940HS & 940-220HS (HK943).pdf

INSTRUCTION MANUAL
940HS & 940-220HS
POWERIG® HYDRAULIC UNITS
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
November 24, 2015
HK943
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
2
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
CONTENTS
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRINCIPLE
OF
PREPARATION
CHECKING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FOR
AND
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTING PRESSURES . . . . . . . . . . . . . . . . . . 11–12
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY DRAWING 940HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ASSEMBLY DRAWING 940-220HS . . . . . . . . . . . . . . . . . . . . . . . . 16
124465 PUMP, MOTOR, VALVE ASSEMBLY 940HS . . . . . . . . . . . . 17
112121 PUMP, MOTOR, VALVE ASSEMBLY 940-220HS. . . . . . . . . 18
124475 CONTROL PANEL ASSEMBLY 940HS . . . . . . . . . . . . . . . . 19
124467 ELECTRICAL ENCLOSURE ASSEMBLY 940HS . . . . . . . . . . . 20
122191 ELECTRICAL ENCLOSURE ASSEMBLY 940-220HS . . . . . . . 21
WIRING DIAGRAM & WIRE LIST. . . . . . . . . . . . . . . . . . . . . . . . 22–23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
KITS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SEAL KIT 124100, LOCATION
OF
RINGS . . . . . . . . . . . . . . . . . . . . 26
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ELECTRICAL SWITCH
AND
CONTROL CORD ASSEMBLY . . . . . . . . . . . 27
PRESSURE GAUGE T-124833CE . . . . . . . . . . . . . . . . . . . . . . . . . 28
3
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
SAFETY INSTRUCTIONS
16. There is possibility of forcible ejection of pintails or spent
mandrels from front of tool.
GLOSSARY OF TERMS AND SYMBOLS:
-
Product complies with requirements set forth by the
relevant European directives.
17. If there is a pinch point between trigger and work piece, use
remote trigger. (Remote triggers are available for all tooling.)
-
READ MANUAL prior to using this equipment.
18. Unsuitable postures may not allow counteracting of normal
expected movement of tool.
-
EYE PROTECTION IS REQUIRED while using this
equipment.
-
HEARING PROTECTION IS REQUIRED while using this
equipment.
19. 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.
WARNINGS: Must be understood to avoid
severe personal injury.
20. Never place hands between nose assembly and work piece.
Keep hands clear from front of tool.
21. There is a risk of crushing if tool is cycled without Nose
Assembly installed.
CAUTIONS: show conditions that will
damage equipment and or structure.
22. Tools with ejector rods should never be cycled with out nose
assembly installed.
N
t
i d
i d procedures.
d
Notes:
are reminders
off required
Bold, Italic type and underlining: emphasizes a specific instruction.
1.
2.
3.
23. When two piece lock bolts are being used always make sure the
collar orientation is correct. See fastener data sheet of correct
positioning.
A 30-minute hands-on training session with qualified personnel
is recommended before using Huck equipment.
24. Tool is only to be used as stated in this manual. Any other use
is prohibited.
Huck 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 qualified repairman trained on Huck
procedures.
25. There is a risk of whipping compressed air hose if tool is
pneudraulic or pneumatic.
26. Release the trigger in case of failure of air supply or hydraulic
supply.
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.
4.
Read MSDS Specifications before servicing the tool. MSDS
Specifications are available from the product manufacturer or
your Huck representative.
5.
When repairing or operating Huck installation equipment,
always wear approved eye protection. Where applicable, refer
to ANSI Z87.1 - 2003.
6.
Disconnect primary power source before performing
maintenance on Huck equipment or changing Nose Assembly.
7.
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.
8.
Mounting hardware should be checked at the beginning of each
shift/day.
9.
Make sure proper power source is used at all times.
27. Use only fluids or lubricants recommended.
28. Disposal instruction: Disassemble and recycle steel, aluminum
and plastic parts, and drain and dispose of hydraulic fluid in
accordance with local lawful and safe practices.
29. If tool is fixed to a suspension device, ensure that the device is
secure prior to operating the tool.
10. Release tool trigger if power supply is interrupted.
11. Tools are not to be used in an explosive environment unless
specifically designed to do so.
12. Never remove any safety guards or pintail deflectors.
13. Where applicable, ensure deflector or pintail collector is
installed and operating prior to use.
14. Never install a fastener in free air. Personal injury from fastener
ejecting may occur.
15. Where applicable, always clear spent pintail out of nose
assembly before installing the next fastener.
4
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
SPECIFICATIONS
WEIGHT
UNIT
WIDTH
LENGTH
HEIGHT
(without
hydraulic fluid)
940HS &
940-220HS
16.1 in.
(40.9 cm)
15.0 in.
(38.1 cm)
21.2 in.
(53.8 cm)
84.0 lbs.
(38.0 kg)
ELECTRICAL SYSTEM:
RESERVOIR CAPACITY: 2.6 gallons (9.8 litres)
• 940HS: 115 volts, 50/60 hertz, single phase, AC
MINIMUM OPERATING TEMPERATURE (ambient):
• 940-220HS: 220 volts, 50/60 hertz, single phase, AC
0º F (-18º C)
CONTROL SYSTEM: PLC operated, 24 volts
MAXIMUM HYDRAULIC FLUID TEMPERATURE:
MOTOR:
150º F (65º C)
• 940HS: 12,000 rpm, 1-1/8 hp, 20 amps. nominal
HYDRAULIC FLUID: Hydraulic fluid shall meet
DEXRON® III, DEXRON VI, MERCON®, Allison C-4
or equivalent Automatic Transmission Fluid (ATF)
specifications. Fire-resistant fluid may be used if it
is an ester-based fluid such as Quintolubric® HFD or
equivalent. Water-based fluid shall NOT be used as
serious damage to equipment will occur.
• 940-220HS: 12,000 rpm, 1-1/8 hp, 10 amps. nominal
PUMP: 2-stage, gear-piston type, 70cu. in/min. @ 5000
psi (1.1472 litres/min @ 344.75 bar) output pressure;
output pressure adjustable to 10,000 psi (689.5 bar)
ELECTRICAL SYSTEM:
• Snub:
1,150–1,350 psi (7,580–8,960 bar)
• Swage:
4,100–4,300 psi (28,300–29,600 bar)
• Return:
2,200–2,400 psi (15,200–16,500 bar)
• Pull:
4,500–4,700 psi (31,000–32,400 bar)
DEXRON is a registered trademark of General Motors Corp.
MERCON is a registered trademark of Ford Motor Corp.
Quintolubric is a registered trademark of Quaker Chemical Corp.
