Alcoa Huck 911D User manual

Instruction Manual
Huck Model
911D
Diesel Engine
Hydraulic Powerig
Manufacturer:
Alcoa Fastening Systems Ltd; Telford, United Kingdom
Form No. 911D ENG
Rev. 24.11.09
Previous revision:

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
(911D)

Contents
Safety Guidelines when using Huck Installation Equipment
to install Huck Fasteners 1
Description 4
Specification 4
Disposal 5
Utilisation 6
Servicing Powerig 7
Principle of operation 8
Main Components 9, 10
911D Hydraulic Schematic 11
911D Electrical Schematic 12
Preparation for First Time Use 13
Checking and Adjusting Pull, Return & Swage Pressures 15
Preparartion for regular use 21
911D Parts List 22, 23, 24, 25
Preventive Maintenance/Maintenance 26
Hydraulic Fluids 28
Hydraulic Oil Information & MSDS (Material Safety Data Sheet) 29
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

Safety Guidelines when using Huck
Installation Equipment to install Huck
Fasteners.
Before using equipment:
1) Only Huck Installation Equipment
should be used to install Huck fasteners.
2) Only persons that have received
training approved by Huck International
Ltd should use Huck Installation
Equipment.
3) The Manuals and/or Data sheets and
warning stickers/labels supplied with the
Installation equipment should be studied
before connecting the equipment to any
primary power supply, in particular the
following sections:
• Warnings and Cautions.
• Specifications
• Electrical and/or Air supply.
• Principals of Operation.
• Preparation for use.
• Regular use.
• Regular maintenance.
4) With hydraulic tooling, ensure that it is
suitable for use with the Huck Powerig or
Huck approved hand pump being used.
5) Check that the Powerig or approved
hand pump "Pull" and "Return" pressures
have been adjusted to suit the tool
being used. Reference must be made to
the instruction manual supplied with the
equipment.
6) Check that the Nose Assembly is of the
correct type suitable for installing the
fastener being used.
7) Visually check all pneumatic and/or
hydraulic hoses, electrical cables,
Powerigs, hand pumps and hand tools, for
any visible signs of damage and leakage.
ALL HYDRAULIC HOSES SHOULD BE
RENEWED EVERY FIVE YEARS.
8) Do not connect any equipment to
primary power supplies or attempt to use
any equipment, that shows signs of
damage or leakage.
9) Ensure that all air and/or hydraulic
hose and/or electrical plugs/connectors
are correctly connected before switching
on supply to equipment.
When operating the equipment:
10) When using fasteners in some types
of structure, the fracturing of the Pintail
during installation may generate noise
levels above the first action level of the
Noise at Work Regulations and therefore
hearing protection must be worn.
11) It is recommended that eye protection,
(e.g.. safety glasses), should be worn by
the operator.
12) Never look directly at the front or rear
of the installation tool.
13) Never hold the Installation Tool around
the Nose Assembly.
14) Keep hands/fingers clear of any
moving parts and also apertures in Nose
Assemblies.
15) Warning
Fasteners should only ever be installed in
the actual workpiece to prevent possible
high velocity ejection from the Nose
Assembly due to tensile forces induced
during Pintail fracture.
HUCK FASTENING SYSTEMS
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

16) When using two piece fasteners, (i.e..
Pin and Collar type), the
conical/chamfered end of the collar MUST
always be towards the Nose assembly,
NOT against the work piece.
17) Keep fingers clear from the underside
of the head, collars and blind side of
fasteners and from within the joint being
fastened, during the installation cycle.
18) Do not look directly at the head or
blind side of fasteners during the
installation cycle.
19) During the installation cycle, the tool
will pull and straighten itself to the axis of
the fastener, beware of hands being
trapped against any nearby structure.
KEEP HANDS CLEAR
20) In the event of any difficulty whilst
installing a fastener, releasing the tool
trigger at any time during the installation
cycle will immediately put the tool into
reverse.
Note
The following symbols are attached to the equipment:
The equipment ,meets the
requirements of CE
Certification.
Read the Instruction Manual
before using or maintaining
this equipment.
Wear eye protection
when using this
equipment.
21) Beware of fastener Pintails which are
ejected, (sometimes forcibly), from the
tool at the completion, or at Pintail
fracture, during the installation cycle.
Tools designed to have Pintail
Deflectors and or catchers must never
be used without them.
22) Do not continue to use any
equipment which develops a fault whilst
being used.
23) Avoid kinking of hoses or dragging of
hoses and electrical cables over sharp
objects.
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
CAUTION
BEFORE OPERATING THIS POWERIG,
READ THE SEPA R ATE DIESEL ENGINE
INSTRUCTION MANUALS PROVIDED.
WITH THIS POWERIG. IN PARTICULAR,
PAY ATTENTION TO A N Y SAFETY
INSTRUCTIONS, CAUTIONS A N D
W ARNINGS.

