Huck BTT35, BTT35R Instruction Manual

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Page 1

10-06-2008

HK1086

INSTRUCTION MANUAL

BOBTAIL INSTALLATION SYSTEM

BTT35

BTT35R

Page 2

BTT35 series Bobtail Installation System Alcoa Fastening Systems

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

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

Equivalent Vibration Level, A8 (m/s

) = (n/480) x .116

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

) = 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.

Page 3

BTT35 series Bobtail Installation System Alcoa Fastening Systems

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

ONTENTS

Page 4

BTT35 series Bobtail Installation System Alcoa Fastening Systems

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.

Page 5

BTT35 series Bobtail Installation System Alcoa Fastening Systems

RINCIPLE

PERATION

ROGRAM

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.

PERATING

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

Cycle Does Not Start

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.

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

De-energize Combination Valve

Start Adjustable (.25-3.75 Sec)

TD-2 Timed Out

TD-1 Timed Out

Timer TD-3

TD-3 Timed Out

End of

Program Cycle

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

Page 6

BTT35 series Bobtail Installation System Alcoa Fastening Systems

PECIFICATIONS

BTT35

• Stroke: 1.625 in

• Weight: Approximately 13 lbs.

INCHES

BTT35 Tool Assembly

Figure 1

INCHES

BTT35R Tool Assembly

• Stroke: 1.625 in

• Weight: Approximately 13 lbs.

8.55

217.3

3.12

79.2

2.38

60.4

2.87

72.8

5.49

139.3

12.03

305.6

2.38

60.4

2.87

72.8

Page 7

BTT35 series Bobtail Installation System Alcoa Fastening Systems

PECIFICATIONS

99-7851

99-7851 Nose Assembly

5/8 Inch, 16mm

INCHES

Figure 2

4.28

108.7

5.84

148.3

1.75

44.45

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)

Page 8

BTT35 series Bobtail Installation System Alcoa Fastening Systems

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

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

ERVICING

THE

OOL

Page 9

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Figure 3

ETUP

SING

THE

918 P

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 pressure).

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, suspend tools and route hoses off of floors.

WARNING: Only use compatible equipment with this tool.

128441-3 3-Tool Controller

99-7581

Optional

Tool

Balancer

BTT35

128418-* Cord Assy

125926-* Hose Assy

115 VAC 15A Plug

Transducer

128415

Relief Valve

118308-* Cord Assy (2-Wire)

128457-* Cable Assy

(Pressure Transmitter)

CAUTION

F F O

CAUTION

TOOL 2

TOOL 1

CAUTIO

N O

24 VAC

15 VAC

TOOL 1

CAUTIO

POWERIG HYDRAULIC UNIT

TOOL 2

CAUTIO

* Two digit number after dash indicates hose length in feet.

(Example: 118308-12 is 12 foot hose assembly.)

918 Powerig

To primary

power source

Page 10

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Load

Cell

Trigger Switch

Test Fastener

PHOTO - A

PHOTO - B

Tool Force

Reading

To decrease Relief Valve pressure, turn the Relief Valve handle gradually counterclockwise; turn clockwise to increase pressure.

Relief

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

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 skidmore, and a test fastener in the tool, energize the Powerig using a trigger switch. Adjust the Relief Valve (see P

HOTO - 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 reenergizing 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 fastener. Check to be sure that the fastener is installed correctly. This can be checked by inspecting the dimples on the collar flange. At least one 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 C

ONTROLLER sec-

tion of this manual to adjust timer.

RENCHING

IPE

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

⁄4

1/4 NPTF 1

⁄2

- 1

⁄4

3/8 NPTF 1

⁄2

- 1

⁄4

Table 2 - Wrenching-up of Pipe Threads

Page 11

Figure 4

BTT35 series Bobtail Installation System Alcoa Fastening Systems

128441-3 C

ONTROLLER

UL & Serial No. Sticker

Instructions &

Wiring Diagram

Digital

Display

PLC

Arrow Buttons

Command

Buttons

ESC - MENU - ENT

3-Position

Mode

Switch

AS SHIPPED:

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 = 0 0 0 0 0 0 0 0

Page 12

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Figure 6

15 (See Figure 8.1)

1-14

128283 Tool Assembly

(See Figure 7)

17 (See Figure 8.2)

VIEW B-B

(Enlarged)

SECTION A-A

1.366

Limit Switch

adjustument for

Make/Break coarse

BTT35 Tool Assembly

Refer to Parts List for individual part numbers.

