.
MOLYKOTE is a registered trademark of Dow Corning Corporation
Never-Seez is a registered trademark of Bostik, Inc.
Quintolubric is a registered trademark of Quaker Chemical Corp.
Slic-tite is a registered trademark of LA-CO Industries, Inc.
Spirolox is a registered trademark of Smalley Steel Ring Company
Teflon is a registered trademark of Chemours Company FC.
Threadmate is a registered trademark of Parker Intangibles LLC.
TRUARC is a trademark of TRUARC Co. LLC.
Vibra-Tite is a registered trademark of ND Industries, Inc. USA.
Where the following trade names are used in this manual, please note:
VI. WORKPLACE HAZARDS:
1. Be aware of slippery surfaces caused by use of the tool
and of trip hazards caused by the air line or hydraulic
hose.
2. Proceed with caution while in unfamiliar surroundings;
there could be hidden hazards such as electricity or
other utility lines.
3. The assembly power tool is not intended for use in
potentially explosive environments.
4. Tool is not insulated against contact with electrical
power.
5. Ensure no electrical cables, gas pipes, etc., can cause a
hazard if damaged by use of the tool.
VII. NOISE HAZARDS:
1. Exposure to high noise levels can cause permanent,
disabling hearing loss and other problems such
as tinnitus, therefore risk assessment and the
implementation of proper controls is essential.
2. Appropriate controls to reduce the risk may include
actions such as damping materials to prevent
workpiece from ‘ringing’.
3. Use hearing protection in accordance with employer’s
instructions and as required by occupational health
and safety regulations.
4. Operate and maintain tool as recommended in the
instruction handbook to prevent an unnecessary
increase in the noise level.
5. Select, maintain and replace the consumable / inserted
tool as recommended to prevent an unnecessary
increase in noise.
6. If the power tool has a silencer, always ensure 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 ngers or hands, stop using the tool, tell your
employer and consult a physician.
4. Support the weight of the tool in a stand, tensioner or
balancer in order to have a lighter grip on the tool.
IX. HYDRAULIC TOOL SAFETY INSTRUCTIONS:
1. Carry out a daily check for damaged or worn hoses or
hydraulic connections and replace if necessary.
2. Wipe all couplers clean before connecting. Failure to
do so can result in damage to the quick couplers and
cause overheating.
3. Ensure that couplings are clean and correctly engaged
before operation.
4. Use only clean oil and lling equipment.
5. Power units require a free ow of air for cooling
purposes and should therefore be positioned in a well
ventilated area free from hazardous fumes.
6. Do not inspect or clean the tool while the hydraulic
power source is connected. Accidental engagement
of the tool can cause serious injury.
7. Be sure all hose connections are tight.
8. Wipe all couplers clean before connecting. Failure to
do so can result in damage to the quick couplers and
cause overheating.
WARNINGS: Do not exceed maximum
pull or return settings on tool.
Be sure all hose connections are tight.
All tool hoses must be connected.
Safety Instructions
Description
The BTT25 is a hydraulic installation tool is designed to
install the Bob-Tail® Fasteners listed below when using the
applicable nose assembly. They include a hydraulic cylinder
and dual in-line piston assemblies, limit switch mechanism
with actuator rod for detecting the presence of a fastener
in the puller, a trigger switch assembly, and come complete
with hoses, quick connect couplers and a control cord. The
BTT25 also includes a rotatable suspension sleeve that can be
used to suspend the tool with a tool balancer (not included) .
The BTT25 is ready to be attached to, and powered by, a
HUCK Powerig® Hydraulic Unit (model 918 or equivalent)
and requires the use of a 128415 Relief Valve & Pressure
Transmitter Assembly and a 128441-3 3-Tool Controller or
equivalent equipment. Correct PULL and RETURN pressures
are important for operation of the tool and nose assembly,
and for the safety of the operator. Use HUCK Set-up Gauge
(P/N T-124833CE) to check and set pressures. The gauge is
available separately and includes instructions for use.
Nose assemblies are available separately. The BTT25 Hy-
draulic Installation Tool can install and remove M12 (12mm),
M14 (14mm) and -16 (1/2”) Bob-Tail® Fasteners.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
6
Specications
Principle of Operation
The operator pushes the tool nose over the end of the
fastener until the tool’s puller bottoms on the fastener.
When the Tool Limit Switch Rod makes contact with the
end of the fastener, the Limit Switch in the back of the
Tool is activated. This sends an input signal to the tool
control. When the operator presses the Trigger on the
Tool, an input is sent to the tool control. When both
conditions are met, the tool control will turn on the
hydraulic pump, PULL pressure, for fastener installation.
The Piston moves back to start the swaging process.
A Pressure Transmitter on the Relief Valve assembly sends
a signal to the control to indicate the “pressure set point”
has been reached and the “hold timer” can start. The
hold timer will keep the hydraulic pump, PULL pressure,
on until the timer times out. An external Relief Valve will
control the amount of pull pressure that can be reached.
After the hold timer times out, the hydraulic pump shifts
to RETURN pressure and the Tool’s Anvil is ejected off of
the collar and the Tool is released from the fastener.
Y
Y
N
N
N
Start
Pull & Hold Trigger
And
Limit Switch Tripped
Cycle Does Not Start
Y
Y
Y
Y
Energize Combination Valve Start 10 Second Timer TD-1
Pressure Setting Attained
Start Adjustable (0-3 sec) | Delay Timer TD-2
De-energize Combination Valve Start ADjustable (.25-3.75 Sec) | Timer TD-3
The LED on the tool is turned on until
the next installation has reached the
pressure setting. Then the LED turns off.