Description
The 911D diesel engine Powerig is
designed to be used with a wide range of
Huck hydraulic Installation Tools (including
Bobtail Tools -see utilisation ), and will
operate one Tool. The maximum Pull
Pressure is 700 bar (10150 psi) and the
maximum Return Pressure is 400 bar (
5800 psi). The Powerig is equipped with a
12 vdc Battery and an electric Starter
Motor operated by a Key Switch.
The Engine and Pump run continuously
and a low hydraulic pressure , (Idle
Pressure ), ensures that the Tool Piston is
kept in the forward position when the Tool
is not being used. The Installation Tool is
connected to the Powerig by means of
Pull and Return pressure Hydraulic Hoses
and an electrical Control Cord. The
Powerig Hydraulic Directional Valve
(HDV), is controlled from the Installation
Tool Trigger by a 12 VDC remote control
circuit.
When operating ST & DT type Bobtail
Tools, or non-Bobtail Tools, the operator
presses and holds the Tool Trigger which
starts the Tool cycle to install the
Fastener. Once the Fastener is installed,
the Trigger is released and the Tool
Piston and Nose Assembly return to the
fully forward position, the Tool/Nose
Assembly are ejected from the installed
Fastener.
When operating “IT” type Bobtail Tools, a
Limit Switch (sometimes referred to as a
Micro-Switch), & a red LED Light on the
Tool are activated when the Nose
Assembly is correctly located onto the
Fastener. The Tool Trigger will only
function if the Limit Switch has been
activated (indicated by the red LED). The
operator now presses and holds the
Trigger which starts the Tool cycle to
install the Fastener. As long as the
Trigger is kept pressed, the Bobtail Collar
will be Swaged correctly and the Tool and
Nose Assembly will return and eject from
the installed Fastener automatically.
“ST” type Bobtail Tools also have a Micro-
Switch and LED light but the operator has
to release the Trigger when the Bobtail
Collar is fully swaged. “DT” Tools also
function that way but do not have a Limit
Switch or LED.
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Powerig type 911d
Flow L/min (Imp. Gals/min) 1.22 (0.26)
(at Engine speed of 1800 RPM)
Pull Pressure max. bar (p si) (See Note 1, p age 5) 700 (10150)
Swage Pressure max. bar (psi)600(8700)
Return Pressure max. bar (p si) (See Note 2, p age 5) 600 (8700)
Diesel Engine, single cylinder Lombardini 15LD350
(see sep arate Manual for additional information)
Hydraulic Pump Axial, 4 piston
Control Circuit 12 VDC via Alternator
Starter Motor Circuit 12 VDC via Battery
Battery 12 VDC 55 Amp Hour
Noise T B A
Hydraulic Oil Reservoir cap acity max ltrs (imp. Gals) 14.0 (3.11)
Length mm (inches) 850 (33 ‰ )
(without removable Handles)
Width (including wheels) mm (inches) 650 (26)
Height mm (inches) 750 (29.5)
Diameter of min wheels mm (inches) 200 (7.5 )
WeightincludingfluidKg(lbs) 158 (344)
Specification

