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