Arconic 918 Series User manual

January 18, 2017
HK786
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories
Safety Instructions
3
Description
4
Specifications
5
Principle of Operation
5
Preparation for Use
6
Checking and Adjusting
Pressures
7
Operating Instructions
8
Maintenance
9
Components Drawings
Components Overview 10-11
Electrical Schematics 12-13
Hydraulic Diagram 14
Hose & Control Cord Hook-up 15
Combination Valve Service Kit 16
Hydraulic Pumps 17-18
Front Bracket Assembly 19
Electrical Enclosure (918-5) 20
Electrical Control Panel 21
Control Panel Wiring 22-23
Suction Line 24
Return Line (918) 24
Return Line (918-5) 25
Troubleshooting
26
Kits and Accessories
26
Instruction Manual
918 series
Powerig®Hydraulic Unit

2
918 series Powerig Hydraulic Units (HK786)

3
918 series Powerig Hydraulic Units (HK786)
Safety Instructions
1. This instruction manual must be read, with particular
attention to the following safety guidelines, by any person
servicing or operating this equipment.
2. A half hour long hands-on training session with qualied
personnel is recommended before using Huck equipment.
3. 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 qualied repairman trained on
Huck procedures.
4. 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 specic safety and other
information.
5. Read MSDS Specications before servicing the tool. MSDS
Specications are available from the product manufacturer or
your Huck representative.
6. When repairing or operating Huck installation equipment,
always wear approved eye protection. Where applicable, refer
to ANSI Z87.1 - 2003
7. Disconnect primary power source before performing
maintenance on Huck equipment or changing Nose Assembly.
8. 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.
9. Mounting hardware should be checked at the beginning of
each shift/day.
10. Make sure proper power source is used at all times.
11. Release tool trigger if power supply is interrupted.
12. Tools are not to be used in an explosive environment unless
specically designed to do so.
13. Never remove any safety guards or pintail deectors.
14. Where applicable, ensure deector or pintail collector is
installed and operating prior to use.
15. Never install a fastener in free air. Personal injury from fastener
ejecting may occur.
16. Where applicable, always clear spent pintail out of nose
assembly before installing the next fastener.
17. There is possibility of forcible ejection of pintails or spent
mandrels from front of tool.
18. If there is a pinch point between trigger and work piece, use
remote trigger. (Remote triggers are available for all tooling).
19. Unsuitable postures may not allow counteracting of normal
expected movement of tool.
20. 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 eciency, eliminating
downtime, and in preventing an accident which may cause
severe personal injury.
21. Never place hands between nose assembly and work piece.
Keep hands clear from front of tool.
22. There is a risk of crushing if tool is cycled without Nose
Assembly installed.
23. Tools with ejector rods should never be cycled with out nose
assembly installed.
24. When two piece lock bolts are being used always make sure
the collar orientation is correct. See fastener data sheet of
correct positioning.
25. Tool is only to be used as stated in this manual. Any other use
is prohibited.
26. There is a risk of whipping compressed air hose if tool is
pneudraulic or pneumatic.
27. Release the trigger in case of failure of air supply or hydraulic
supply.
28. Use only uids or lubricants recommended.
29. Disposal instruction: Disassemble and recycle steel, aluminum
and plastic parts, and drain and dispose of hydraulic uid in
accordance with local lawful and safe practices.
30. If tool is xed to a suspension device, ensure that the device is
secure prior to operating the tool.
GLOSSARY OF TERMS AND SYMBOLS:
- Product complies with requirements set forth by the
relevant European directives.
- READ MANUAL prior to using this equipment.
- EYE PROTECTION IS REQUIRED while using this
equipment.
- HEARING PROTECTION IS REQUIRED while using this
equipment.
Notes: are reminders of required procedures.
Bold, Italic type and underlining: emphasizes a specic instruction.
WARNINGS: Must be understood to avoid
severe personal injury.
CAUTIONS: show conditions that will
damage equipment and or structure.