Intended Use
The 911D Powerig is designed to be used
with Huck Installation Tools (refer to
Utilisation on Page 5), to install various
Huck Bobtail Fasteners, in a factory
(where permitted),or outdoor working
environment. The unit should be not be
placed on a surface with an angle
exceeding 15 degrees from the horizontal.
Noise
The sound measurement is in accordance
with BS EN ISO 3746: 1996 is less than
70dB(A).
Disposal
Fluids should be disposed of by
processing through authorised methods
and in accordance with current legislation.
This symbol indicates that this product
must be disposed of according to the
WEEE Directive and our national law.
Products of this nature should be
forwarded to a designated collection point
e.g. on an authorised one-for-one basis
when you buy a similar new product or to
an authorised collection site for recycling
waste electrical and electronic equipment
(EEE). Improper handling of this type of
waste could have a possible negative
impact on the environment and human
health due to potentially hazardous
subst ances that are generally associated
with EEE. At the same time, your co-
operation in the correct disposal of these
product s will contribute to the ef fective
usage of natural resources.
Special Note
The 911D Series Powerigs include a 12
VDC 55 Amp Hour Lead Acid Battery.
Batteries are classed as hazardous waste
and should be disposed of in accordance
with legal requirement s.
For more information with respect to the
management of waste equipment for
recycling please cont act our Customer
Services desk at Alcoa Fastening
Systems Ltd,Telford Shropshire TF3 3BQ.
The Producer Identification Number for
Alcoa Fastening Systems Lt d,Telford is:
WEE/AF0044SY
The Waste Electrical &
Electronic Equipment
Regulations 2006
CAUTION
THE HYDRAULIC OUTPUT PRESSURE
VALVES (PULL & RETURN) ON THIS
POWERIG MAY HAVE BEEN SET AND
SEALED BY THE MANUFACTURER
AND SHOULD ONLY BE CHANGED IN
ACCORDANCE WITH THE
INSTRUCTIONS SHOWN IN THIS
MANUAL.
ANY NEW PRESSURES SET MUST
ALWAYS BE CHECKED AND TESTED.
CAUTION
THE POWERIG SHOULD NOT BE USED
AS A STEP. NO PERSON SHOULD
CLIMB ON THE POWERIG.
CAUTION
THE POWERIG SHOULD NOT BE USED
IN AN EXPLOSIVE AND/OR HIGHLY
FLAMMABLE ATMOSPHERE
Notes:
1) If the Powerig is delivered without an Installation Tool, Pull Pressure is factory preset at
510 bar, (7400 psi).
2) If the Powerig is delivered without an Installation Tool, Return Pressure is factory
preset at 221 bar, (3200 psi).
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

Utilisation
Swage Swage
Pressure Pressure
Bobtail Tool Pull Installation Collar Cutter
Model Fastener Pressure Nose Assy. Assy. Return Pressure
Series Diameter Max. bar/psi Max. bar/psi Max. bar/psi Max. bar/psi
BTT25 12 mm 389/5640 289/4200 235/3408 289/4200
BTT25 12 mm 389/5640 289/4200 235/3408 289/4200
BTT25 14 mm 389/5640 340/4930 290/4205 289/4200
BTT35 16 mm 380/5510 357/5177 270/3915 350/5075
BTT35 16 mm 380/5510 357/5177 270/3915 350/5075
SFBTT20 16 mm TBA TBA TBA
BTT57 20 mm TBA TBA TBA
BTT57 20 mm TBA TBA TBA
6
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Huck Tool Pull Pressure Return Pressure
Series/Model Max. bar/psi Max. bar/psi
2400, 2480 (See Note below) 579/8400 221/3200
2502, 2503 (See Note below) 579/8400 165/2400
2580 Series 393/5700 221/3200
2600 Series 393/5700 193/2800
2620,2624, 2628, 2630 Series 510/7400 221/3200
506, 507, 585, 586, 5901, 393/5700 165/2400
516, 520, 524, 528, 532, 536
6042, 7042, 8042 510/7400 221/3200
Non-Bobtail T ools
Note
Pressures may be reduced for some smaller diameter Fasteners. Refer to appropriate
Installation Tool Instruction Manual.
Bobtail T ools
Notes
1)TheaboveSwagePressuresareonlyaguideandmayhavetobeadjustedtoobtain
consistent correct Collar swaging. The Pull Pressure should always be a maximum of
60 (870 p si) to 100 bar (1450 p si) higher than the the Swage Pressure to minimise the
risk of Bobt ail (the p art of the Fastener held by the Nose Assembly), fracture.