End of Program Cycle
TD-2 Timed Out
TD-3 Timed Out
TD-1 Timed Out
Program Cycle
Figure 1
NOTES:
• Trigger is the go signal. • If the trigger is released, cycle backs out.
• Limit switch may be made before trigger is pulled and cycle will start.
• Limit switch must be made for .1 seconds after cycle starts; then program no
longer looks for limit switch during cycle.
• If hydraulic cycle is started/proceeding when trigger is released, the combination
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 timed out, the
operation may release trigger and the program will finish normally.
Timer Ranges
TD-1: 10 sec
TD-2: Adjustable 0-3 sec
TD-3: Adjustable .25-3.75 sec
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.
continued...
TD-2: Time to hold hydraulics after pressure is met.
TD-3: Time to eject or release hydraulics.
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’s an ester based fluid such as Quintolubric HFD or
equivalent. Water based fluid shall NOT be used as serious damage to equipment will occur.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
7
10.4 inches
(26.5 cm)
5.2 inches
(13.3 cm)
2 inches
(5.1 cm)
2.4 inches
(6.1 cm)
Specications (continued)
DESCRIPTION DETAIL DESCRIPTION DETAIL
POWER SOURCE Huck Powerig® Hydraulic Unit MAX FLOW RATE 2 gpm 7.57 l/m
MIN OPERATING TEMP 32 ° F 0 ° C STROKE 1.63 inches 4.1 cm
MAX OPERATING TEMP 125 ° F 51.7 ° C WEIGHT (approximate) 8 lbs 3.62 kg
MAX INLET PULL PRESSURE 8400 psi 580 bar PULL CAPACITY 25,000 lbf (111 kN) @ 8,000 psi
MAX INLET RETURN PRESSURE 6500 psi 448 bar RETURN CAPACITY 11,200 lbf (50 kN) @ 6,500 psi
Dimensions
Spare Parts & Accessories
5.7 inches
(14.5 cm)
4.4 inches
(11.3 cm)
2.3 inches
(5.9 cm)
1.3 inches
(3.3 cm)
1.6 inches
(4.1 cm)
501736
Setscrew
(1)
501920
Setscrew
(3)
128757
Puller
Apply Anti-seize Lubricant (P/N 508183)
or equivalent per manufacturer’s instructions
to outside of puller and inside of anvil.
Apply Loctite 222 or equivalent
per manufacturer’s instructions
to these threaded joints.
Apply Loctite 243 (P/N 508567) or equivalent
per manufacturer’s instructions to setscrew threads.
128759
Anvil Assembly
128758
Anvil Holder
Nose Assembly
12mm
Figure 3
Figure 2
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.
These components are available independently.
DESCRIPTION PART #
Service Kit BTT25KIT
TEFLON® STICK 503237
LOCTITE® 243 508567
ANTI-SEIZE LUBRICANT 508183
LUBRIPLATE® 130-AA 502723
CE COMPATIBLE PUMP/CONTROLLER HK432BT
LOAD CELL ASSEMBLY 128463
Gauge, Pressure Setting, CE T-124833CE
Test Plates
DESCRIPTION PART # DESCRIPTION PART #
12 mm Small 128484 16 mm Small 128484
12 mm Large 128483 16 mm Large 128483
14 mm Small 128484 20 mm Small 128484
14 mm Large 128483 20 mm Large 128483
Hose Cable Extension Assembly
DESCRIPTION PART #
12 foot Hose Cable Extension Assembly 128641-12
26 foot Hose Cable Extension Assembly 128641-26
Gauge, Pressure Setting, CE
T-124833CE
Load Cell Assembly
128463

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
8
Carefully handle individual parts; examine them
for damage and wear. Replace parts when required.
Always replace O-rings and Back-up Rings when the
tool is disassembled.
• The efficiency and life of your tool depends on
proper maintenance. Read this section completely
before proceeding with maintenance and repair. Use
proper hand tools in a clean and well-lighted area.
Only standard hand tools are required in most cases.
Where a special tool is required, the description and
part number are given.
• While clamping tool or parts in a vise, and when parts
require force, use suitable soft materials to cushion
impact. For example, using a half-inch brass drift,
wood block, and vise with soft jaws greatly reduces
possibility of damaging tool. Remove components
in a straight line without bending, cocking or undue
force. Re-assemble tool with the same care.
• Consult Troubleshooting in this manual if a
malfunction occurs, and then see the appropriate
Assembly and Assembly Drawings
SEALANTS, LUBRICANTS, SERVICE KITS
• See Specifications for fluid type. Dispose of fluid
in accordance with local environmental regulations.
Recycle steel, aluminum, and plastic parts in
accordance with local lawful and safe practices.
• Apply Parker Threadmate®, Loctite®567, or Slic-Tite®
(per manufacturer’s instructions) to pipe plug threads
and quick connect fittings.
• Smear LUBRIPLATE®130-AA (P/N 502723) or
equivalent on O-rings and mating surfaces to aid
assembly and prevent damage to O-rings.
• 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.
Maintenance
CAUTIONS: Keep dirt and other material
out of hydraulic system (tool, hoses,
couplers, and Powerig).