4
918 series Powerig Hydraulic Units (HK786)
GENERAL
The models 918 and 918-5 HUCK Powerig®Hydraulic Units
are electrically operated hydraulic power sources designed to
operate Huck Installaon Equipment.
Model 918 can operate two pieces of equipment
simultaneously and independently of each other. The units
are semi-portable and can be moved with a fork-li truck.
Model 918-5 can operate three tools simultaneously and
independently of each other. The 918-5 is the basic 918 with
an addional combinaon valve bracket assembly mounted
to the reservoir.
Figures 1 and 2 show features of model 918 and 918-5
POWERIG Hydraulic Units and idenfy main components.
Hydraulic pressure is developed by an axial piston pump
driven by an electric motor. Hydraulic pressure from the
pump is directed to PULL and RETURN ports by combinaon
valves controlled from the installaon equipment by relays
and solenoids.
Hydraulic uid is stored in the 22 gallon (83.3 liters) reservoir
which serves as a base for motor and pump. A 70 micron
strainer in the sucon line, and a 10 micron lter in the
RETURN line, assure clean, ltered hydraulic uid for the
hydraulic system. A ller-strainer is provided for adding
hydraulic uid. However, any hydraulic uid that is added to
the reservoir must be ltered by a 10 micron (or beer) lter.
Before returning to the reservoir, circulang hydraulic uid
passes through the cooler where the temperature of uid is
lowered to proper operang level. A fan, aached to the rear
sha extension of the electric motor, aids in dissipang heat
from the cooler.
*Note: Kits are available for conversion from 440 to 220
volts and conversion from 220 to 440 volts.
ELECTRICAL CONTROL PANEL
The electrical control panel contains two compartments:
Disconnect Compartment and the Control/Transformer
Compartment. The Disconnect Compartment contains a
three-pole main disconnect switch, three main line fuses, two
transformer fuses, and terminals for power cable connecon.
The Control/Transformer Compartment contains two
transformers (one is to convert to 110 and the other is
to convert to 24 volt current), motor contact with three
overload relays (heaters), mul-contact relays for control
circuit, START and STOP buons, 24 volt and 110 volt circuit
breakers, bases (sockets) for plugging in the tool control
cords, and power cable entrance connector.
INPUT POWER CABLE
A four-conductor power cable, including ground conductor, is
used to connect the Powerig to the electrical power source.
The cable is NOT shipped with unit. User must furnish power
cable in accordance with his parcular requirements. Only
a qualied electrician should install power cable. (See the
 procedure in the 
secon.)
The standard 440-volt unit can be converted to 220-volt
operaon with conversion kit 918-220KIT.
The 220-volt unit can be converted to 440-volt operaon with
conversion kit 918-440KIT.
COMBINATION VALVE
Each combinaon valve contains a 
, , and 
.
The Four-way Valve is controlled by a tool trigger through a
relay and solenoid, and directs hydraulic uid under pressure
to PULL or RETURN hoses connected to installaon tool, or
other equipment.
The Pressure Relief Valve protects the POWERIG and
installaon tools from excessive pressure during the pull
cycle. The valve is factory preset to 5600 psi (386 BAR).
The Idler Valve (Figure 7) protects the POWERIG and
installaon tools from excessive pressure during the return
cycle. The Idler Valve is factory preset to provide 2800 psi
(193 BAR) return pressure and approximately 200 psi (14
BAR) idling pressure.