Pull Pressure:
This is the maximum hydraulic pressure of
the Pump which is set and adjusted with
the Main Pressure Relief Valve (5). In
particular, it controls the maximum
hydraulic pressure applied to the front of
the Tool Piston during the “Pull” stroke
(Pulling on the Fastener Pintail), enabling
the complete Fastener installation.
Swage Pressure:
Sometimes called Cut-Off Pressure, this is
the hydraulic pressure which is applied to
the front of the Tool Piston, enabling
swaging of the Collar during the
installation of Bobtail Fasteners when
using IT type Bobtail Tools. This pressure
Pressures - definitions
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Servicing Powerig
Only an appropriately qualified and competent person should service any Diesel Engine
hydraulic or electrical components.
A SEPARATE Manual is provided for the Diesel Engine.
Alcoa Fastening Systems Account Managers and Systems Engineers are located in your
area to offer assistance you require in solving your installation problems.
If you need assistance by telephone, please call Alcoa Fastening Systems Customer
Services at Telford UK. tel [phone]
is set using the Digital Pressure Switch (6)
and is adjusted to ensure complete
swaging of the Collar when the value of
the set Swage Pressure is reached. This
pressure will always be set lower than the
Pull Pressure.
Return Pressure:
This is the hydraulic pressure applied to
the rear of the Tool Piston and is set and
adjusted with the Pressure Switch (7). In
particular, it controls the maximum
hydraulic pressure applied to the rear of
the Tool Piston during the return stroke,
enabling the Tool/Nose Assembly to eject
from the installed Fastener.

3 close to operate the HDV 3Pull
Pressure solenoid, allowing fluid through
the HDV via outlet port P. Normally closed
Relay contacts R3-2 open, preventing
Return Pressure HDV solenoid from
operating while the pull pressure HDV
solenoid is energised.
The Installation Tool Piston moves
rearwards to begin the Fastener
installation cycle
When the Swage Pressure reaches the
pressure set on the Digital Swage
Pressure Switch 6Relay R4 energises
and latches in via Relay R1-3 and Relay
R4-2 contacts.
Normally closed Relay R4-1 contacts
open and de-energises Relay R3.
R3-3 contacts open to de-energise the
HDV Pull Pressure solenoid.
Relay R3-2 contacts close to energise the
HDV Return Pressure solenoid allowing
fluid through the HDV outlet port R
The Installation Tool Piston moves
forward.
When the Piston reaches the fully forward
position, pressure in the return line
increases and opens the Digital Return
Pressure Switch 7which de-energises
Relay R1. This also de-energises the HDV
Return Pressure solenoid. The Digital
Return Pressure Switch then recloses (re-
closes-sets).
The installation cycle is now complete
Notes:
1. The latching of Relay R3, allows the
fastener inst allation to continue even if the
Limit Switch cont act s in the T ool open
after activating the Tool Trigger.
Principle of Operation with Bobtail Tools
Non Bobtail Tools
When the tool trigger is depressed :-
Relay R2 is energised which also
energises Relay R1 via contact R2-1
(latched in by the Digital Return Pressure
Switch 7).
Normally open Relay contacts R2-3 closes
to operate the HDV 3solenoid, allowing
fluid through the HDV via outlet port P
Normally closed Relay contacts R2-2
open, preventing the Return Pressure
HDV solenoid from operating while the
pull pressure HDV solenoid is energised.
The Installation Tool Piston moves
rearwards to begin the Fastener
installation cycle.
When the Installation Tool trigger is
released, Relay R2 is de-energised,
contacts R2-3 open to de-energise the
HDV Pull Pressure solenoid. relay
contacts R2-2 close to energise the
Return Pressure solenoid, allowing fluid
through the HDV via outlet port R.
The Installation Tool piston moves
forward.
When the Piston reaches the fully forward
position, pressure in the return line
increases and opens the Digital Return
Pressure Switch 7contacts, which de-
energises Relay R1. This also de-
energises the HDV Return Pressure
solenoid and the Digital Return Pressure
Switch then recloses (re-closes-sets).
The installation cycle is now complete.
Bobtail Tools (when connected to the
Powerig via the Multi-Pin Lemo Plug)
When the Bobtail Tool Limit Switch is
activated (LED Light on ), and the Tool
trigger is pressed, Relay R3 is energised
(and latched - see Note 1). which also
energises relay R1 via contact R3-1
(latched in by the Digital Return Pressure
switch). Normally open Relay contacts R3-
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