Keep separated parts away from dirty
work surfaces. Dirt in hydraulic system
causes valve failure in hydraulic unit.
WARNINGS: Inspect your tool for damage
and/or wear before every use. Do NOT
operate the tool if it is damaged or worn;
severe personal injury may occur.
CAUTIONS: Do NOT use Teflon® tape on
pipe threads. Tape can shred and break free
into fluid lines, resulting in malfunctions.
Noses for BTT25
NOSE DESCRIPTION PART # DETAILS
BTT25 12MM BT 99-7850
12MM BT BTT25 CUT 99-7850CX Cutter Nose
14MM BT BTT25 99-7854
14MM BT BTT25 CUT 99-7854CX Cutter Nose
-16 BT BTT25 99-7855
-16 BT BTT25 CUT 99-7854CX Cutter Nose
12MM BT BTT25 CA 99BT-M12-IRAN-X Coated Anvil
12MM BT BTT25 LS 99BT-M12-IRAN-XA Low Swage Profile Coated Anvil
14MM BT BTT25 CA 99BT-M14-IRAN-X Coated Anvil
14MM BT BTT25 LS 99BT-M14-IRAN-XA Low Swage Profile
128457-* Cable Assembly
(Pressure Transmitter)
PART # DETAILS
128457-10 Cable Asm, Press Xmitter 10 FT
128457-25 Cable Asm, Press Xmitter 25 FT
128457-50 Cable Asm, Press Xmitter 50 FT
125926 Hose Assembly
PART # DETAILS
125926-12 Kit, Hose HSpin 12 FT
125926-15 Kit, Hose HSpin 15 FT
125926-26 Kit, Hose HSpin 26 FT
125926-38 Kit, Hose HSpin 38 FT
125926-52 Kit, Hose HSpin 52 FT
118308 Control Cord Assembly
PART # DETAILS PART # DETAILS PART # DETAILS
118308-6 Cord Asm, Control 6 FT 118308-26 Cord Asm, Control 26 FT 118308-52 Cord Asm, Control 52 FT
118308-12 Cord Asm, Control 12 FT 128457-38 Cord Asm, Control 38 FT
Spare Parts & Accessories (continued)
continued...

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
9
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 control
cord, and Powerig. Therefore, an effective preventive
maintenance program includes scheduled inspections of
the system to detect and correct minor troubles. At the
beginning of each shift/day:
• Inspect tool and nose assembly for external damage.
• Verify that hydraulic hose fittings, couplings, and
electrical connections are secure.
• Inspect hydraulic hoses for damage and deterioration.
Do not use hoses to carry tool. Replace hoses if
damaged.
• Observe tool, hoses, and hydraulic unit during
operation to detect abnormal heating, leaks, or
vibration.
• Max contamination level: NAS 1638 class 9, or ISO
CODE 18/15, or SAE level 6.
POWERIG MAINTENANCE
Refer to the applicable Powerig instruction manual.
TOOL MAINTENANCE
Whenever disassembled and at regular intervals
(depending on severity and length of use), replace all
seals, wipers, and back-up rings in tool. Service Kits,
hoses, and extra parts should be kept in stock. Inspect
cylinder bore, pistons, and piston rods for scored surfaces
and excessive wear or damage. Replace as necessary.
NOSE ASSEMBLY MAINTENANCE
Clean nose assembly often. Dip in mineral spirits or
similar solvent to clean puller and wash away metal chips
and debris. At regular intervals, as experience shows,
disassemble nose and use a sharp “pick” to remove
embedded particles from grooves of puller.
Maintenance (continued)
Tool Disassembly Instructions
For part identification, refer to Component Drawings
on pages 14-16. The following procedures are for
complete disassembly of tool. Remove ONLY those parts
necessary. Check components for wear and damage and
replace as needed. Replace O-rings, Polyseal, wiper, and
Back-up Rings.
1. Turn power source OFF at end of PULL stroke so that
Piston Assembly is at rear of cylinder (opposite of
position that is shown).
2. First, disconnect tool’s electric cord from 128441-3
3-Tool Controller, then disconnect 128457-* Cable
Assembly from hydraulic unit, and only then
uncouple hoses.
NOTE: Disassemble electric control switch only when
necessary to rewire or replace.
3. Carefully cut cable ties from hoses. Remove both
couplers (nipple and body) from hoses. Drain hoses
into container by pushing rearward on piston.
Discard fluid.
4. Remove both 502472 screws that hold 128779
Trigger Box Clamp to 128788 Trigger Box to unclamp
the 128781 Trigger & Terminal Box Assembly
from the hoses. Leave 128781 Trigger & Terminal
assembly connected to 128745 Limit Switch
Assembly by both switch cable and tension cable.
5. Remove four 500057 Cap Screws to remove 128745
Limit Switch Assembly from the 128696 Rear Piston
Assembly.
6. Remove hoses from tool, then Guard.
NOTE: If applicable, remove rear piston shields
by removing retaining rings and sleeve that holds
locator buttons in place. Remove locator buttons and
slide off shield.
7. Hold tool vertically, and in vise with soft jaws, clamp
vise jaws on flats of Rear Piston.
8. Install a puller (a component of a nose assembly)
onto pull piston; thread all the way down until it
bottoms out.
9. Remove 128701 Locking Screw from 128696 Rear
Piston Assembly.
10.Unscrew Rear Piston from piston rod; remove tool
from vise. Drain remaining fluid into container.