Description

5
918 series Powerig Hydraulic Units (HK786)
918 series Powerigs are intended for use in
indoor factory environments. If used outdoors,
they must be protected from the elements.
SYSTEMS:
918: Two (2) open-center circuits with 8,400 psi (580 BAR)
maximum operating pressure
918-5: Three (3) open-center circuits with 8,400 psi (580 BAR)
maximum operating pressure
POWER SOURCE:
10 HP (7.46 kw) Reuland electric motor 220 VAC (27.6A),
440 VAC (13.8A), or 550 VAC (10.8A), 3 phase; 60 Hertz; or
8.3 HP (6.19 kw) Reuland electric motor 380 VAC (13A), 3
phase; 50 Hertz. For other voltages and frequencies, contact
Alcoa Fastening Systems & Rings, Fasteners Division, Kingston
Operations.
PUMP: Dynex/Rivet constant-displacement hydraulic piston
pump, direct mounted to motor. Pump has six axial pistons.
Flow is split: 3 pistons per circuit in 918; 2 pistons per circuit
in 918-5
FLUID CONTROL: Four-way solenoid-operated directional
valve, pressure relief valve, and idler valve on each circuit.
RESERVOIR CAPACITY:
22.0 gallons (83.28 liters) center of sight gauge
COOLER: Fan and radiator air/oil heat exchanger
REMOTE CONTROL: 24 volt AC control circuit
OUTPUT PRESSURE:
PULL range: 5,800–8,400 psi (400–580 bar)
RETURN range: 800–7,000 psi (55–482 bar)
MAX FLOW RATE:
918: 2.0 gpm (7.6 l/m) per circuit
918-5: 1.33 gpm (5.0 l/m) per circuit
MAX OPERATING TEMP: 125° F (51.7° C)
HOSE KITS: Use only genuine Huck Hose Kits rated @ 10,000
psi (689.5 BAR) working pressure.
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.
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.
Specifications
NOTE: The units are shipped without hydraulic uid.
CSA CERTIFIED
UNIT WIDTH
inch (cm)
LENGTH
inch (cm)
HEIGHT
inch (cm)
WEIGHT
lbs. (kg)
OPERATIONAL
WEIGHT
lbs. (kg)
918 25.0 (63.5)44.0 (111.8)30.0 (76.2)585 (265)708 (321)
9185 29.0 (73.7)44.0 (111.8)30.0 (76.2)601 (272)724 (328)
Principle of Operation
See Figures 3 and 4, ElEctrical SchEmaticS, and Figure
5, hydraulic diagram. With the disconnect switch ON,
input power is supplied to open motor contacts and to
the transformer which develops 110 volts AC across its
secondary.
When the START button is momentarily pressed, the circuit is
completed through the motor contact, closing the contacts
and starting the motor. The START button is now bypassed
by a closed motor contact and the motor continues to run
when the START button is released, unless the STOP button is
pressed or the overload relay in the motor contact opens due
to motor overload.
After the START button is pressed, 24 volts AC is developed
across the secondary of transformer for the tool control
circuits. When tool trigger 1 is pressed, relay 1CR energizes,
closing its contacts in the operating solenoid circuit. This
action energizes the solenoid, changing the position of the
directional valve spool so that high-pressure hydraulic uid is
directed out the PULL pressure port and hose to Tool 1.
When the tool trigger is released, the solenoid de-energizes
and the valve spool returns to its original position, directing
the hydraulic uid out the RETURN pressure port and hose
to the tool. Each tool has a control circuit that allows it to
operate simultaneously and independently.