Main Components
FIG. 1
14 Filler/Strainer
40 Main Wheel
6Digital Pressure
Switch
(Swage Pressure)
34 12 VDC Electrical
Connector
(non Bobtail Tools or
remote Triggers)
19 Hydraulic Quick
Disconnect Coupling
(Return Pressure)
16 Oil
Level/Temp
Gauge
41 Handle -
Screw in,
removable)
15/15A Oil Return
Line Filter &
Condition Gauge
5Main
Pressure Relief
Valve
(Pull Pressure)
18 Hydraulic Quick
Disconnect
Coupling (Pull
Pressure)
35 12 VDC Electrical
Connector
(Bobtail Tools)
7Digital Pressure
Switch
(Swage Pressure)
1Diesel Engine
Key Start
Switch (Starter
Motor) -
Diesel Engine
Fuel Tank
Filler Cap
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Indicator
Lights

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Engine Controls
Throttle Control
Lever Lock
Throttle Control
Lever
Stop Lever
(shown in Engine
run position)
Stop Lever
(stop Engine
position)
Main Components
FIG. 1A

911D Hydraulic Schematic
FIG. 2
LEGEND
Ref. N0. Part Number Item
1 911D/1 Lombardini 15LD-350 Diesel Engine
2 911D/2 Pump
3 911D/3 Hydraulic Directional Valve
5 911D/5 Main Pressure Relief Valve (Pull Pressure)
6 911D/6 Digital Pressure Switch (Swage Pressure)
7 911D/7 Digital Pressure Switch (Return Pressure)
15 911D/15 Hydraulic Oil Return Line Filter
15A 911D/15A Oil Filter Condition Gauge
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Installation Tool
3
67
5
2
RP
1
15/15A

911D Electrical Schematic
FIG. 3
BOBTAIL TOOL
LIMIT SWITCH R1 - 3
R4 - 2
R4
R4 - 1
R3
R3 - 3
R2 - 3
R2 - 2
R1 - 2
R3 - 2
R1 - 1
R2 - 1
R3 - 1
R1
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
R2 3
HDV PULL PRESSURE SOLENOID
3 HDV RETURN PRESSURE SOLENOID
HDV PULL P R E S S U R E SOLENOID
HDV RETURN PRESSURE SOLENOID
DIGITA L PRESSURE SWITCH (PULL PRESSURE)
DIGITA L PRESSURE SWITCH (RETURN PRESSURE) 24 VDC SUPPLY
BOBTAIL
TO O L
TRIGGER
7DIGITAL PRESSURE SWITCH (RETURN PRESSURE)
6DIGITALPRESSURE SWITCH (PULL PRESSURE)
LEMO PLUG/SOCKET
CONNECTOR (BOBTAIL TOOLS)
NOTE: R1 TO R4 ARE RELAYS REF. 37
42 F u s e
42 F u s e
42 F u s e