5
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
MAIN COMPONENTS
FIGURE 1
PUMP and
MOTOR
FOUR-WAY
DIRECTIONAL
VALVE
HIGH PRESSURE
RELIEF VALVE
FILL CAP /
DIPSTICK
SIDE PANEL
CONTROL PANEL
ELECTRICAL
ENCLOSURE
HYDRAULIC
COUPLERS
RESERVOIR
6
POWER CORD
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
ELECTRICAL SCHEMATICS
FIGURE 2A
FIGURE 2B
MODEL
940HS
MODEL
940-220HS
120 V, 50-60 Hz, SINGLE
220 V, 50-60 Hz, SINGLE
PHASE ELECTRICAL
PHASE ELECTRICAL
SCHEMATIC DIAGRAM FOR
SCHEMATIC DIAGRAM FOR
R
940HS POWERIG
L1
1
MC
T1
9
L3
12
MC
2
L2
4
1
T3
2
MC
5
MC
L1
L1
9
1
L3
SOL
5
2
8
MC
12
T2
MOT
MC
MC
T3
PS3
SOL
5
2
8
SNUB
PS2
PS1
LS2
LS2
14
LS1
14
LS1
13
13
12
12
11
HS TRIGGER
11
HS TRIGGER
10
10
9
15
15
1
2
3
4
5
6
2
PLC
9
1
1
204
205
1
17
CCW
CW
.1A
5
6
6
204
205
6
7
17
16
2
CCW
CW
.05A
1
J
1A
8
12VA
220V
2
8
12VA
24V
TRIGGER
6
CR
14
13
7
CR
14
590326 REV B
590338 REV C
7
2
2
6
TRIGGER
7
2
1
2
24V
4
2
120V
1A
3
18
203
6
7
16
2
PLC
18
203
6
2
MC
5
PS1
1
2
4
PS2
1
L2
2
3
CR
1
SNUB
T1
CR
1
PS3
G
L2
2
3
CR
1
T2
MOT
CR
1
1
G
L2
L1
R
940-220HS POWERIG
13
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
DESCRIPTION
Models 940HS and 940-220HS Powerig® hydraulic
power sources are portable, electrically-operated units
designed to operate all Huck hydraulic installation
equipment, including Huck-Spin® tools. (See Figure 1.)
•
The 940HS operates on 115 volt AC, 50–60 Hz,
one-phase electrical power. The power cord is type
SO 600 volt 12/3 with a 3-prong molded plug. The
940HS requires a 20-amp (minimum) circuit with a
common wall outlet.
•
The 940-220HS operates on 220 volt AC, 50–60 Hz,
one-phase electrical power. The power cord is type
SJTO 600 volt 14/3 with a 3-prong molded plug. The
940-220HS requires a 10-amp (minimum) circuit.
electric motor. Pressurized fluid is directed by a fourway directional valve to either the PULL or RETURN
port of the installation equipment.
The high pressure relief valve controls PULL pressure
(maximum pressure of the unit) and is adjustable by the
operator. An internal relief valve is pre-set at the factory
to protect the operator and the equipment. The internal
relief is not adjustable by the operator.
A set of three pressure switches controls RETURN,
SWAGE, and SNUB pressures on Huck-Spin tools. The
RETURN pressure switch turns off the Powerig at the
end of an installation cycle.
Pressures are adjustable to match Huck equipment
being used. See TABLE 1 for pressure settings
for Huck-Spin tools; see applicable tool instruction
manual for pressure settings for other Huck installation
equipment.
An electrical enclosure contains a motor contactor,
a transformer, a relay, a circuit breaker, and a
Programmable Logic Controller (PLC). (Figures 6A
and 6B) The installation equipment is connected to the
Powerig at the control panel. The side panel may be
removed with a screwdriver to access the pressure
switches
Hydraulic fluid is stored in the reservoir which also
serves as the base. Remove the filler cap/dipstick to
the check fluid level and to add fluid. Hydraulic quick
disconnect couplers are included for connecting hoses
from installation equipment.
Hydraulic pressure is developed by a two-stage, gearpiston pump driven by a 1-1/8 horsepower universal
8
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
PRINCIPLE
OF
See Figures 2A and 2B.
OPERATION
Snub-only Installation Cycle (Panel Switch set to
"Snub")
NON-HUCK-SPIN® TOOLS
Pressure Switch (PS) contacts are usually closed. When
the tool trigger switch is pressed, 24volts AC is applied
between relay terminals CR13 and CR14, activating the
relay coil and closing two sets of contacts: CR9–CR5
and CR12–CR8. Closing set CR9–CR5 starts the motor;
closing set CR12–CR8 activates the solenoid coil of the
pilot valve. The pilot valve shifts the directional valve
spools. Pressurized fluid is directed to the PULL port of
the tool.
When the tool trigger switch is released, the relay
contacts open. The solenoid coil is de-activated and the
spring return of the pilot valve shifts the directional valve
spools. Pressurized fluid is directed to the RETURN
port of the tool. The motor contactor is held closed until
the pre-set RETURN pressure is reached and pressure
switch 3 (PS3) contacts open. The motor turns off, the
pressure drops, and PS3 returns to the closed position.
HUCK-SPIN® TOOLS
Signals from the Huck-Spin tool (trigger, LS1, LS2)
and from pressure switches 1 and 2 (PS1 & PS2) are
processed by the Programmable Logic Controller (PLC)
to control operation of the Powerig and the tool. Output
205 of the PLC takes the place of the tool trigger switch
in the circuit described in the preceding section. Outputs
230 & 204 of the PLC control the air valve which, in
turn, controls the rotation of the air motor in the HuckSpin tool. The 940HS allows three fastener installation
cycles: swage, snub-only, and automatic-snub. The
swage cycle is used for standard operation. Snub-only
allows fasteners to be “snubbed-up” to remove gap in
fastened parts. (Fasteners installed in this cycle are not
permanently swaged and can be removed with hand
tools.) Automatic snub occurs during a swage cycle
when gap in fastened parts prevents proper thread
engagement. Fasteners are snubbed, then permanently
swaged.
Swage Installation Cycle (Panel Switch set to
"Swage")
The tool trigger is pressed. The air motor spins the
thimble clockwise (looking toward the fastener from
the tool). The thimble is the threaded part in the nose
assembly that engages the fastener. The thimble
engages the fastener threads. Limit Switch 2 (LS2)
closes when the fastener is engaged enough to allow
swaging. Hydraulic fluid is directed to the PULL port
of the tool. The tool pulls the fastener, swaging the
collar. PS2 senses when the fastener is fully swaged.
Hydraulic fluid is sent to the RETURN port of the tool.
The swaged collar is ejected from the anvil (the nose
assembly cavity that swages the collar). The thimble
spins counter-clockwise allowing the tool to come off the
fastener.
9
The tool trigger is pressed. The air motor spins the
thimble clockwise. The thimble partially engages the
fastener threads. LS1 closes when the fastener is
engaged enough to allow snubbing. Hydraulic fluid is
directed to the PULL port of the tool. The tool pulls
the fastener, removing any gap. PS1 senses when
the fastener is snubbed. Hydraulic fluid is sent to
the RETURN port of the tool. The partially swaged
collar is ejected from the anvil and the thimble spins
counterclockwise allowing the tool to come off the
fastener.
Automatic-snub Installation Cycle (Panel Switch set
to "Swage")
The tool trigger is pressed. The air motor spins the
thimble clockwise. The thimble partially engages the
fastener threads. Gaps in the fastened parts prevent full
engagement. LS1 closes when the fastener is engaged
enough to allow snubbing; LS2 remains open. A timer in
the PLC expires. Hydraulic fluid is directed to the PULL
port of the tool. The tool pulls the fastener, removing
the gap. PS1 senses when the fastener is snubbed.
Hydraulic fluid is sent to the RETURN port of the tool.
The partially swaged collar is ejected from the anvil.