Page 13

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Figure 7

Hole

Actuator

(qty 2)

1d 3c 3e

1d 1d 3c 3e 3d 3c

128283 Tool Assembly

Refer to Parts List for individual part numbers.

Page 14

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Figure 8

15b

15a

15k(4)

15c 15d 15e

15f

15g

15h15 j

Section A-A

Figure 8.1 - 128401 Trigger & Terminal Box Assembly

Refer to Parts List for individual part numbers.

Apply Loctite 242

17a

or equivalent, per

manufacturers

instructions*

17b

17k 17m 17n 17p

17c

17d

17 j

Actuator Lever

17e

Dimple for

17f17g17h

Limit Switch

Rod

17q17r

Section A-A

Figure 8.2 - 128398 Limit Switch Housing Assembly

Refer to Parts List for individual part numbers.

* Loctite is a trademark of Henkel Corporation, U.S.A.

Page 15

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Item

note

Description Part

Number

Qty.

1 Main 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

2 Piston Assembly contains: 128282 1

2a Piston 128014 1 2b Pipe Plug 503703 2 2c Back-up Ring 501151 2 2d O-Ring 506089 1

3 Rear Piston Assy contains: 128281 1

3a Rear Piston 128590 1 3b Polyseal 505918 1 3c Back-up Ring 50 111 2 2 3d O-Ring 500818 1 3e O-Ring 503808 1

4 Forward 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 6 Locater Button 125902 2 7 Retaining Ring 507474 2 8 Suspension Sleeve 128430 1 9 Locking 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

OOL

SSEMBLY

ARTS

IST

Page 16

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Figure 9

118944-2

High Pressure

Hoses

503431

Reducing

Bushings

110438

Coupler

110439

Coupler

Nipple

Body

Pinch

Guard

128425

Handle

128429

Screw

502468

Rod

128395-1

Limit Switch

BTT35R Tool Assembly

128412

Tool Assembly

(See Figure 10)

128396

Rod Guide

Limit Switch

Spring

508308

Rod

128397

Actuator

Page 17

Figure 10

BTT35 series Bobtail Installation System Alcoa Fastening Systems

Item

note

Description

Part

Number

Qty.

Piston 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

Forward Gland Assy contains: 121890 1

2a Forward Gland 121878 1

Back-up Ring 501151 1

2c O-Ring 506089 1

Wiper 506065

Back-up Ring 501144 1

O-Ring 506079 1

3 Main Housing Assembly contains: 121981 1

Main Housing 119018 1

3b Lockscrew 121343-35 1

O-Ring 506078 13dBack-up Ring 501142 2

Item

note

Description Part

Number

Qty.

4 Rear Piston Assy contains: 128413 1

4a Rear Piston 128591 1

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

5 Suspension Sleeve 128430 1

6 Retaining Ring

507474 2

7 Shield

125903 1

Locater Button 125902 2

9 Locking Screw 128440 1

3d 4c 4e

128412 Cylinder Assembly

Refer to Parts List for individual part numbers.

Page 18

BTT35 series Bobtail Installation System Alcoa Fastening Systems

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 LED

505344-3

Cord Grip

508313

Washer

508310

Red LED

Figure 11

(3)

500051

Screws

Switch

128414

Housing

500108

Mounting

Screws (4)

508310

Red LED

128422

Mounting

Plate Assy

505344-3

Cord Grip

Spring

508309

Adjuster

502467

508310

Screw(4)

Red LED

505879

128423 Switch

Housing Assembly

Wiring

124379

Handle

128428

Assembly

Screw

Bridge

508313

Washer

Screw

500047

Trigger

120361

Assembly

Screw

500069

Handle

128424

500101

Screws (4)

Flange

502468

Handle

128426

Screw

500077

Handle

128427

Screws (4)

128428 Handle Assembly

Cover

128416-1

Cable

Assembly

128423

Assembly

Switch Housing

128429 Handle & Housing Assembly

Page 19

BTT35 series Bobtail Installation System Alcoa Fastening Systems

ULLER

EAR

AND

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 components 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 L

IMIT

SWITCH ADJUSTMENT on the next page.)

