Alcoa Huck POWERIG 940HS User manual

05-25-2004
Form HK943
INSTRUCTION MANUAL
940HS & 940-220HS
POWERIG®HYDRAULIC UNIT

SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by any
person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will
damage equipment and or structure.
Notes - are reminders of required
procedures.
Bold, Italic type and underlining -
emphasizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with
equipment before connecting equipment to any
primary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye
protection. Where applicable, refer to ANSI
Z87.1 - 1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote
triggers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. 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.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is
correct. See fastener data sheet of correct
positioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

1
Width • • • • • • • • • • • • • • • • • • 16.1 inches • • • • • • • • • • • • 409 mm
Length • • • • • • • • • • • • • • • • • 15.0 inches • • • • • • • • • • • • 381 mm
Height • • • • • • • • • • • • • • • • • 21.2 inches • • • • • • • • • • • • 538 mm
Weight (w/o hyd. fluid) • • • • 84.0 pounds • • • • • • • • • • • 38 kg
Electrical system • • • • • • • •940HS • • • • • • • • 115 volts, 50/60 hertz, single phase, AC
940-220HS • • • •220 volts, 50/60 hertz, single phase, AC
Control System • • • • • • • • • PLC operated, 24 volts
Motor • • • • • • • • • • • • • • • • • • 940HS • • • • • • • •12,000 RPM, 1-1/8 HP, 20 amps. nominal
940-220HS • • • •12,000 RPM, 1-1/8 HP, 10 amps. nominal
Pump • • • • • • • • • • • • • • • • • 2-stage, gear-piston type, 70cu. in/min. @5000 psi output pressure
Output pressure adjustable to 10,000 psi
Pressure setting as shipped:
Snub • • • • • • • • • • • • 1,150 - 1,350 psi • • • • • • • • 7,580 - 8,960 kPa
Swage • • • • • • • • • • • 4,100 - 4,300 psi • • • • • • • • 28,300 - 29,600 kPa
Return • • • • • • • • • • • 2,200 - 2,400 psi • • • • • • • • 15,200 - 16,500 kPa
Pull • • • • • • • • • • • • • • 4,500 - 4,700 psi • • • • • • • • 31,000 - 32,400 kPa
Reservoir Capacity • • • • • • 2.6 gallons • • • • • • • • • • • • • 9.8 liters
Minimum Operating Temperature (ambient) • • • • • • • • • 0ºF • • • • • • • -18ºC
Maximum Hydraulic Fluid Temperature • • • • • • • • • • • • • 150ºF • • • • • 65ºC
Hydraulic Fluid is not supplied by Huck. Use automatic transmission fluid, DEXRON III, or
equivalent. Fire-resistant hydraulic fluid must be used to comply with OSHA regulation
1926.302 paragraph (d): “the fluid used in hydraulic power tools shall be fire-resistant fluid
approved under Schedule 30 of the US Bureau of Mines, Department of Interior, and shall
retain its operating characteristics at the most extreme temperatures to which it will be
exposed.” Fluid viscosity 300 SUS @ 100ºF and 50 SUS @ 210ºF is recommended for
ambient temperatures 0 to 130ºF.
SPECIFICATIONS

590326 REV B
18
16 17
7
6
15
14
13
12
11
10
9
HS TRIGGER
LS1
LS2
PS1
PS2
SNUB
PLC
654321
205204203
120 V, 50-60 Hz, SINGLE
PHASE ELECTRICAL
SCHEMATIC DIAGRAM OR
940HS POWERIG
R
2
2
21
1
CW
CCW
L1
L3
T2
95
12 8
CR
TRIGGER
.1A
SOL
CR
25
MC
MC
CR
MC
MOT
MC
2
2
24
3
1
1
1
1
1
T1 L2
T3
1A
86
67
1314
2
PS3
L1 L2 G
12VA
24V
120V
Fig. 2A