11.Clamp tool in vise with rear of cylinder facing down
the remove collet.
12.Unscrew Lockscrew that locks Front Gland in tool.
Then remove front gland with face spanner wrench.
13.Slide Front Piston Assembly out of Cylinder.
14.Remove all O-rings and Back-up Rings. Clean out
O-ring grooves; clean all components in mineral
spirits or isopropyl alcohol. Dry parts before
reassembly as solvent is detrimental to O-rings.
WARNINGS: Be sure to disconnect the
tool’s electric cord from 128441-3 3-Tool
Controller, then disconnect 128457-* Cable
Assembly from Powerig® Hydraulic Unit
before disconnecting tool’s hydraulic hoses
from unit. If not disconnected in this order,
severe personal injury may occur.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
10
Preparation for Use
Tool Assembly Instructions
POWER SOURCE CONNECTIONS
1. Coat hose fitting threads with a non-hardening
TEFLON® thread compound. Parker Threadmate™,
available independently, is recommended.
2. Use only a Huck Powerig 918, 940, or equivalent
that has been prepared for operation per applicable
instruction manual. Check both PULL and RETURN
pressures and adjust as necessary to match
installation tool. Gauge part number T-124833CE for
checking Powerig pressures is available from Huck.
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 fluid.
Observe action of tool. Check for fluid leaks.
5. Attach the proper Nose Assembly to the tool.
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 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’s safety and for Installation Tool’s
function. Gauge T-124833CE is available for
checking pressures. See Pressure Settings and
Gauge Instruction Manual. Failure to verify
pressures may result in severe personal injury.
Be sure to connect Tool’s hydraulic hoses to Powerig
Hydraulic Unit before connecting Tool’s switch
control cord to unit. If not connected in this order,
severe personal Injury may occur.
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
SPECIFICALLY NOT RECOMMENDED AND MAY BE
DANGEROUS.
Do not bend tool to free if stuck. Tool should only
be used to install fasteners. NEVER use as a jack/
spreader or hammer.
CAUTIONS: Do not use TEFLON®* tape on
pipe threads. Pipe threads may cause tape
to shred resulting in tool malfunction. (The
use of Parker Threadmate™ is recommended.)
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.
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.
For part identification, refer to Component Drawings on
pages 14-16.
Review Maintenance for good service practices. Use
correct assembly procedures and materials. Clean O-ring
grooves and reinstall perishable parts (O-rings, etc.) of
Service Kit.
1. Slide Piston Assembly into threaded end of cylinder.
Push piston to the rear of the cylinder.
2. Thread a puller onto the piston rod until it bottoms
out on the piston threads. Thread rear piston
assembly onto main piston. Back rear piston off just
enough to allow installation of the 128701 Locking
Screw into rear piston rod, tighten with hex key.
NOTE: If applicable, shield, locator button, and flat-
head socket screw are installed; use hex key.
3. Invert tool in vise clamping jaws on flats of rear
piston.
4. Thread Front Gland into cylinder using a face-
spanner wrench, bottom out threads. (See General
Notes, Item 6.) Back gland out until face of gland to
face of cylinder dimension is between .515” and .530”
and a groove is visible in the threaded hole in the
cylinder for the 121343 Lock Screw. Install Lock Screw
in cylinder. The screw must seat in groove of gland.
Slide Guard over back end of tool.
5. Install one hydraulic hose in rear piston port marked
“P” and one in port marked “R”.
6. Mount 128745 Limit Switch Assembly to the 128696
Rear Piston Assembly using four 500057 Cap Screws.
7. Mount 128779 Trigger Box Clamp to 128788 Trigger
Box using two 502472 screws to clamp the 128781
Trigger & Terminal Box Assembly to the hoses.
8. Install Coupler Nipple 110438 (PULL pressure hose)
and Coupler Body 110439 (RETURN pressure hose).
(Figures 6 & 7)
CAUTION: Do NOT use Teflon® tape on
pipe threads. Tape can shred and break free
into fluid lines, resulting in malfunctions.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
11
Operating Instructions
Hydraulic Couplings
Sticker Locations
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 flange 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.
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 fastener/pin in hole.
3. Slide BobTail collar over fastener. (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.
A
501102
Back-up Ring
504438
O-ring
110439
Female
Connector
110438
Male Connector
Use a fine India stone to remove any nicks
or burrs from diameter A and leading edge
to prevent damage to O-ring.
HUCK hydraulic tools come labeled with stickers which contain safety and pressure settings information. Stickers must
remain on the tool and readable. If a sticker becomes damaged or worn, or if it has been removed from the tool, or
when replacing the hydraulic Cylinder, it must be ordered and placed in the locations shown.
590512-15
CE & Warning
Sticker, 8400 PSI
A. 590517
HUCK Trademark &
Year of Manufacture
Sticker
B.
AB
8400580
6500 450
1. Push the tool’s nose over the end of the fastener until
it bottoms out.
2. Press and hold the trigger until the collar is swaged
and the tool’s Anvil is ejected off the collar and the
tools is released from the fastener.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
12
FASTENER
SIZE TOOL POWERIG PULL PRESSURE SETTING (PSI)
POWERIG
RETURN PRESSURE
SETTING (PSI)
CONTROLLER
PRESSURE SETTING
(PSI)
12MM BTT25 7500 PSI (517 Bar) (Minimum) 6500 PSI (448 Bar) 4200 PSI (289 Bar)
To decrease the Relief Valve pressure,
gradually turn the Relief Valve handle
counterclockwise; turn clockwise to
increase pressure.