The thimble spins on further, engaging enough thread to
allow a full swage. LS2 closes. Hydraulic fluid is directed
to the PULL port of the tool. The remainder of the
installation cycle is the same as for the normal cycle.
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
PREPARATION
FOR
USE
SERVICE
BEFORE USE
Foreign material in the hydraulic unit will result in poor
performance and down time for repair. To avoid this:
The Powerig is shipped without hydraulic fluid. Fill the
reservoir with hydraulic fluid—approximately 2.6 gallons
(9.8 litres)—until the fluid level is between the grooves
of the dipstick.
1. Clean around the filler cap before removing it.
2. Use a clean funnel with a filter.
Install a quick-disconnect nipple that is compatible with
your shop air supply in the 1/4 female NPT fitting on the
control panel.
3. Keep quick-disconnect couplers off the floor.
4. Wipe off quick-disconnect couplers before
connecting them.
TABLE 1 - PRESSURE SETTINGS FOR HUCK-SPIN® TOOLS
Huck-Spin
Fastener Size
Huck-Spin Tool
M12
1/2"
Pressure (psi)
PULL
RETURN
3750–3950
HS37
3850–4050
2200–2400
SNUB
SWAGE
925–1125
3400–3600
950–1150
3500–3700
M14
4500–4700
1150–1350
4100–4300
1/2"
2600–2800
650–850
2350–2550
M14
3100–3300
750–950
2800–3000
1150–1350
4100–4300
1450–1650
5100–5300
M16 & 5/8"
3/4"
HS52
4500–4700
2200–2400
5600–5800
M20
7250–7450
1885–2085
6600–6800
1"
8100–8300
2300–2500
7900–8100
NOTES
•
SWAGE pressures can be adjusted to compensate for collar hardness and lubricity. Set the PULL pressure to
approximately 110% of the SWAGE pressure. However, DO NOT EXCEED THE MAXIMUM PRESSURE RATING OF
THE INSTALLATION EQUIPMENT.
•
For non-Huck-Spin tools, set the PULL and RETURN pressures in accordance with the tool's manual. SNUB and
SWAGE pressure settings do not affect operation of non-Huck-Spin tools.
10
940HS & 940-220HS Powerig Hydraulic Units (HK943)
CHECKING
AND
Alcoa Fastening Systems & Rings
ADJUSTING PRESSURES
CHECKING PRESSURES
Use Huck Pressure Gauge (P/N T-124833CE, Figure
11) to check the PULL and RETURN pressures: before
each use, before troubleshooting, and after overhauling.
•
Use the pressure gauge ONLY as directed in its
instruction manual.
•
See each tool's instruction manual for the
recommended pressures that are specific to that
tool. See TABLE 1 for Huck-Spin tools.
To check the PULL and RETURN pressures:
1. Plug the 940HS into a 115 volt 20 amp wall outlet
OR the 940-220HS into a 220 volt 10 amp outlet.
2. Plug an auxiliary trigger (P/N 113056, Figure 10)
into the outlet on the Powerig.
3. Connect pressure gauge T-124833CE to the
hydraulic quick-disconnects.
4. Move the pressure gauge lever to the middle (open)
position.
5. Press and hold the auxiliary trigger to start the
Powerig. The motor will start, and hydraulic fluid will
be directed to the PULL pressure port of the tool.
CAUTION: This check must be completed
quickly because the Powerig's components
should not be subjected to sustained high
pressure.
6.
7.
8.
9.
Move the lever to the PULL position.
Read the PULL pressure on the gauge.
Move the lever to the OPEN position.
Release the tool trigger. Hydraulic fluid is directed to
the RETURN pressure port of the tool.
10. Slowly move the lever to the RETURN position.
11. Read the maximum pressure on the gauge (just
before it turns off). This is the RETURN pressure.
12. Disconnect the electrical power to reset the PLC
memory.
10. Stop moving the lever when light #5 on the PLC (in
the electrical enclosure) turns off.
11. Read the pressure on the gauge; this is the SWAGE
pressure.
12. Move the lever to RETURN to stop the unit.
13. Close the electrical enclosure.
14. Disconnect the electrical power to reset the PLC
memory.
15. Remove the pressure gauge.
ADJUSTING PRESSURES
Use Huck pressure gauge T-124833CE—ONLY as
directed in its manual—to aid in adjusting the PULL and
RETURN pressures. See each tool's instruction manual
for the recommended pressures that are specific to that
tool. See TABLE 1 for Huck-Spin tools.
To adjust the PULL pressure:
NOTE: The PULL pressure is the maximum Powerig
pressure. Do NOT exceed the pressure rating of
the installation equipment; see each tool-specific
manual for pressure ratings.
WARNING: If the recommended maximum
pressure is exceeded, violent failure of
the fastening system may occur. Severe
personal injury and damage to the tool
(such as premature wear) may result.
1. Loosen the jam nut of the high pressure relief valve.
2. Turn the adjusting screw:
• clockwise to increase the pressure
• counterclockwise to decrease the pressure.
3. Tighten the jam nut.
4. Use Huck pressure gauge T-124833CE to check
the PULL pressure (as instructed in the previous
section).
5. Disconnect the electrical power to reset the PLC
memory.
CHECKING SNUB AND SWAGE PRESSURES
1. Open the electrical enclosure.
WARNING: Do NOT insert anything into the
electrical enclosure; electrical shock may
cause severe injury.
2. Press and hold the auxiliary trigger.
3. Slowly move the pressure gauge lever toward the
PULL side.
4. Stop moving the lever when light #4 on the PLC (in
the electrical enclosure) turns off.
5. Read the pressure on the gauge; this is the SNUB
pressure.
6. Move the lever to RETURN to stop the unit.
7. Move the lever to OPEN.
8. Press and hold the auxiliary trigger.
9. Slowly move the lever toward the PULL side.
11
continued...
940HS & 940-220HS Powerig Hydraulic Units (HK943)
CHECKING
AND
Alcoa Fastening Systems & Rings
ADJUSTING PRESSURES (CONTINUED)
To adjust the RETURN pressure:
1. Remove the side panel with a screwdriver to access
the pressure switches.
7. Loosen the jam nut on pressure switch 1 (the
uppermost switch).
8. Turn the adjusting screw on pressure switch 1:
- clockwise to increase SNUB pressure
- counterclockwise to decrease SNUB pressure.
2. Loosen the jam nut on pressure switch 3 (the lowest
switch).
3. Turn the adjusting screw:
- clockwise to increase RETURN pressure
- counterclockwise to decrease RETURN
pressure.
9. Tighten the jam nut on pressure switch 1.
10. Check the SNUB pressure following the instructions
in the appropriate section of this manual.
11. Replace the side panel.
4. Tighten the jam nut on pressure switch 3.
12. Disconnect the electrical power to reset the PLC
memory.
5. Check the RETURN pressure following instructions
in the appropriate section of this manual.
6. Replace the side panel.
7. Disconnect the electrical power to reset the PLC
memory.
ADJUSTING SNUB AND SWAGE PRESSURES
Swage pressure is the maximum PULL pressure for
Huck-Spin® tools. Do not exceed the pressure rating of
the installation tool. See each tool's instruction manual
for its recommended pressure settings.
