Huck BTT35, BTT35R Instruction 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 fas­teners 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 fas­teners will result in an equivalent weighted RMS vibration
level A(8) of:

.121 m/s

2

To calculate equivalent vibration level for other quantities of
fasteners in an eight hour period, use the formula:

Equivalent Vibration Level, A8 (m/s

2

) = (n/480) x .116

where n = number of fasteners in eight hours,
and .116(m/s

2

) = 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

C

ONTENTS

ONTENTS

BTT35 series Bobtail Installation System Alcoa Fastening Systems

4

S

S

AFETY

AFETY

This instruction manual must be read,
with particular attention to the following
safety guidelines, by any person servic­ing 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 stick­ers/labels supplied with equipment must be under­stood before connecting equipment to any primary
power supply. As applicable, each of the sections
in this manual have specific safety and other infor­mation.

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 deflec­tors.

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 impor­tant factor in maintaining tool efficiency, eliminat­ing 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

P

RINCIPLE

RINCIPLE

OF

OF

O

O

PERATION

PERATION

P

P

ROGRAM

ROGRAM

C

C

YCLE

YCLE

Operating Temperature Range: 32-125F (0-51.7C)

The operator pushes the Tool's Nose over the end of the fas­tener until the Tool's Puller bottoms on the fastener. When the
Tool's Limit Switch Rod makes contact with the end of the
fastener, the Limit Switch in the back of the Tool is activated.
This sends an input signal to the tool control. When the oper­ator presses the Trigger on the Tool an input is sent to the tool
control. When both conditions are met, the tool control will
turn on the hydraulic pump, PULL pressure, for fastener
installation. The Piston moves back to start the swaging
process.

A Pressure Transmitter on the Relief Valve assembly sends a
signal to the control to indicate the "pressure set point" has
been reached and the "hold timer" can start. The "hold timer"
will keep the hydraulic pump, PULL pressure, on until the
timer times out. An external Relief Valve will control the
amount of pull pressure that can be reached.

After the "hold timer" times out, the hydraulic pump shifts to
RETURN pressure and the Tool's Anvil is ejected off of the
collar and the Tool is released from the fastener.

O

O

PERATING

PERATING

I

I

NSTRUCTIONS

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 fas­tener.

!

WARNING: Only use compat­ible equipment with this tool.

!

WARNING: To avoid pinch
point, never place hand
between nose assembly and
work piece

NOTES:

Start

Pull & Hold Trigger

AND

Limit Switch Tripped

N

Cycle Does Not Start

Y

Energize Combination Valve

Start 10 Second Timer TD-1

Pressure Setting Attained

Start Adjustable (0-3 sec)

Delay Timer TD-2

- Trigger is the go signal.

- If trigger is released, cycle backs out.

- Limit switch may be made before trigger is pulled and cycle will still 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.

Y

Y

Timer Ranges

N

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

N

De-energize Combination Valve

Start Adjustable (.25-3.75 Sec)

N

TD-2 Timed Out

Y

TD-1 Timed Out

N

Timer TD-3

TD-3 Timed Out

Y

End of

Program Cycle

Y

The LED on the tool is

turned on until the next

installation has reached

the pressure setting.

Then the LED turns off.

TD-1: Stop hydraulics from

TD-2: Time to hold hydraulics

TD-3: Time to eject or release

Timer Uses

staying on too long in
case a hydraulic leak
occurs

after pressure is met

hydraulics

BTT35 series Bobtail Installation System Alcoa Fastening Systems

6

S

S

PECIFICATIONS

PECIFICATIONS

BTT35

BTT35

• Stroke: 1.625 in

• Weight: Approximately 13 lbs.

INCHES

mm

BTT35 Tool Assembly

Figure 1

INCHES

mm

BTT35R Tool Assembly

• Stroke: 1.625 in

• Weight: Approximately 13 lbs.

8.55

217.3

3.12

79.2

2.38

Ø

60.4

2.87

Ø

72.8

5.49

139.3

12.03

305.6

2.38

Ø

60.4

2.87

Ø

72.8

BTT35 series Bobtail Installation System Alcoa Fastening Systems

7

S

S

PECIFICATIONS

PECIFICATIONS

99-7851

99-7851

99-7851 Nose Assembly

5/8 Inch, 16mm

INCHES

mm

Figure 2

4.28

108.7

5.84

148.3

1.75

44.45

Ø

Anti-seize Lubricant

P/N 508183 to

Outside of Puller

and inside of Anvil

Apply

128379

Anvil Assy

Apply

Loctite 242

P/N 505016
to these
threaded joints

128376

Anvil Holder

128389

Puller

500648

Setscrew

(Qty. 3)

501736

Setscrew

(Qty. 1)

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 prop­er maintenance. Using the manual will help give a
clear understanding of the tool and basic mainte­nance procedures. Please read this section com­pletely before proceeding with maintenance and
repair. Use proper hand tools in a clean and well­lighted 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

A

SSEMBLY 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 lubri­cant, 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 deplet­ed, you can get kit items from any regular retailer of
these items. See kit parts list for: O-ring size
(AS568- number); material; durometer. For kit parts
lists and related information, see General Notes.

* 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 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 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 sur­faces and excessive wear or damage. Replace as nec­essary. 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 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.

!

WARNING: Inspect tool for damage or wear
before each use. Do not operate if damaged
or worn, as severe personal injury may occur

S

S

ERVICING

ERVICING

THE

THE

T

T

OOL

OOL