Photo A
Photo B
Tool Force Reading
Tool Force
Reading Tool Force
Reading
Relief Valve
Load
Cell
Test Fastener
Tool to 918 Powerig® Setup
10.Set the PULL and RETURN pressures on the Powerig
using Huck Gauge P/N T-124833CE and TABLE 1.
11.Using a load cell (Photo A) or a skidmore, and a test
fastener in the tool, energize the Powerig using a
trigger switch. Adjust the Relief Valve (Photo B) so the
tool generates 12,000-13,000 lbs. force. This is a direct
force reading, not pressure. It equals approximately
4,250 psi (293 bar) Powerig pressure.
NOTE: It is important to release the trigger while
adjusting the pressure, then re-energizing to re-
check pressure. Otherwise, the reading on the
pressure display may be incorrect. When the desired
pressure is achieved, reconnect the Controller Cord.
12.Tool #2 and Tool #3: Set up the same way as Tool 1.
13.After the system is set up, install a test fastener. Verify
that the fastener is installed correctly. This can be
checked by inspecting the dimples on the collar flange;
at least on dimple should be marked by the anvil. If
not, add time to Timer #2 (Hold Timer) in the Controller
box, and test with fasteners until the proper installation
is achieved. See “Set Point Adjustments” in the
Controller section of this manual to adjust the timer.
1. Connect the nose assembly to the tool.
2. Connect the hydraulic hoses to the Powerig.
3. Connect the Relief Valve to the other end of the
Powerig hydraulic hoses.
4. Connect Hose Assembly to the Transducer (PULL
pressure) and Relief Valve (RETURN pressure).
5. Connect Cord Assembly from the Controller to the
Powerig labeled TOOL 1.
6. Connect Cable Assembly from the Controller to the
Transducer.
7. Connect the Hose Assembly to the installation tool.
8. Connect the Cord Assembly to the installation tool.
9. a. Connect the other end of Cord Assembly to the
Controller at TOOL 1.
b. Connect optional 128461-* Hose/Cable
Assembly.
128441-3
3-Tool Controller
115 VAC
15A Plug
128457-*
Cable Assembly
(Pressure Transmitter)
Optional Tool Balancer
(available Independently)
918 Powerig
to primary Power Source
99-7850
BTT25
128418-*
Cord Assembly
125926-*
Hose Assembly
128415
Relief Valve
118308-*
Cord Assembly (2-wire)
*Two digit number after dash indicates hose length in feet.
Example: 118308-12 is a 12 foot hose assembly.
Figure 4
WARNINGS: To prevent tripping hazard,
suspend tools and route hoses off floors.
Only use compatible equipment with this tool.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
13
Arrow
Buttons
Command
Buttons
ESC • MENU • ENT
3-Position
Mode
Switch
Instructions &
Wiring Diagram
Digital
Display
UL & Serial Number Sticker (located on left inside
of the box behind the flange - not visible from this view)
Arro
Arro
Bu
tt
o
CoCo
mm
Bu
tt
o
E
SC
• MEN
U
py
py
i
lb
lb
PLC
(Programmable logic
controller)
3. Press the ENT Command Button to select “Data
Monitor”. Press ENT again to select “V” data type.
4. Enter the address button of the value you need to alter.
Use the left (◄ ) and right ( ►) buttons to position
cursor, and the up ( ▲ ) and down ( ▼ ) buttons to
change individual digits. Press the ENT Command
Button when 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 Pressure Set Point 1000-9999 4200 psi
07412 T2 Pressure Set Point 1000-9999 4200 psi
07413 T3 Pressure Set Point 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.
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.
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
AS SHIPPED
Controller Pressure:
4200 psi (289 bar)
Hold Timer:
500 (.50 seconds)
Eject Timer:
600 (.60 seconds)
Figure 5
128441-3 Controller
AIR FITTINGS
1) Apply TEFLON®stick to male threads which do
not have pre-applied sealant per manufacturer’s
recommendations. (Proceed to All Fittings step 2)
HYDRAULIC FITTINGS
1) Apply Threadmate™ to male and female threads which
do not have pre-applied sealant per manufacturer’s
recommendations. (Proceed to All Fittings step 2)
ALL FITTINGS:
2) Tighten to finger-tight condition.
3) Wrench tighten to 2-3 turns past finger-tight condition.
4) Final thread engagement can be checked (optional)
by measuring the dimension from the flange of male
fitting to the end of the thread before assembly
and subtracting the distance under the flange after
assembly.