WARNING: If the recommended maximum
pressure is exceeded, violent failure of
the fastening system may occur. Severe
personal injury and damage to the tool
(such as premature wear) may result.
1. Open the electrical enclosure.
WARNING: Do NOT insert anything into the
electrical enclosure; electrical shock may
cause severe injury.
2 Remove the side panel with a screwdriver to access
2.
the pressure switches.
3. Loosen the jam nut on pressure switch 2 (the middle
switch).
4. Turn the adjusting screw on pressure switch 2:
- clockwise to increase SWAGE pressure
- counterclockwise to decrease SWAGE
pressure.
5. Tighten the jam nut on pressure switch 2.
6. Check the SWAGE pressure following the
instructions in the appropriate section of this
manual.
12
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
OPERATING INSTRUCTIONS
BEFORE EACH USE OF THE POWERIG®
HYDRAULIC UNIT
1. Check the hydraulic fluid level in the reservoir; add
fluid as necessary.
2. Inspect hoses for damage and wear. If a hose
has wear that has removed more than the surface
texture, do NOT use; replace.
3. Check the entire system for leaks; repair as
necessary.
4. Check electrical cord and extension for abrasion;
replace as necessary.
OPERATING HUCK-SPIN® TOOLS
1. Plug the power cord into a grounded wall outlet.
NOTE: If an extension cord is used, make sure it is
UL type SO or STO, 600 volt, and
- 12/3 (25' long)
- 10/3 (50' long)
2. Check pressures and adjust as necessary. See
CHECKING AND ADJUSTING PRESSURES in this manual.
WARNINGS must be understood before checking
pressures.
3. Connect a Huck-Spin tool to the Powerig hydraulic
power source using a hose kit. See TABLE 3 for
hose kit part numbers.
Be sure that:
- The hose from the PULL PRESSURE on the control
panel runs to the port stamped with "P" on the tool.
- The hose from RETURN PRESSURE on the control
panel runs to the port stamped with "R" on the tool.
collar. Snubbed fasteners can be removed with
hand tools.
- Attach a nose assembly to the tool.
- Fasteners can now be installed. Follow the
instructions in the tool manual.
OPERATING OTHER TOOLS
1. Plug the power cord into a grounded wall outlet.
NOTE: If an extension cord is used, make sure it is
UL type SO or STO, 600 volt, and
- 12/3 (25' long)
- 10/3 (50' long)
2. Check pressures and adjust as necessary. See
CHECKING AND ADJUSTING PRESSURES in this manual.
WARNINGS must be understood before checking
pressures.
3. Connect a Huck hydraulic tool to the Powerig
hydraulic power source using a hose kit. See
TABLE 3 for hose kit part numbers.
Be sure that:
- The hose from the PULL PRESSURE on the control
panel runs to the port stamped with "P" on the tool.
- The hose from RETURN PRESSURE on the control
panel runs to the port stamped with "R" on the tool.
- Plug the control cable from the tool into the two-prong
socket on the Powerig control panel.
- The two air fittings on the Powerig control panel are
not used.
- Plug the control cable from the tool into the 8-pin
socket on the control panel.
- The snub switch on the control panel has no effect
on the operation of installation equipment other than
Huck-Spin tools.
- The two-prong socket is not used with Huck-Spin
tools.
- Only Huck-Spin tools require an air suppiy.
WARNING: Do NOT use an auxiliary trigger
to operate Huck-Spin tools. An auxiliary
trigger will cause the tool piston to move
with or without a fastener in the nose
assembly.
- P
Push
h th
the ttwo air
i lilines ffrom th
the ttooll iinto
t the
th air
i fifitti
ttings
on the control panel. If the air motor rotates in the
wrong direction, swap the air hoses in the air fittings.
- To remove the air lines from the Powerig, push the
collar on the air fitting while pulling on the air line.
- Connect an air supply hose to the nipple on the
control panel; use 90–100 psi (6.2–6.9 bar) air
pressure.
- Set the snub switch on the control panel to either
Snub or Swage.
- Use Swage for normal operation.
- Use Snub for “snubbing up” fasteners to remove
any gap in fastened parts without swaging the
13
- The 8-pin connector on the control panel is used with
Huck-Spin tools only.
- Press the tool trigger switch and let the Powerig
operate for a few minutes to circulate fluid and remove
air from the system.
- Attach a nose assembly to the tool.
- Fasteners can now be installed. Follow the
instructions in the tool manual.
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
MAINTENANCE
PARTS LIST
See the ASSEMBLY DRAWINGS for part numbers.
DIRECTIONAL VALVE OVERHAUL
If minor overhaul of the directional valve (cleaning and
replacing O-rings and back-up rings) is necessary, Seal
Kit 124100 (Figure 8) is available. If a major overhaul
is necessary, return the directional valve to the nearest
repair facility listed on the inside of the back cover.
WIRING
See Figure 7 for the wiring diagram and TABLE 2 for
the wire list.
WARNING: Only a qualified electrician is to
install the power cable, according to local
electrical codes, and service the electrical
control and disconnect panel.
Clean components in mineral spirits. Smear LUBRIPLATE®
130-AA (Huck P/N 502723), or equivalent, on O-rings and
mating surfaces to aid assembly and prevent damage to
O-rings. LUBRIPLATE is available in most localities.
ALWAYS DISCONNECT PRIMARY POWER
SOURCE FROM HYDRAULIC UNIT
BEFORE PERFORMING MAINTENANCE.
This includes opening panels and access
doors. SEVERE ELECTRICAL BURNS OR
ELECTROCUTION COULD RESULT IF THIS
PRECAUTION IS IGNORED.
REPLACING PUMP TO MOTOR COUPLING
The pump to motor coupling can be replaced by
removing the four socket cap screws holding the motor
housing to the cover plate and lifting the motor to one
side. Lift out the original coupling with needle-nose
pliers. Drop in the new coupling, align the slots, and
reassemble motor to cover plate.
PUMP OVERHAUL
If the pump requires an overhaul, return it (or the
complete unit) to the nearest repair facility listed on the
inside of the back cover.
PREVENTIVE MAINTENANCE
An effective preventive maintenance program includes
scheduled inspections to detect and correct minor
troubles. Perform the following steps monthly during
normal use:
INTERNAL ADJUSTMENT OF PRESSURE SWITCH
See Figure 9.
1. Remove the top cover of the switch.
2. Loosen the two screws in the bottom of the switch
housing.
3. Place a 0.20-inch-thick shim between the spring
retainer and the platen.
4. Loosen the set screw on the spring retainer until it
contacts the shim.
5. Lock the spring retainer in place with the set screw.
6. Slide the switch mounting bracket toward the switch
button until it contacts the platen surface.
7. Secure with the two screws located in the middle of
the bottom cover.
8. Connect a volt/ohm meter to the electrical cord.
9. Tighten the switch adjustment screw against the
switch mounting bracket until the switch button
contacts the platen and actuates. The volt/ohm
meter will react when the button actuates. A click
can be heard.
10. Continue tightening the switch adjustment screw 1/8
of a turn after the switch button actuates.
11. Replace the top cover of the switch.
- Inspect hydraulic and electrical fittings to be sure they
are secure.
- Inspect hoses for signs of damage. Replace hoses if
abrasion is deeper than the surface texture.