TOOLS NEEDED

1. Interchangeable Anvil Micrometers or Dial Calipers

2. Depth Micrometers

3. Allen Wrenches

Spring

Limit Switch Rod

Puller

Rod Guide

Piston

Page 20

BTT35 series Bobtail Installation System Alcoa Fastening Systems

IMIT

WITCH

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 system. 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

(Styles

may vary)

Hold micrometer face

firmly to Puller face when

measuring.

SERVICE NOTES

Page 21

BTT35 series Bobtail Installation System Alcoa Fastening Systems

IRING

NSTRUCTIONS

Figure 12

128416

Cable Assy

Crimp conductors in

positions shown.

Eight Pin Connector

PIN COLOR

1 WHITE

2 RED

3 YELLOW

4 GREEN

5 BLACK

6 BROWN

7 NOT USED

8 NOT USED

Trigger

120361

Switch

506038

LS1 - NC

Wire

505231

Wire

505231

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)

RED - 3

BLACK -1

BLACK - 2

BLACK - 6

BLACK - 5

BLACK - 4

RED

LED

508310

BLACK

Trigger

120361

Switch

506038

LS1 - NC

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

Pin - Color at Plug (Function)

LED

508310

GND

OUTPUT

TO CONTROL

LS1

+24VDC

8 - NOT USED

INPUT

TO CONTROL

NOT USED

TRIGGER

Plug

506504

Page 22

BTT35 series Bobtail Installation System Alcoa Fastening Systems

PTIONAL

QUIPMENT

Service Kit - BTT35KIT

Teflon Stick - 503237

Loctite* 242 - 505016

*Loctite is a trademark of Henkel Corporation, U.S.A.

Anti-seize Lubricant - 508183

CE Compatible Pump/Controller - HK432BT

Hose Cable Extension Assy - 128461-(length)

Test Plates:

12mm Small - 128484 12mm Large - 128483 14mm Small - 128467 14mm Large - 128466 16mm Small - 128465 16mm Large - 128464 20mm Small - 128486 20mm Large - 128485

Load Cell Assembly - 128433

(Shown Below)

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.

Page 23

BTT35 series Bobtail Installation System Alcoa Fastening Systems

LIMITED WARRANTIES

Tooling Warranty: Huck warrants that tooling and other

items (excluding fasteners, and hereinafter referred as "other items") manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase.

Warranty on "non standard or custom manufactured products": With regard to non-standard products or cus-

tom manufactured products to customer's specifications, Huck warrants for a period of ninety (90) days from the date of purchase that such products shall meet Buyer's specifications, be free of defects in workmanship and materials. Such warranty shall not be effective with respect to non-standard or custom products manufactured using buyer-supplied molds, material, tooling and fixtures that are not in good condition or repair and suitable for their intended purpose.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. HUCK MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ANY OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS FOR ANY PARTICULAR PURPOSE AND HUCK SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECTLY OR INDIRECTLY, ARISING FROM THE USE OF SUCH TOOLING, OTHER ITEMS, NONSTANDARD OR CUSTOM MANUFACTURED PRODUCTS OR BREACH OF WARRANTY OR FOR ANY CLAIM FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Huck's sole liability and Buyer's exclusive remedy for any breach of warranty shall be limited, at Huck's option, to replacement or repair, at FOB Huck's plant, of Huck manufactured tooling, other items, nonstandard or custom products found to be defective in specifications, workmanship and materials not otherwise the direct or indirect cause of Buyer supplied molds, material, tooling or fixtures. Buyer shall give Huck written notice of claims for defects within the ninety (90) day warranty period for tooling, other items, nonstandard or custom products described above and Huck shall inspect products for which such claim is made.

Tooling, Part(s) and Other Items not 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, MER-

CHANTABILITY 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.