Thread Size Final thread engagement at full
make-up
1/8-27 NPTF .235 inch (.59 cm)
1/4-18 NPTF .339 inch (.86 cm)
3/8-18 NPTF .351 inch (.89 cm)
Assembly of NPTF Threaded Components

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
14
A
A
B B
VIEW B-B
128745 Limit Switch Housing Assembly
(see Figure 8.2)
128781 Trigger & Terminal Box Assembly
(see Figure 8.1)
128700
Tool Assembly (see Figure 7)
128750
Limit Switch
Rod
128772
Actuator
Rod
128752
Limit Switch Rod Guide
508308
Spring SECTION A-A
(Enlarged)
590512-15
CE & Warning Sticker, 8400 PSI
590517
HUCK Trademark & Year of Manufacture Sticker
128698
Main Housing Assembly
(see Figure 7)
128708
Forward Gland Assembly
(see Figure 7)
128696
Rear Piston Assembly
(see Figure 7)
110439
Female Coupler
110438
Male Coupler
128788
Hydraulic
Hose
(2)
125902
Locator Button
(2) 507473
Retaining Ring
(2)
503431
Reducing
Bushing
(2)
128701
Locking Screw
Actuator Hole
128694
Piston Assembly
(see Figure 7)
128706
Rear Piston Shield
128702
Suspension
Sleeve
Figure 7
Figure 6
Component Drawings
BTT25 Tool Assembly
128700 Tool Subassembly

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
15
128698
Main Housing Assembly
128694
Piston Assembly
128696
Rear Piston Assembly
128708
Forward Gland Assembly
501148
Back-up Ring
501142
Back-up Ring
128697
Rear Piston
505917
Polyseal
506064
Wiper Seal
506080
O-Ring
506078
O-Ring
500814
O-Ring (2)
501138
Back-up Ring (2)
501148
Back-up Ring (2)
501108
Back-up Ring
(3)
507635
Pipe Plug
(2)
506080
O-Ring
128695
Piston
128707
Forward Gland
121343
Lockscrew 506077
O-Ring
128699
Main Housing
Figure 8
Component Drawings continued...
128700 Subassemblies
A
A
505879
Screw
505588
Screw
502472
Screw
(2)
505344-3
Strain Relie
f
128416
Cable Assembly
128779
Trigger Box Clamp
124379
Terminal Strip
128786
Switch Cable
128785
Tension Cable
Assembly
501050
Self-Locking
Nut
506358
Strain Relief
128778
Trigger Box
128756
Trigger Assembly
128780
Trigger Box Cover
508310
LED Lamp
502468
Screw
(4)
SECTION A-A
Figure 8.1
128781 Trigger & Terminal Box Assembly

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
16
Component Drawings continued...
Wiring Instructions
500048
Cap Screw
500051 Cap Screw
506038 Microswitch
501342 Dowel
500166
Flat Washer
(2)
500166 Flat Washer (2)
500063 Screw (2)
500057 Cap Screw (4)
507570
Button-head Cap Screw (2)
508307 Spring
508360 Spring
128749 Switch Plate
128747
Limit Switch
Upper Housing
128746
Limit Switch
Lower Housing
128748
Actuator Lever Secon A-A
A
A
Apply Locte 243 or equivalent,
per manufacturer’s instrucons.
Dimple for Limit Switch Rod
Pin - Color at Plug (Function)
Crimp conductors in
positions shown.
Eight Pin Connector.
PIN COLOR
128786
Switch
Cable
128756 Trigger
506038 Switch
LS1 - NC
506038 Switch
LS1 - NC
TRIGGER
NOT USED
508310
LED RED
BLACK - 1
WHITE - 2
RED - 3
BLACK - 4
BLACK - 5
BLACK - 6
1 - WHITE (SOURCE +_24VDC - TRIGGER)
2 - RED (SOURCE +24VDC -LS1)
3 - YELLOW (+24VDC - LED)
4 - GREEN (SIGNAL +24VDC -LS1)
5 - BLACK (SIGNAL+24VDC -TRIGGER)
6 - BROWN (GROUND - LED)
1 - WHITE (SOURCE +24VDC - TRIGGER)
2 - RED (SOURCE +24VDC - LS1)
3 - YELLOW (+24VDC - LED)
4 - GREEN (SIGNAL +24VDC - LS1)
5 - BLACK (SIGNAL+24VDC -TRIGGER)
6 - BROWN (GROUND - LED)
7 - NOT USED
8 - NOT USED
1
1
2
3
4
5
6
7
8
WHITE
RED
YELLOW
GREEN
BLACK
BROWN
NOT USED
NOT USED
BLACK
505231
Wire
506504 Plug
508310
LED
+24VDC
GND
TO CONTROL
OUTPUT
TO CONTROL
INPUT
TO CONTROL
INPUT
128756 Trigger
128416
Cable Assembly
Figure 8.2
Figure 9
128745 Limit Switch Housing Assembly

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
17
TOOLS NEEDED
1. Interchangeable Anvil Micrometers or Dial Calipers
2. Depth Micrometers
3. Allen Wrenches
TOOLS NEEDED
1. Controller or Light Box
2. Depth Micrometers
3. Allen Wrench
1. Using Dial Calipers or an interchangeable Anvil
Micrometer, measure the Puller to determine if it is
worn out or new. (The Puller does not have to be
removed from the tool to be measured.)
2. Remove the setscrews from the anvil holder, and
unscrew the anvil holder from the tool.
3. Unscrew the setscrews from the Puller, then unscrew
the Puller from the piston.
4. After the Puller has been unscrewed from the Piston,
remove and clean all its components.
NOTE: To add life to the Puller, always clean
components upon changing or checking Puller.
a) Insert the spring into the piston.
b) Insert the actuator rod into the piston.
c) Insert the rod guide into the piston.
d) Screw the puller onto the piston.
5. Reinstall the components before screwing a NEW
Puller onto the Piston.
6. Apply Loctite Anti-Seize or an equivalent lubricant to
the Puller to keep it from wearing against the Anvil
during the first several drives.
7. a) Bottom the anvil holder on the piston.
b) Back off the anvil holder until a groove is visible
through the setscrew hole.
c) Install the setscrew.