- Rotate hoses end-for-end to equalize wear and
fatigue.
- Inspect during operation to detect any abnormal
heating, vibration, or leakage.
- Inspect hydraulic fluid. If contamination (particles,
water, sludge, etc.) is detected, clean the reservoir
and replace the fluid.
- Clean exterior surfaces.
- Check the supply voltage. Do not operate the
Powerig® if the line voltage is more than 5 percent
above or below the rated voltage (115 volts for the
940HS; 220 volts for the 940-220HS).
SPARE PARTS
The quantity of spare parts that should be kept on hand
varies with the application and number of the Powerig
units in service. For directional valve and pilot valve
maintenance, Seal Kit 124100 (Figure 8) should be kept
on hand at all times. This kit contains O-rings and backup rings required to service one directional valve and one
pilot valve. Other parts that should be available to the
service technician are: Pump to Motor Coupling, Relay,
Transformer, Pilot Valve, and Motor Brushes.
LUBRIPLATE is a registered trademarked of Fiske Brothers Refining Co.
14
15
13
15
14
23
PRESSURE
RETURN
CAUTION
PRESSURE
PULL
CAUTION
(CW)
37, 11
Note 4
35
4, 5, 10,
17, 18
Note 4
1
PUSH IN FOR
SNUB ONLY
(CCW)
90 PSI
SHOP AIR
SUPPLY
CAUTION
34
Note 4
7, 26
Note 4
See
Detail "B"
6, 25
Red Mark
on Top
0.1
V AC
29
Notes 5 & 8
9
Note 4
12
8, 30
2, 22, 28
Note 7
See
Detail "A"
32
R
CYCLES
H.P.
PHASE
HUCK P/N 590299 REV B
VOLTS
SERIAL NUMBER
HUCK INTERNATIONAL INC.
INSTALLATION SYSTEMS DIVISION
1 CORPORATE DRIVE
KINGSTON N.Y. 12401
MODEL NUMBER
POWERIG HYDRAULIC UNIT
AMPS
WARNING
Power
Cord
Ground
Wire
3
DISCONNECT POWER BEFORE
OPENING. CLOSE COVER PRIOR
TO RESTORING POWER
Note 6
31
PLC
Ground
Wire
Detail "A"
16
Detail B
33
(.380)
(1.045)
2.140
2.040
Note 1
5, 27
Power Cord
PART NO.
124465
124467
107316
111351
506360
124473
124475
124484
124735
500063
590056
590067
590132
590133
590181
500811
502366
505142
501214
590328
124468
500076
507262
505704
123432
501214
500073
502778
500553
500214
590346
590295
504239
DESCRIPTION
QTY
Pump, Motor & Valve Assembly
1
Electrical Enclosure Assembly
1
Dipstick
1
Pilot Valve
1
Strain Relief
2
Manifold Assembly
1
Control Panel Assembly
1
Base Panel
1
Wiring Assembly
1
Socket-head Cap Scr 10-24X3/4
4
Notice Tag
1
Huck Decal
2
Pull Pressure Sticker
1
Return Pressure Sticker
1
Caution Sticker
1
O-ring
1
Locknut 1/2
2
Bullet Plug
2
Socket Hd Scr 10-24x3/8 (Note 7) 3
Pressure Settings Tag
1
Wiring Diagram (Note 4)
1
Socket Hd Cap Scr 1/4-20x1-3/4
2
Truss Screw 6-32x1/4
5
Ring Terminal (Note 1)
2
Motor Gasket
1
Socket Hd Scr 10-24x3/8 (Note 8) 2
Socket Hd Cap Screw 1/4-20x1
3
Machine Screw 10-24x5/8
1
Lock Washer, ext. teeth, #10
2
Hex Nut 10-24
1
Air Supply Sticker
1
Huck-Spin Sticker
1
Nylon Cable Tie
1
Also included in this assembly, but not shown, are:
Carton 590271, Carton Insert 590292, and Instruction
Manuals HK959 and HK943 (this instruction manual).
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
NOTES
1.) Use Terminal 505704 on power cord wires L1 &
L2.
2.) Test and inspect to Huck Specification 42-513.
3.) Product assembled and tested according to
applicable drawings. Bill of material and Huck
Specification meet National Electrical Code, 1993.
4.) Wire according to wiring diagram 124468.
5.) Install Item 8 between motor and brush cover as
shown.
6.) Attach ground wires as shown.
7.) Fastener is prevailing torque type. Do not re-use
fastener. Torque to 90 in-lbs.
8.) Fastener is prevailing torque type. Do not re-use
fastener. Torque to 106 in-lbs.
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
940HS
FIGURE 3A
16
13
15
14
23
PRESSURE
RETURN
CAUTION
PRESSURE
PULL
CAUTION
(CW)
37, 11
Note 4
35
4, 5, 10,
17, 18
Note 4
1
(CCW)
90 PSI
SHOP AIR
SUPPLY
CAUTION
34
Note 4
7, 26
SNUB ONLY
SWAGE
Note 4
See
Detail "B"
6, 25
Red Mark
on Top
0.1
V AC
29
Notes 5 & 8
9
Note 4
12
8, 30
2, 22, 28
Note 7
See
Detail "A"
32
R
CYCLES
H.P.
PHASE
HUCK P/N 590299 REV B
VOLTS
SERIAL NUMBER
HUCK INTERNATIONAL INC.
INSTALLATION SYSTEMS DIVISION
1 CORPORATE DRIVE
KINGSTON N.Y. 12401
MODEL NUMBER
POWERIG HYDRAULIC UNIT
AMPS
WARNING
Power
Cord
Ground
Wire
3
DISCONNECT POWER BEFORE
OPENING. CLOSE COVER PRIOR
TO RESTORING POWER
Note 6
31
PLC
Ground
Wire
Detail "A"
16
Detail B
33
(.380)
(1.045)
2.140
2.040
PART NO.
124472
122191
107316
111351
506360
124473
122193
124484
124735
500063
590056
590067
590132
590133
590181
500811
502366
505142
501214
590328
124468
500076
507262
505704
123432
501214
500073
502778
500553
500214
590346
590295
504239
DESCRIPTION
QTY
Pump, Motor & Valve Assembly
1
Electrical Enclosure Assembly
1
Dipstick
1
Pilot Valve
1
Strain Relief
2
Manifold Assembly
1
Control Panel Assembly
1
Base Panel
1
Wiring Assembly
1
Socket-head Cap Scr 10-24X3/4
4
Notice Tag
1
Huck Decal
2
Pull Pressure Sticker
1
Return Pressure Sticker
1
Caution Sticker
1
O-ring
1
Locknut 1/2
2
Bullet Plug
2
Socket Hd Scr 10-24x3/8 (Note 7) 3
Pressure Settings Tag
1
Wiring Diagram (Note 4)
1
Socket Hd Cap Scr 1/4-20x1-3/4
2
Truss Screw 6-32x1/4
5
Ring Terminal (Note 1)
2
Motor Gasket
1
Socket Hd Scr 10-24x3/8 (Note 8) 2
Socket Hd Cap Screw 1/4-20x1
3
Machine Screw 10-24x5/8
1
Lock Washer, ext. teeth, #10
2
Hex Nut 10-24
1
Air Supply Sticker
1
Huck-Spin Sticker
1
Nylon Cable Tie
1
Also included in this assembly, but not shown, are:
Carton 590271, Carton Insert 590292, and Instruction
Manuals HK959 and HK943 (this instruction manual).