Preparation for First Time Use (Refer to FIG. 1 )
CAUTION
To avoid explosions or fire outbreaks, do
not smoke or use naked flames during
operations. Fuel vapours are highly
toxic.
Only carry out operations outdoors or in
a well ventilated area.
Keep face well away from the filler cap
and fuel tank to prevent inhalation of
harmful vapours.
Dispose of fuel in accordance with
applicable laws and regulations as it is
highly polluting.
Use the same type of fuel as used in
cars as use of other types could damage
the engine. The cetane rating of the fuel
must be higher than 45 to prevent
difficult starting.
Do not use dirty fuel of mixtures of
diesel fuel and water, since this would
cause serious engine damage
5. Check that there is sufficient engine
diesel fuel for the time intended to operate
the Powerig. A full tank of fuel will run the
engine for approx. 4 hours at 2400 r.p.m.
Do not fill the fuel tank completely but just
up to 1 cm (0.39”) from the top of the fuel
tank. This allows space for fuel movement.
Only use clean fuel and wipe any fuel
spillage from the engine before starting.
6. Using the Oil Level/Temp Gauge 16,
check that the hydraulic fluid (oil) level is at
the top of the glass. To avoid overheating
of the fluid, the level should not be allowed
to fall lower than half way down the glass. .
7. If necessary, remove Filler Cap 14 and fill
Powerig Oil Reservoir with recommended
hydraulic fluid, (refer to page 28) to the top
of the glass.
CAUTION
For filling the reservoir, only use clean
fluid and a clean funnel with a maximum
of a 60 micron filter. Failure to do this
will cause malfunction and component
damage.
8. Reinstall Filler Cap.
1. Check the diesel
engine oil level by
using the dipstick.
The oil level should
be near the
maximum.
If necessary add
clean oil via the filler
cap.
Note:
Refer to the Diesel
Engine maintenance
Manual for correct
grade of oil.
2. Open air cleaner
and remove element.
3. Fill with engine oil
up to the level mark.
4. Reassemble air cleaner. Ensure that the
air filter is mounted the correct way
otherwise dust and other impurities could
enter the intake ducts.
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Starting & stopping the engine...
9. Apply the brake
on the Castor
Wheel to avoid
unexpected
movement of the
Powerig during
operation.
Push down with
foot to operate
brake.
Starting...
10. Set the throttle
at 50% maximum speed.
11. Turn the key clockwise
to position 1 as shown
below. The warning light
should illuminate.
12. Continue to turn the
key clockwise to position
2 to operate the electric
starter motor. Release
the key once the engine
has started. The key will
now return to position 1
and should be left in this position whilst the
engine is running.
CAUTION
Do not operate the starter for more than
20 seconds at a time. If the engine does
not start, wait 1 minute before trying
again.
If the engine does not start after two
attempts, trace the cause according to
the Diagnosis Chart (page 75 - 77) of the
Diesel Engine Maintenance Manual.
All warning lights should stay off when
the engine is running.
Note:
If there is not enough battery power to
operate the electric starter motor, the engine
maybe started with the recoil starter. Refer
to page 53 of the Diesel Engine
Maintenance Manual for instructions.
13. Move throttle lever to the idle position
and allow engine to run at idle for a few
minutes before increasing speed and
putting under load.
Note:
During the first 50 hours of running the
engine, do not exceed 70% of maximum
load.
Stopping...
14. Move throttle lever to the idle position
and allow engine to run at idle for a few
minutes.
15. Move the stop lever
fully to the left until the
engine stops.
16. Rotate the key anti-
clockwise to the stop
position.
Throttle Lever
Throttle Lever
Lock