12VA
J
590338 REV C
18
16 17
7
6
15
14
13
12
11
10
9
HS TRIGGER
LS1
LS2
PS1
PS2
SNUB
PLC
654321
205204203
220 V, 50-60 Hz, SINGLE
PHASE ELECTRICAL
SCHEMATIC DIAGRAM OR
940-220HS POWERIG R
220V
24V
2
2
21
1
CW
CCW
L1
L3
T2
95
12 8
CR
TRIGGER
.05A
SOL
CR
25
MC
MC
CR
MC
MOT
MC
2
2
24
3
1
1
1
1
1
T1 L2
T3
1A
86
67
1314
2
PS3
L1 L2 G
Fig. 2B

16 3
2.140
2.040
Detail "A"
(1.045)
(.380)
34
Red Mark on Top
CAUTION
13 14
15
(CCW)
(CW)
Note 4
35
SUPPLY 90 PSI
SHOP AIR
PUSH IN OR SNUB ONLY
CAUTION
PULL
PRESSURE PRESSURE
RETURN
CAUTION
0.1
V AC
Note 4
See Detail "B"
Note 4
33
32
31
Detail B
PLC Ground Wire
Power Cord Ground Wire
Note 6
23
See Detail "A"
37, 11
2, 22, 28
1
4, 5, 10, 17, 18 Note 4
9 Note 4
Note 7
29 Notes 5 & 8
7, 26
8, 30
5, 27
6, 25
AMPS
R
POWERIG HYDRAULIC UNIT
MODEL NUMBER SERIAL NUMBER
HUCK INTERNATIONAL INC.
INSTALLATION SYSTEMS DIVISION
1 CORPORATE DRIVE
KINGSTON N.Y. 12401
VOLTS CYCLES
PHASE H.P.
WARNING
DISCONNECT POWER BE ORE
OPENING. CLOSE COVER PRIOR
TO RESTORING POWER
HUCK P/N 590299 REV B
12
Power Cord
Note 1
1 124465 Pump, Motor & Valve Assembly 1 2 124467 Electrical Enclosure Assembly 1 3 107316 Dipstick 1 4 111351 Pilot Valve 1 5 506360 Strain Relief 2 6 124473 Manifold Assembly 1 7 124475 Control Panel Assembly 1 8 124484 Base Panel 1 9 124735 Wiring Assembly 1
10 500063 Socket Hd Cap Scr 10-24X3/4 4
11 590056 Notice Tag 1
12 590067 Huck Decal 2 13 590132 Pull Pressure Sticker 1 14 590133 Return Pressure Sticker 1 15 590181 Caution Sticker 1 16 500811 O-ring 1 17 502366 Locknut 1/2 2 18 505142 Bullet Plug 2 22 501214 Socket Hd Scr 10-24X3/8 (Note 7) 3 23 590328 Pressure Settings Tag 1 24 124468 Wiring Diagram (Note 4) 1 25 500076 Socket Hd Cap Scr 1/4-20X1 3/4 2 26 507262 Truss Screw 6-32X1/4 5 27 505704 Ring Terminal (Note 1) 2 28 123432 Motor Gasket 1 29 501214 Socket Hd Scr 10-24X3/8 (Note 8) 2 30 500073 Socket Hd Cap Screw 1/4-20X1 3 31 502778 Machine Screw 10-24X5/8 1 32 500553 Lock Washer, ext. teeth, #10 2 33 500214 Hex Nut 10-24 1 34 590346 Air Supply Sticker 1 35 590295 HuckSpin Sticker 1 37 504239 Nylon Cable Tie 1
ITEM PART NO.DESCRIPTION QTY
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 meets National Electrical Code, 1993.
4.) Complete wiring 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 inch pounds.
8.) Fastener is prevailing torque type. Do not re-use
fastener. Torque to 106 inch pounds.
Also included in this assembly, but not shown, are: Carton 590271, Carton Insert 590292, and Instruction Manuals HK959 and HK943 (this instruction manual).
940HS Fig. 3A