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
5, 27
22
Power Cord 23
Note 1
24
25
26
27
28
29
30
31
32
33
34
35
37
NOTES
1.) Use Terminal 505704 on power cord wires L1 &
L2.
2.) Test and inspect to Huck Specification 42-513.
3.) Product assembled and tested according
to applicable drawings. Bill of material and Huck
Specification meet National Electrical Code, 1993.
4.) Wire according to wiring diagram 124468.
5.) Install Item 8 between motor and brush cover as
shown.
6.) Attach ground wires as shown.
7.) Fastener is prevailing torque type. Do not re-use
fastener. Torque to 90 in-lbs.
8.) Fastener is prevailing torque type. Do not re-use
fastener. Torque to 106 in-lbs.
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
940-220HS
FIGURE 3B
22
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
PART NO.
103596
124483
103900
103901
103903
103904
103918
106397
107217
111189
111346
111347
111355
111357
111364
111365
111366
17
DESCRIPTION
Directional Valve
Gland Assembly
Check Valve
Relief Valve
Accumulator
Return Line
Pump Motor Coupling
External Relief Valve
Adapter Union
Reservoir
Motor 1-1/8 HP 115V
Pump Assembly
Filter Assembly
Cover Plate Gasket
Cover Plate
Motor Base
Pilot Line Assembly
8
31
30
QTY.
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7, 11
17, 29
23
1
16
15
26
27
10
5
12
25 18
14
6
ITEM
PART NO.
DESCRIPTION
QTY.
19
111367
Pump Line Assembly
1
20
111368
Relief Line Assembly
1
21
124325
Power Cord & Plug Assembly
1
22
107317
Filler/Breather Cap
1
23
500067
Socket Hd Cap Scr 10-24x1-1/2
4
24
503165
Back-up Ring
1
25
504157
Connector
2
26
504158
Elbow
1
27
504161
Nipple
1
28
504408
O-ring
1
29
504743
Machine Screw 10-24x2
4
30
500071
Socket Hd Cap Scr 1/4-20x3/4
10
31
112625
Pilot Valve Adapter Plate
1
NOTE
This assembly is purchased complete. The bill of materials listed is for
reference and replacement part purposes only.
21
2
9, 24, 28
20
3
4
19
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
124465 PUMP, MOTOR, VALVE ASSEMBLY 940HS
FIGURE 4A
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
19
PART NO.
103596
103599
103900
103901
103903
103904
103918
106397
107217
111189
112117
111347
115753
111357
111364
111365
111366
111367
8
21
22
31
DESCRIPTION
Directional Valve
Manifold
Check Valve
Relief Valve
Accumulator
Return Line
Pump Motor Coupling
External Relief Valve
Adapter Union
Reservoir
Motor 1-1/8 HP 220V
Pump Assembly
Pressure Switch Assembly
Cover Plate Gasket
Cover Plate
Motor Base
Pilot Line Assembly
Pump Line Assembly
30
18
QTY.
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7, 11
16
15
1
26
10
27 5
9, 24, 28
12
14
25 18
ITEM
PART NO.
DESCRIPTION
QTY.
20
111368
Relief Line Assembly
1
21
112630
Power Cord for 220v AC 940 Rig
1
22
111371
Strain Relief
1
23
500067
Socket Hd Cap Scr 10-24x1-1/2
4
24
503165
Back-up Ring
1
25
504157
Connector
2
26
504158
Elbow
1
27
504161
Nipple
1
28
504408
O-ring
1
29
504743
Machine Screw 10-24x2
4
30
500071
Socket Hd Cap Scr 1/4-20x3/4
10
31
112625
Pilot Valve Adapter Plate
1
32
107317
Cap-Filler Breather
1
NOTE
This assembly is purchased complete. The bill of materials listed is
for reference and replacement part purposes only.
17, 29
23
2
6
20
3
4
19
FIGURE 4B
32
13
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
112121 PUMP, MOTOR, VALVE ASSEMBLY 940-220HS
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
124475 CONTROL PANEL ASSEMBLY 940HS
FIGURE 5
ITEM
PART NO.
DESCRIPTION
1
124485
Panel Control
1
2
124474
Air Valve Assembly
1
3
110685
Base Female
1
4
590327
Sticker, Snub - Swage
1
5
130688
Push Button ASM, 16mm MNT, GRN
1
6
500008
Screw, Hex Head 1/4-20 x 1 3/4
2
7
500559
Nut, Self-lock 1/4-20
2
8
500398
Screw, Round Head Machine #6-32 x 1/4
2
19
QTY.
28
0.1
115V AC
7
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
12, 26,
17, 23
6
25
8, 15
21, 22
9
18
20
PART NO.
506362
590299
124628
506365
506366
506363
124477
507293
124466
124629
506368
507042
121487
505412
500261
500730
507049
506033
PIN 28
1, 16
DESCRIPTION
Contactor
Warning Sticker (Disconnect Pwr)
Window
Relay Socket
Relay
Circuit Breaker .1 AMP
Electrical Enclosure
Transformer
Enclosure Panel
Window Gasket
Enclosure Gasket, 2.25’
28-PIN Bulkhead Connector
Terminal Block 12 PLCS
Machine Screw 02-56 x .69
Pan Head Screw 8-32 x .38
Machine Screw 10-32 x .38
Cable Clamp
Socket Head Cap Screw 10-32x.25
4, 5, 15,
19, 20
13, 14
15
12
L3
9
L1
T1
LS1
PS1
6
.1A
6
1A
PLC
1
3
HS TRIGGER
8
T3
5
MC
MC
CR
CR
2
24V
10
T2
R
L2
CW
14
13
2
2
2
6
7
2
18
2
27
8
2
2
2
L2
G
11
24
1
WARNING
R
VOLTS
PHASE
H.P.
CYCLES
SERIAL NUMBER
HUCK INTERNATIONAL INC.
INSTALLATION SYSTEMS DIVISION
1 CORPORATE DRIVE
KINGSTON N. Y. 12401
MODEL NUMBER
POWERIG HYDRAULIC UNIT
AMPS
HUCK P/N 590299 REV B
DISCONNECT POWER BEFORE
OPENING. CLOSE COVER PRIOR
TO RESTORING POWER
ITEM
PART NO. DESCRIPTION
QTY.
19
506393
Hold Down Spring, Relay
1
20
500262
Pan Head Screw 8-32 x .50
1
21
127154
PLC, Programmed
1
22
500049
Socket Head Cap Screw 6-32 x .50
4
23
507044
Plug, 28-PIN Std Numbering
1
24
590012
Nameplate
1
25
590131
Sticker, 115 VAC
1
26
500398
Machine Screw 6-32 x .25
4
27
590326
Sticker, Electrical Schematic
1
28
590119
Sticker, Class 2 Circuit 30V
1
29
500212
Hex Nut 6-32
4
30
124482
Wire Harness
1
31
500402
Machine Screw 6-32 x .50
4
33
124468
Wiring Diagram / Schematic
1
NOTES
1) Punch Gasket .17-.35 Dia. in way of PEM Fastener.