The only warranties made with respect to such tool, part(s) or other items thereof are those made by the manufacturer thereof and Huck agrees to cooperate with Buyer in enforcing such warranties when such action is necessary.

Huck shall not be liable for any loss or damage resulting from delays or nonfulfillment of orders owing to strikes, fires, accidents, transportation companies or for any reason or reasons beyond the control of the Huck or its suppliers.

Huck Installation Equipment

Huck International, Inc. reserves the right to make changes in specifications and design and to 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 (845) 331-7300 FAX (845) 334-7333

Canada 6150 Kennedy Road Unit 10, Mississauga, Ontario, L5T2J4, Canada. Telephone (905) 564-4825 FAX (905) 564-1963

Outside USA and Canada Contact your nearest Huck International Office, see back cover.

In addition to the above repair facilities, there are Authorized Tool Service Centers (ATSC's) located throughout the United States. These service centers offer repair services, spare parts, Service Parts Kits, Service Tools Kits and Nose Assemblies. Please contact your Huck Representative or the nearest Huck office listed on the back cover for the ATSC in your area.

Page 24

Americas

Alcoa Fastening Systems

Aerospace Products Tucson Operations

3724 East Columbia Tucson, AZ 85714 800-234-4825 520-747-9898 FAX: 520-748-2142

Alcoa Fastening Systems

Aerospace Products Carson Operations

PO Box 5268 900 Watson Center Rd. Carson, CA 90749 800-421-1459 310-830-8200 FAX: 310-830-1436

Alcoa Fastening Systems

Commercial Products Waco Operations

PO Box 8117 8001 Imperial Drive Waco, TX 76714-8117 800-388-4825 254-776-2000 FAX: 254-751-5259

Alcoa Fastening Systems

Commercial Products Kingston Operations

1 Corporate Drive Kingston, NY 12401 800-431-3091 845-331-7300 FAX: 845-334-7333 www.hucktools.com

Alcoa Fastening Systems

Commercial Products Canada Operations

6150 Kennedy Road, Unit 10 Mississagua, Ontario L5T2J4 Canada 905-564-4825 FAX: 905-564-1963

Alcoa Fastening Systems

Commercial Products Latin America Operations

Avenida Parque Lira. 79-402 Tacubaya Mexico, D.F. C.P. 11850 FAX: 525-515-1776 TELEX: 1173530 LUKSME

Far East

Alcoa Fastening Systems

Commercial Products Australia Operations

14 Viewtech Place Rowville, Victoria Australia 3178 03-764-5500 Toll Free: 008-335-030 FAX: 03-764-5510

Europe

Alcoa Fastening Systems

Commercial Products United Kingdom Operations

Unit C, Stafford Park 7 Telford, Shropshire England TF3 3BQ 01952-290011 FAX: 0952-290459

Alcoa Fastening Systems

Aerospace Products France Operations

Clos D’Asseville BP4 95450 Us Par Vigny France 33-1-30-27-9500 FAX: 33-1-34-66-0600

A Global Organization

Alcoa Fastening Systems (AFS) maintains company offices throughout the United States and Canada, with subsidiary offices in many other countries. Authorized AFS distributors are also located in many of the world’s

industrial and Aerspace centers, where they provide a ready source of AFS fasteners, installation tools, tool parts, and application assistance.

For The Long Haul, The Future of Fastening Technology, The Future of Assembly Technology, The Future of Tooling Technology, and Tools of Productivity are service marks of Huck International. Huck provides technical assistance regarding the use and application of Huck fasteners and tooling.

NOTICE: The information contained in this publication is only for general guidance with regard to properties of the products shown

and/or the means for selecting such products, and is not intended to create any warranty, express, implied, or statutory; all warranties are contained only in Huck’s written quotations, acknowledgements, and/or purchase orders. It is recommended that the user secure specific, up-to-date data and information regarding each application and/or use of such products.

HWB898 1003-5M

1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • E-mail: [email protected] • www.alcoafasteningsystems.com

One Great Connection

Alcoa Fastening Systems world-wide locations:

For the Long Haul

™

Certified to

ISO 9001:2000

Commercial

Products

Commerical

Products

Certified to

ISO 14001:2004