Alcoa BTT20SF, Assembly Manual

Page 1: ...1 BTT20SF Cutter and Installation tool Assembly...

Page 2: ...2 BTT20SF Cutter and Installation tool Installation tool 6 5 O A L Weight 11 lbs 2 stroke Cutter tool 8 O A L Weight 12 lbs 2 stroke...

Page 3: ...Section 2 Cylinder Assembly Section 3 Limit switch housing Assembly Section 4 Cutter Nose Assembly Section 5 Installation Nose Assembly Section 6 Setting the limit switch Index BTT20SF Cutter Tool and...

Page 4: ...4 Section 1 BTT20SF Handle Assembly...

Page 5: ...emo wire through the strain relief which is attached to the alum Base plate and feed the wires up through the handle and attach the alum Base plate using two 10 24x1 2 long BHCS CV plugs CVES2503231A...

Page 6: ...ch will attach the manifold to the handle Slide the other half of the alum Base plate onto the hydraulic hose and push into place for the other two 10 24X3 3 BHCS Then the BLACK and WHITE wires go out...

Page 7: ...s in the top of the manifold where the barrel connectors go Then put some lubriplate grease on the assembled barrel connectors o rings and back up rings and push carefully into the holes in the manifo...

Page 8: ...connectors be careful when not to pinch or tear the o rings or back up rings Attach the hydraulic cylinder to the handle using a 10 32x3 8 BHCS Put the limit switch rod into the tool before the puller...

Page 9: ...andard Generic Part number Material Description Standard Replacement Part Numbers 227 Urethane back up ring 227 Urethane o ring 220 Urethane o ring 220 Urethane back up ring 227 Urethane o ring 227 Ur...

Page 10: ...10 AN 19 Rod wiper 224 O ring 224 Back up ring Cylinder End Cap 227 O ring 227 back up ring Cylinder Assembly cont d...

Page 11: ...on I D O rings 220 O ring 220 Back up ring Apply liberal amount of lubrication to all components prior to assembly O D O rings 227 O ring 227 back up ring Cylinder Assembly cont d Cylinder End Cap and...

Page 12: ...inder Assembly cont d Slide the piston into the cylinder lining it up with the rod wiper in the front of the tool Press the piston into the cylinder using a arbor press until it bottoms out Piston Cyl...

Page 13: ...13 Cylinder Assembly cont d With the piston in place put the end cap into the rear of the piston and apply pressure using a arbor press View of piston after insertion process completed...

Page 14: ...ly anti seize to the threads of the End Cap Screw the End Cap into the cylinder Torque the End Cap down to 250 lbs of torque View of piston after end cap insertion process completed Cylinder Assembly...

Page 15: ...15 Section 3 Limit Switch Housing Assembly...

Page 16: ...sembly cont d Mount the micro switch to the limit switch mounting plate using two 2 56 x 5 16 SHCS Place a 125 x 75 dowel pin and the actuator into place making sure the dowel pin is centered in the h...

Page 17: ...Switch Housing Assembly cont d Use a 8 32 x BHCS on each side of the housing to lock the dowel pin into place LC 022BC 02M Lee Spring 6 32 x SHCS Now with the spring and SHCS in place attach it to the...

Page 18: ...it Switch Housing Assembly cont d View of switch plate attached to the housing Now place the 8 32 X 7 8 lock down SHCS into the bottom of the housing and into the 8 32 nut and slightly tighten 8 SHCS...

Page 19: ...19 Limit Switch Housing Assembly cont d Now run the red and green wires through the housing as shown Using two 10 32 x 375 SHCS tighten the housing to the handle assembly...

Page 20: ...20 Limit Switch Housing Assembly cont d Solder the wires as shown in photo Red to common Green to Normally closed Cable tie the wires Put rear cover on the tool...

Page 21: ...21 Section 4 BTT20SF Cutter Nose Assembly...

Page 22: ...t d With the handle assembly complete place the limit switch rod into the hydraulic cylinder Limit switch assembly 1 Bronze sleeve 2 Washer 3 Retaining ring 4 Set screw is loctited into place at 420 o...

Page 23: ...e other end of the puller Place the puller into the end cap inside the cylinder and screw the puller until it bottoms out Then screw the jam nut down Using a torque wrench torque the jam nut down to 1...

Page 24: ...r of special vise grips and slide the spring onto the puller Then remove the vise grips The sleeve goes on next but you have to start a dowel pin 3 16 X 5 16 Long into the sleeve Note the photos BTT20...

Page 25: ...in using the vise grips and slide the sleeve onto the puller This is how the sleeve should look once on the puller Now using a arbor press push the dowel pin into the sleeve until it bottoms out BTT20...

Page 26: ...n should remain out side of the sleeve for now Now using the Arbor press once again push the sleeve down until it pops into place Once in place this is what it should look like almost flush with the p...

Page 27: ...ith the sleeve If not completely flush tap in with a hammer and punch Slide cutter anvil over sleeve to make sure there is no interference with dowel pin Remove cutter anvil Now you can screw the cutt...

Page 28: ...ocket set screws holding the Cutter anvil into the extension Place the cutter anvil into the extension and apply a small amount of force with an arbor press to install the cutter anvil Make sure there...

Page 29: ...29 Section 5 Installation Tool Nose Assembly...

Page 30: ...30 Installation Nose Assembly cont d...

Page 31: ...he limit switch rod into the end cap of the tool Screw the jam almost all the way through the puller and then screw the puller into the end cap of the tool left handed threads Installation Nose Assemb...

Page 32: ...grips 10LW from MSC close the puller enough to put the socket for the jam nut over the puller Once the socket is on the puller remove the vise grips and push the socket into the slots on the jam nut I...

Page 33: ...to 150 ft lbs counter clock wise Then remove the socket and torque wrench from the puller Now apply the pair of vise grips to the puller once again to place the anvil over top of the puller Remember...

Page 34: ...er wrench screw the anvil down until it bottoms out on the piston of the tool clock wise Once the anvil is in place you need to put the 3 set screws into the piston to lock the anvil into place Now yo...

Page 35: ...tool which is 6 8 O A L And the installation tool limit switch is 5 375 O A L First check to see what your limit switch is set at the specification for the limit switch for the cutter tool and install...

Page 36: ...he limit switch the LED light on the test box comes on when the circuit is made by inserting a fastener or other object depth micrometers into the puller of the tool making contact with the limit swit...

Page 37: ...Switch cont d The limit switch test box you can check the trigger switch and the limit switch to make sure they are adjusted and working properly Showing the test box connected to the tool by means of...

Page 38: ...o tighten down the lock screw for the final time Once the switch has been adjusted within the specification of 390 400 snug the lock down screw down Then check your reading once again to ensure the se...