2) Wire according to Wiring Diagram 124468.
CR
CCW
6
14
MC
205
13
5
SOL
12VA
12
4
7
17
204
120V
3
11
4
MC
SNUB
PS3
PS2
TRIGGER
16
203
9
LS2
5
MOT
940HS POWERIG
SCHEMATIC DIAGRAM FOR
PHASE ELECTRICAL
120 V, 50-60 Hz, SINGLE
QTY.
1
2
1
1
1
1
1
1
1
1
1
1
1
2
3
4
1
4
590326 REV B
1
1
1
1
1
1
1
L1
2
31
3, 10
29
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
124467 ELECTRICAL ENCLOSURE ASSEMBLY 940HS
FIGURE 6A
28
0.05
220V AC
21
7
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
12, 26,
17, 23
6
25
8, 15
21, 22
9
18
6
5
PIN 28
7
PART NO.
506627
590299
124628
506365
506366
506530
124477
507194
124466
124629
506368
507042
121487
505412
500261
500730
507049
506033
8
4, 5, 15,
19, 20
1, 16
DESCRIPTION
Contactor
Warning Sticker (Disconnect Pwr)
Window
Relay Socket
Relay
Circuit Breaker .05 AMP
Electrical Enclosure
Transformer
Enclosure Panel
Window Gasket
Enclosure Gasket, 2.25’
28-PIN Bulkhead Connector
Terminal Block 12 PLCS
Machine Screw 02-56 x .69
Pan Head Screw 8-32 x .38
Machine Screw 10-32 x .38
Cable Clamp
Socket Head Cap Screw 10-32x.25
HUCK P/N: 127154
PROGRAM REVISION-*
13, 14
15
12
L3
9
L1
8
LS1
PS1
6
.05A
1
6
1A
PLC
HS TRIGGER
CR
T3
3
2
10
TRIGGER
T2
3
J
4
12
14
14
2
2
2
2
2
6
7
2
18
2
27
8
2
CCW
6
13
205
CR
CW
5
13
MC
L2
G
11
24
1
WARNING
R
VOLTS
PHASE
H.P.
CYCLES
SERIAL NUMBER
QTY.
1
1
1
4
1
1
1
4
1
1
4
1
4
1
HUCK INTERNATIONAL INC.
INSTALLATION SYSTEMS DIVISION
1 CORPORATE DRIVE
KINGSTON N. Y. 12401
MODEL NUMBER
POWERIG HYDRAULIC UNIT
AMPS
HUCK P/N 590299 REV B
DISCONNECT POWER BEFORE
OPENING. CLOSE COVER PRIOR
TO RESTORING POWER
ITEM
PART NO.
DESCRIPTION
19
506393
Hold Down Spring, Relay
20
500262
Pan Head Screw 8-32 x .50
21
127154
PLC, Programmed
22
500049
Socket Head Cap Screw 6-32 x .50
23
507044
Plug, 28-PIN Std Numbering
24
590012
Nameplate
25
590221
Sticker, 220 VAC
26
500398
Machine Screw 6-32 x .25
27
590338
Sticker, Electrical Schematic
28
590119
Sticker, Class 2 Circuit 30V
29
500212
Hex Nut 6-32
30
125219
Wire Harness
31
500402
Machine Screw 6-32 x .50
33
122192
Wiring Diagram / Schematic
NOTES
1) Punch Gasket .17-.35 Dia. in way of PEM Fastener.
2) Wire according to Wiring Diagram 122192.
7
24V
L2
R
SOL
220V
17
204
11
4
MC
SNUB
PS3
PS2
12VA
16
203
9
LS2
5
MOT
940-220HS POWERIG
SCHEMATIC DIAGRAM FOR
PHASE ELECTRICAL
220 V, 50-60 Hz, SINGLE
T1
5
MC
MC
CR
QTY.
1
2
1
1
1
1
1
1
1
1
1
1
1
2
3
4
1
4
590338 REV C
1
1
1
1
1
1
1
L1
2
31
3, 10
29
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
122191 ELECTRICAL ENCLOSURE ASSEMBLY 940-220HS
FIGURE 6B
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
WIRING DIAGRAM
FIGURE 7
22
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
WIRE LIST
TABLE 2 - WIRE LIST
Wire Number
Color
From
To
1A
Red
transformer line
circuit breaker
1
Red
CR 12
CR 9
1
Red
circuit breaker
MC L3
1
Red
MC L1
MC L3
1
Red
MC L3
CR 9
1
Red
MC L1
PLC 204A
1
Red
PLC 203A
PLC 204A
1
Red
PLC L1
PLC 203A
2
White
MC L2
transformer line
2
White
MC terminal
MC L2
2
White
PLC L2
terminal block 23
2
White
MC L2
terminal block 12
2
White
terminal block 9
terminal block 10
2
White
terminal block 10
terminal block 11
2
White
terminal block 11
terminal block 12
3
Red
MC T3
CR 5
6
Blue
transformer load
PLC 205B
7
Blue
PLC 205A
CR 14
8
Blue
transformer load
CR 13
15
Blue
PLC common
terminal block 13
15
White
terminal block 13
terminal block 14
15
White
terminal block 15
terminal block 16
15
White
terminal block 14
terminal block 15
18
Green
ground
PLC ground
23
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
TROUBLESHOOTING
Always check the simplest possible cause (such as a blown fuse, tripped circuit breaker, defective switch or control
cord) 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. A qualified electrician should examine
the electrical system. Use this section as an aid in locating trouble and correcting it. Use this Troubleshooting
information to aid in locating and correcting trouble.
4. Tool will not return when switch is released,
or will not push nose assembly off swaged
fastener.
a) RETURN pressure set too low.
b) Hoses not properly coupled.
c) Worn or defective solenoid.
d) Worn or defective pilot valve.
1. Motor fails when tool switch is pressed.
a) Loose or defective control cord or connectors.
b) Power source not properly fused.
c) Defective tool switch.
d) Loose wire(s).
e) Defective relay.
f) Incorrect power source.
g) Defective motor contactor.
h) Defective transformer.
5. Motor fails to shut-off when installation cycle is
completed.
a) RETURN pressure switch set too high.
b) Hydraulic fluid viscosity not proper or level is
low.
c) Hydraulic fluid overheated.
d) Defective limit switch in pressure switch
assembly.
2. Motor runs, but tool will not reciprocate.
a) Hoses not properly coupled.
b) Hydraulic fluid viscosity not proper or level is
low.
c) Defective pilot valve solenoid or coil.
d) Unloading valve missing in tool.
e) Bind in tool or nose assembly.
f) Defective directional valve.
g) Pump to motor coupling damaged.
6. Pump making noise throughout entire cycle.
a) Pump is cavitating; fluid level too low or fluid
viscosity too heavy.
b) Strainer is dirty and clogged.
3. Pintail of fastener fails to break off.
a) PULL pressure set too low.
b) Worn or defective hose couplers.
c) Hydraulic fluid viscosity not proper or level is
low.
d) Hydraulic fluid overheated.
e) Worn or defective directional valve.
f) Internal relief valve set too low or defective.
g) Worn or defective pump.