8. Check the Limit Switch setting using the Controller
or a Light Box and the
depth micrometers. Adjust
within the specification
of .430”–.435”. See Limit
Switch Adjustment
section below.
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. Use an Allen wrench to loosen the Lockdown Screw.
3. To increase the switch setting, turn the Limit Switch
Adjustment Screw counterclockwise; to decrease it,
turn it clockwise.
4. Adjust the switch to the specification of .430”–.435”.
You will notice the Light Box light will come on after
the switch has been made.
5. Tighten the Lockdown Screw.
NOTE: After tightening the Lockdown Screw, verify
the adjustment again by measuring with the depth
micrometer. In some cases, because of the tight
tolerance, it is possible for the adjustment to be
jarred when the Lockdown Screw is tightened.
6. After it has been adjusted to the specification of
.430”–.435”, disconnect the Light Box and reconnect
the system.
The tool is now ready to drive fasteners.
Piston
Puller
Rod Guide
Limit Switch Rod
Spring
Puller Wear and/or Replacement
Limit Switch Adjustment
Limit Switch
Adustment
Screw
Lockdown
Screw
Light Box
(Styles may
vary)
Hold micrometer face
firmly to Puller face
when measuring.

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
18
1. Tool fails to operate when trigger is pressed.
a. Inoperative Powerig® Hydraulic Unit. See
applicable instruction manual.
b. Loose electric connections.
c. Damaged trigger assembly or control cord.
d. Loose or faulty hydraulic hose couplings.
e. Tool limit switch is not adjusted correctly or is
damaged.
2. Tool operates in reverse.
a. Reversed hydraulic hose connections between
Powerig® Hydraulic Unit and tool.
3. Hydraulic fluid leaks at front of pull piston.
a. Worn or damaged front gland O-rings, and
Back-up ring. Replace if necessary.
4. Hydraulic fluid leaks at rear of pull piston.
a. Worn or damaged piston polyseal. Replace if
necessary.
5. Hydraulic couplers leak fluid.
a. Damaged or worn O-rings in coupler body.
See Coupler 110440.
6. Hydraulic fluid overheats.
a. Powerig® Hydraulic unit not operating properly
See unit’s manual.
b. Powerig® Hydraulic Unit running in reverse
(918: 918-5). See unit’s manual.
7. Tool operates erratically and fails to properly install
fastener.
a. Low or erratic hydraulic pressure; air in system.
b. Operator is releasing trigger prior to hydraulic
pressure set point being reached and Timer TD-2
is timed out.
c. Damaged or worn piston O-ring or polyseal in
tool.
d. Excessive wear on sliding surfaces of tool parts.
8. Pull grooves on fastener pintail stripped during PULL
stroke.
a. Operator not sliding anvil completely onto
fastener pintail.
b. Incorrect fastener grip.
c. Worn or damaged puller.
d. Metal particles in puller pull grooves.
e. Excessive sheet gap.
9. Collar of BobTail® Fastener not completely swaged.
a. Improper tool operation. See Trouble 6.
b. Scored anvil in nose assembly.
10. Tool “hangs-up” on swaged collar of BobTail®
Fastener.
a. Improper tool operation. See Trouble 6.
b. RETURN pressure too low.
c. Nose assembly not installed correctly.
d. Not enough collar lubricant.
Troubleshooting
Always check the simplest possible cause (such as a loose or disconnected trigger line) of a malfunction first. Then
proceed logically, eliminating other possible causes until the cause is discovered. Where possible, substitute known
good parts for suspected defective parts. Use this Troubleshooting information to aid in locating and correcting trouble.
Assembly Instructions
1. If tool is equipped with a switch, install spring, actuator rod, and rod
guide into piston prior to installing puller.
2. Thread puller onto forward piston until machined alignment notch
on puller hub is in line with face of forward gland when piston is fully
retracted (in pull position).
3. Tighten all 3 setscrews on puller to lock in place.
4. Extend piston fully into return position.
5. Apply Loctite Anti-Seize or an equivalent lubricant to the surfaces of
puller that would slide against the inner surfaces of the anvil to reduce
puller wear.
6. If necessary, apply low strength purple Loctite 222 to threads of anvil and fully thread into anvil holder.
7. Remove the setscrew from anvil holder.
8. Install anvil holder/anvil assembly over puller and thread anvil holder onto forward gland fully.
9. Unthread anvil holder until groove on forward groove is first visible in one of empty setscrew holes.
10. Apply medium strength blue Loctite 243 to setscrew, then install in the threaded hole on the anvil holder in which
the groove of the forward gland is visible and tighten fully.
11. Verify that when piston is fully extended in return position, a BobTail® pin to be used inserts freely into puller
grooves. If pin does not insert freely, remove anvil holder/anvil assembly, loosen setscrews on puller and unthread
puller ½-turn, then re-tighten setscrews. Reinstall anvil holder/anvil assembly per steps 8 – 10 above, and verify
that BobTail pin to be used inserts freely into puller grooves. Repeat this step as needed until pin inserts freely
into puller.