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
Checking & Adjusting Pull,
Return & Swage Pressures...
Pull Pressure (FIG.4)
(refer to Utilisation (page 6) for correct
setting)
1. With the engine running at operating
speed, observe the display on the Digital
Pressure Switch (Swage Pressure). This
will show the unit of measurement set and
will periodically show “bAr” or “PSI”.
Note:
When facing the hydraulic connectors, the
Digital Pressure Switch (Swage Pressure),
is on the right hand side.
2. Connect a remote electrical trigger (or the
plug/cable from a non-Bobtail Installation
Tool), to the Powerig electrical connector
34.
3. Operate the
remote Trigger
momentarily and
note pressure
reading displayed on
the Digital Pressure
Switch.
CAUTION
Complete this test as quickly as possible
to prevent overload of hydraulic
components.
4. Refer to FIG. 4 and adjust the Pull
Pressure to suit the Installation Tool being
used. Refer to Utilisation (Page 6) and/or
the Installation Tool Instruction Manual for
correct Pull Pressure setting. Only make
small adjustments (1/4 turn) at one time. Do
not remove any pre-installed washers or
locknut from the adjusting screw.
5. Check the Pull Pressure again as
described above. Repeat adjustment if
necessary until correct value is obtained.
6. Once the Pull Pressure has been set,
tighten the Lock Nut on the Adjustment
Screw to ensure setting is retained. Check
the pressure one more time to ensure it had
not changed whilst tightening the Lock Nut.
Return Pressure (FIG 4)
(refer to Utilisation (page 6) for correct
setting)
Notes:
a) The diesel engine does not have to be
running during checking or adjustment of
the return pressure but the key must be in
position 1.
b) When facing the hydraulic connectors,
the Digital Pressure Switch (Return
Pressure), is on the left hand side.
c) The Digital Pressure Switches are able to
measure two SEPARATE pressure switch
points; S1 & S2. Only the S1 is used and
for the Return Pressure, the normally
closed (N/C) switch contacts are utilised. If
the left hand indicator light is on, then the
N/C contacts are closed.
d) The reset pressures r1 & r2 should left at
the factory setting of 50 bar (725 psi).
e) The S1 button is used to change to the
different menu items. The S2 button is
used to access the menu items and the S1
button used again to change the settings of
those menu items.
1. Press both the S1 & S2
buttons at the same time
and the display will show
the first menu item.
2. Press the S2 button
and the current unit
setting will be displayed.

FIG. 4
Lock Nut
Adjustment Screw
Clockwise to increase Pull
Pressure
Anti-clockwise to decrease
Pull Pressure
!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
6Digital Pressure
Switch
(Swage Pressure)
7Digital Pressure
Switch
(Swage Pressure)
5Main Pressure Relief Valve
(Pull Pressure)

!""#$%&'()*+$,()*(-$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$./0&1$21-3(4*4+$,5-3(6-
3. To keep this setting,
press S2 again and the
display will return to
“Unit”. Pressing S1 now
will change the display to
the next menu item (S1);
continue from step 5.
To change the
measurement units, press
S1. Consecutive pressing
of S1 will change the
units between bAr and
PSI.
When the required unit is
shown, press S2 again
and the display will return
to “Unit”
4. Press S1 to continue to
the next menu item. The
display will show “S1”.
This is switch point 1, the
value of this is the Return
Pressure.
5. Press the S2 button
and the current Return
Pressure setting will be
displayed.
To keep this setting, press S2 several times
until “S1” is displayed again.
Pressing S1 now will change the display to
the next menu item (r1); continue from step
9.
To change the settings, note the
flashing/blinking cursor under the space for
the first digit of Return Pressure setting.
Note:
The display is able to show 4 digit numbers.
In this example a value of 350 bar is shown
and therefore the space for the first digit is
blank. 4 digit numbers are only used if the
measurement units are set to PSI. The
Return Pressure must always be lower
than the Pull Pressure by at least 6.9 bar
(100 psi), to ensure correct Powerig
function
6. Consecutive pressing of S1 will change
the value of the digit over the cursor from 1
to 9 and then 0.
7. When the required value shown, press
S2 and the cursor will move to the right
under the next digit.
8. Continue adjusting each digit in turn.
Pressing S2 after adjusting the last digit will
change the display back to “S1”.
9. Pressing the S1 button
will change the display to
the next menu item.
r1 is the value at which
the Return Pressure (S1),
resets to zero and should
be set at 50 bar (725 psi).
Press S2 to check the
setting. If it is necessary to change the
setting then follow the procedure as in steps
6 & 7.
10 Press S1 to continue
to the next menu item
which is S2.
The S2 & r2 switch points
are not used.
The next steps will save
the settings...
11. Press the S2 button
several times until the
display shows “Stor”.
12. Press the S2 button
and the display will show
“no”. Press the S1 button
to change the display to
“yes”.
13. Press the S2 button to
save the settings. The
display will return to zero.