7. Tool operation slow; entire cycle does occur.
a) Pump is cavitating; fluid level too low or fluid
viscosity too heavy.
b) Strainer is dirty and clogged.
c) Worn or defective directional valve.
d) Worn or damaged pump.
e) Worn or defective hydraulic couplers.
8. Huck-Spin® tool does not spin onto fastener.
a) Air motor is spinning in the wrong direction
because the air hoses are reversed; swap
hoses at control panel.
24
940HS & 940-220HS Powerig Hydraulic Units (HK943)
KITS
Alcoa Fastening Systems & Rings
ACCESSORIES
&
KITS
HOSE AND CONTROL CORD KITS
Kits are available with hoses of various lengths (12' to
52') as shown in TABLE 3.
TABLE 3 - HOSE AND CONTROL CORD KITS
ACCESSORIES
AUXILIARY SWITCH AND CONTROL CORD - 113056
An auxiliary switch for use when checking and adjusting
pressures, and troubleshooting; see Figure 10.
PRESSURE GAUGE - T-124833CE
Recommended for use when checking and adjusting
pressures, and when troubleshooting; see Figure 11.
Huck Part No.
Length
(feet)
Huck-Spin® Tools
Other Tools
12
26
38
52
124463-12
124463-26
124463-38
124463-52
118309-12
118309-26, 111955*
118309-38
118309-52, 112176*
* For use in severe conditions and in a welding environment.
SERVICE NOTES
25
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
SEAL KIT 124100, LOCATION
FIGURE 8
OF
RINGS
DIRECTIONAL VALVE
3,/279$/9(
$'$37(53/$7(
SHOWING
O-RINGS
',5(&7,21$/
9$/9(
35(6685(
6:,7&+
COMPONENT
Directional Valve
Pilot Valve
Pressure Switch
ITEM
PART NO. DESCRIPTION
QTY.
1
501084
Back-up Ring Shamban S-11248-012
8
2
501087
Back-up Ring Shamban S-11248-015
8
3
501088
Back-up Ring Shamban S-11248-016
4
4
504404
O-ring AS568-008 Parker V747 75D
13
5
504408
O-ring AS568-012 Parker V747 75D
9
6
504411
O-ring AS568-015 Parker V747 75D
8
7
504412
O-ring AS568-016 Parker V747 75D
4
8
504552
O-ring AS568-013 National V25 95D (not shown) is between
the Pilot Valve (P/N 111351, not shown) and the Adapter
Plate (ref. 112625).
4
9
501078
Back-up Ring Shamban S-11248-006
1
10
504402
O-ring AS568-006 Parker V747 75D
1
26
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
PRESSURE SWITCH
FIGURE 9
ELECTRICAL SWITCH & CONTROL CORD ASSEMBLY
FIGURE 10
PART NO. 113056
(12 FT. AUXILIARY SWITCH USED WITH
PRESSURE GAUGE T-124833CE)
27
28
110438
503683
507008
507299
507205
507207
110439
2
3
4
5
6
7
Body, Hydraulic Coupler
Hose Assembly 36X.38MNPT .390D 200
Valve, Needle, 10000 psi
Gauge, Pressure 10000 psi / bar 200
Tee, NPTF .38M X .25F X .38F
Nipple, Hex .38X1.69(10,000)
Nipple, Hydraulic Coupler
PART NO. DESCRIPTION
1
ITEM
1
1
1
2
2
1
1
QTY.
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
PRESSURE GAUGE T-124833CE
FIGURE 11
940HS & 940-220HS Powerig Hydraulic Units (HK943)
Alcoa Fastening Systems & Rings
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
PRODUCTS”:
STANDARD OR CUSTOM MANUFACTURED
With regard to non-standard products or custom
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)
HUCK:
AND
OTHER ITEMS
NOT MANUFACTURED BY
HUCK MAKES NO WARRANTY WITH RESPECT
TO THE TOOLING, PART(S) OR OTHER ITEMS
MANUFACTURED BY THIRD PARTIES. HUCK
EXPRESSLY DISCLAIMS ANY WARRANTY
29
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.
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 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 (845) 331-7300 FAX (845) 334-7333
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.
One Great ConnecƟon
SM
About Alcoa Fastening Systems & Rings
Alcoa Fastening Systems & Rings, a business unit
of Alcoa, is a leading worldwide designer and
manufacturer of fastening systems and rings, including
specialty fasteners, fluid fittings, assembly components,
installation systems, and seamless rings for aerospace
and industrial applications. Headquartered in Torrance,
California, the company has over 8,300 employees at 39
manufacturing and distribution/logistics locations in 13
countries. For more information, visit afsr.alcoa.com.
Alcoa Fastening Systems & Rings world-wide locations:
Americas
Aerospace Products
Tucson OperaƟons
3724 East Columbia
Tucson, AZ 85714
800-234-4825
520-747-9898
FAX: 520-748-2142
Industrial Products
Kingston OperaƟons
1 Corporate Drive
Kingston, NY 12401
800-278-4825
845-331-7300
FAX: 845-334-7333
Aerospace Products
Carson OperaƟons
PO Box 5268
900 Watson Center Rd.
Carson, CA 90749
800-421-1459
310-830-8200
FAX: 310-830-1436
Industrial Products
LaƟn America OperaƟons
Avenida Parque Lira. 79-402
Tacubaya Mexico, D.F.
C.P. 11850
FAX: 525-515-1776
TELEX: 1173530 LUKSME
Far East
Europe
Industrial Products
Australia OperaƟons
14 Viewtech Place
Rowville, Victoria
Australia 3178
03-764-5500
Toll Free: 008-335-030
FAX: 03-764-5510
Industrial Products
United Kingdom OperaƟons
Unit C, Stafford Park 7
Telford, Shropshire
England TF3 3BQ
01952-290011
FAX: 0952-290459
Aerospace Products
France OperaƟons
Clos D’Asseville
BP4
95450 Us Par Vigny
France
33-1-30-27-9500
FAX: 33-1-34-66-0600
Industrial Products
Waco OperaƟons
PO Box 8117
8001 Imperial Drive
Waco, TX 76714-8117
800-388-4825
254-776-2000
FAX: 254-751-5259
For The Long Haul, The Future of Fastening
Technology, The Future of Assembly Technology,
The Future of Tooling Technology, and Tools
of ProducƟvity are service marks of Huck
InternaƟonal. Huck provides technical assistance
regarding the use and applicaƟon of Huck
fasteners and tooling.
NOTICE: The informaƟon contained in this
publicaƟon is only for general guidance with
regard to properƟes of the products shown
Certified to
ISO 9001:2008
Industrial
Products
Industrial
Products
Certified to
ISO 14001:2004
and/or the means for selecƟng such products,
and is not intended to create any warranty,
express, implied, or statutory; all warranƟes
are contained only in Huck’s wriƩen quotaƟons,
acknowledgments, and/or purchase orders. It
is recommended that the user secure specific,
up-to-date data and informaƟon regarding each
applicaƟon and/or use of such products.
HWB898
1003-5M
For the Long Haul™
®
© 2015 Alcoa Fastening Systems & Rings
1 Corporate Drive, Kingston, NY 12401 • Tel: 800-431-3091 • Fax: 845-334-7333 • www.alcoafasteningsystems.com
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