Disassembly Instructions
1. Loosen setscrew on anvil holder, and unthread anvil holder/anvil assembly fully and pull off of puller.
2. Loosen all 3 setscrews on puller, and unthread puller fully from forward piston.
Nose Assembly & Disassembly Instructions
Puller
Anvil Holder
Anvil Assembly

BTT25 BobTail® Hydraulic Installation Tool (HK1098)
19
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 Powerig®hydraulic power sources manufactured
after December 1, 2016 shall be free from defects in
materials and workmanship for a period of two years
from date of purchase by the end user. This warranty
does not cover special order / non-standard products,
or part failure due to normal wear, tool abuse or
misapplication, or user non-compliance with the service
requirements and conditions detailed in the product
literature.
90 Day Limited Warranty on Nose Assemblies and
Accessories:
Huck International, Inc. warrants that its nose assemblies
and accessories shall be free from defects in materials
and workmanship for a period of 90 days from date of
purchase by the end user. This warranty does not cover
special clearance noses, or special order / non-standard
product, or part failure due to normal wear, abuse or
misapplication, or user non-compliance with the service
requirements and conditions detailed in the product
literature.
Useful lifetime is defined as the period over which the
product is expected to last physically, up to the point
when replacement is required due to either normal
in-service wear, or as part of a complete overhaul.
Determination is made on a case-by case basis upon
return of parts to Huck International, Inc. for evaluation.
Tooling, Part(s) and Other Items not manufactured by
Huck:
HUCK makes no warranty with respect to the tooling,
part(s), or other items manufactured by third parties.
HUCK expressly disclaims any warranty expressed
or implied, as to the condition, design, operation,
merchantability, or fitness for use of any tool, part(s), or
other items thereof not manufactured by HUCK. HUCK
shall not be liable for any loss or damage, directly or
indirectly, arising from the use of such tooling, part(s),
or other items or breach of warranty or for any claim for
incidental or consequential damages.
Huck shall not be liable for any loss or damage resulting
from delays or non-fulfillment of orders owing to strikes,
fires, accidents, transportation companies or for any
reason or reasons beyond the control of the Huck or its
suppliers.
Huck Installation Equipment:
Huck International, Inc. reserves the right to make
changes in specifications and design and to discontinue
models without notice.
Huck Installation Equipment should be serviced by
trained service technicians only.
Always give the serial number of the equipment when
corresponding or ordering service parts.
Complete repair facilities are maintained by Huck
International, Inc. Please contact one of the offices listed
below.
Eastern
One Corporate Drive Kingston, New York 12401-0250
Telephone [phone] FAX [phone]
Outside USA and Canada
Contact your nearest Huck International location (see
reverse).
In addition to the above repair facilities, there are
Authorized Tool Service Centers (ATSC’s) located
throughout the United States. These service centers offer
repair services, spare parts, Service Parts Kits, Service
Tool Kits and Nose Assemblies. Please contact your Huck
Representative or the nearest Huck International location
(see reverse) for the ATSC in your area.
Limited Warranties

Huck provides technical assistance in the use
and application of Huck fasteners & tooling.
NOTICE: This publication is only to be used for gen-
eral guidance in properties of the products shown
and/or the means for selecting such products, and
is not intended to create any warranty, express,
implied, or statutory; all warranties are contained
only in Huck’s written quotations, acknowledgments, and/or purchase
orders. It is recommended the user secure specific, up-to-date data and
information regarding each application and/or use of such products.
©2023 Howmet Aerospace, Inc.
Howmet Fastening Systems
Kingston Operations
1 Corporate Drive, Kingston, NY 12401
Tel: [phone] • Fax: [phone]
www.hfsindustrial.com/us
Industrial North America
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
Tel: [phone]
Fax: [phone]
[email protected]
Tracy Operations
1925 North MacArthur Drive
Tracy, CA 95376
Tel: [phone]
Fax: [phone]
[email protected]
Waco Operations
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
Tel: [phone]
Fax: [phone]
[email protected]
Industrial Global
Tokyo Operations (Japan & Korea)
1013 Hibiya U-1 Bldg.
Uchisaiwai-cho 1-1-7
Chiyoda-ku, Tokyo
100-0011 Japan
Tel: [phone]
Fax: [phone]
Melbourne Operations
1508 Centre Road
Clayton, Victoria
Australia 3168
Tel: [phone]
Fax: [phone]
[email protected]
Telford Operations
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
Tel: [phone]
Fax: [phone]
[email protected]
Suzhou Operations
58 Yinsheng Road,
SIP Suzhou, Jiangsu
215126 China
Tel: [phone]-8888
Aerospace North America
Kingston Operations
1 Corporate Drive
Kingston, NY 12401
Tel: [phone]
Fax: [phone]
[email protected]
Simi Valley Operations
3990A Heritage Oak Court
Simi Valley, CA 93063
Tel: [phone]
Fax: [phone]
www.afs-simivalley.com
[email protected]
Aerospace Global
Aichach Operations
Robert-Bosch Str. 4
Aichach 86551
Germany
Tel: [phone]
[email protected]
Cergy Operations
15 Rue du Petit Albi
F-95611 Cergy Pontoise
France
Tel: [phone]
Fax: [phone]
Hong Kong Operations
88 Hing Fat Street, 27th Floor
Causeway Bay
Hong Kong, China
Tel: [phone]
[email protected]
Howmet Fastening Systems Tooling Support Locations
Howmet Inc. (NYSE: HWM) creates breakthrough products that shape industries. Working in close
partnership with our customers, we solve complex engineering challenges to transform the way we fly,
drive, build and power.
Through the ingenuity of our people and cutting-edge advanced manufacturing, we deliver these
products at a quality and efficiency that ensures customer success and shareholder value.