6
918 series Powerig Hydraulic Units (HK786)
Preparation for Use
NOTE: Electric current and PULL and RETURN pressure
requirements must be understood before preparing
these Powerig® Hydraulic Units for rst-time use. Set
PULL and RETURN pressures for each tool according to
tool instruction manual. Electric current to be used:
440 volts, 60 Hz, 3 phase; or
550 volts, 60 Hz, 3 phase; or
380 volts, 50 Hz, 3 phase.
GOOD SERVICE PRACTICES
The introduction of foreign material into the hydraulic
system will result in poor performance and repair down time.
To avoid this, observe the following good service practices:
1. Clean area around reservoir ller cap before removing it.
2. When adding hydraulic uid to the reservoir, use a clean
funnel and lter the uid with a 10 micron lter.
3. Do not let hose ttings and couplers lay on or drag
around on a dirty oor, or on the ground.
FIRST TIME STARTUP
1. Check that drain plug and hydraulic uid beater port
plugs are tight.
2. Fill reservoir with hydraulic uid (approximately 22
gallons) until uid level is in middle of uid level gauge.
3. Remove plastic shipping plugs from PULL and RETURN
pressure ports of TOOL 1, TOOL 2, (and for 918-5: TOOL 3).
4. Connect installation tools.
5. Remove POWERIG Hydraulic Unit hood.
6. Remove pipe plug in service tee in suction line. Use 5/8
inch hex key, P/N 504249.
7. Turn fan by hand to prime pump. Add uid until pump is
lled level with top of service tee. Reassemble pipe plug.
Use TEFLON stick type thread compound.
220*, 380, 440* OR 550 VOLT, 3PHASE OPERATION
1. Turn disconnect switch to OFF (see WARNING above) and
open covers or electrical control panel. See Figure 12.
2. Bring 220, 380, 440 or 350 volt, three-phase input cable (4
conductors) into disconnect compartment through hole
in front of panel and secure with connector furnished.
3. Remove line shield.
4. Connect power cable leads to terminals L1, L2, and L3.
Replace line shield.
5. Connect ground wire (green) to ground terminal
provided. Tighten nut on ground connection securely.
6. Close covers of electrical control panel.
7. Connect power cable to input power source.
8. Turn disconnect switch to ON and push START button.
9. Check that motor rotation is in the same direction as
arrow on motor cover. To reverse rotation, disconnect
power cable from power source, turn disconnect switch
to OFF and open covers. Remove line shield. Change
position of any two wires connected to terminals L1, L2, or
L3. Replace line shield. Close covers. Connect power cable
to power source. Turn disconnect switch to ON and push
START button.
10.Let hydraulic unit operate for approximately ve minutes
to remove air from hydraulic uid circuit. Check for leaks.
11.Push STOP button.
12.Check uid level and add hydraulic uid if necessary.
13. Reinstall hood.
14.Check output pressures. See Checking & Adjusting
Pressures section of this manual.
REGULAR USE BEFORE EACH OPERATION
1 Check hydraulic uid level in reservoir and add hydraulic
uid as required. Whenever hydraulic uid is added, it
must be ltered by a 10-micron lter.
2. Never operate unit without hood in place.
3. Inspect hoses for any damage, and replace as required.
4. Check and correct any leaks.
5. Connect power cable to power source compatible with
internal wiring of unit.
CONNECTING INSTALLATION TOOLS TO POWERIG
Figure 6 shows a typical hose and control cord hook-up Hose
and cord kits for connecting Installation Tools to the unit
are shown in the KitS and accESSoriES section of this manual.
Be sure that hose from port P of tool is connected to PULL
pressure port on POWERIG Hydraulic Unit, and hose for port
R of tool is connected to RETURN pressure port of unit.
WARNINGS:
Only a qualied electrician is to install the
power cable, according to local electrical
codes, and service the electrical control and
disconnect panel.
ALWAYS CONNECT PRIMARY POWER
SOURCE FROM HYDRAULIC UNIT WHEN
ANY MAINTENANCE IS PERFORMED ON
UNIT, including opening any panels or
access doors. SEVERE ELECTRICAL BURNS
and/or ELECTROCUTION MAY RESULT IF
THIS PRECAUTION IS NOT TAKEN. Other
severe injuries may occur from mechanical
components such as the fan if motor starts
up.
See PULL and RETURN pressures listed in
applicable tool instruction manual. Improper
settings of PULL and RETURN pressures
could cause violent rupture of the system or
tool. Fatal or severe injury from exploding
components/hydraulic uid could occur to
anyone in the immediate vicinity.
CAUTIONS:
Always prime pump after lling reservoir.
Do not use TEFLON®tape on pipe threads.
Tape can shred and break free into uid
lines, resulting in malfunctions. Apply Parker
Threadmate, Loctite 567, or Slic-tite stick
to male pipe threads per manufacturer’s
instructions.

7
918 series Powerig Hydraulic Units (HK786)
Checking & Adjusting Pressures
PREPARATION FOR USING GAUGE T124833CE
If necessary, prime and bleed the POWERIG®Hydraulic Unit.
See the PrEParation for uSE section of this manual. NOTE:
Check each tool's pressure separately.
1. Turn OFF the POWERIG. Connect the male coupler of
gauge to PULL pressure female coupler of Powerig.
2. Connect female coupler of gauge to RETURN pressure
male coupler of Powerig.
3. Turn needle valve of T-124833CE all the way out.
4. Install auxiliary electric switch and control cord assembly
(P/N 113056) in the control cord socket of the tool port
being checked, or use the trigger of the tool connected
to the ports being checked. Fluid will be directed out the
PULL pressure port when the switch is pressed. Connect
the Powerig to the primary power source and turn it ON.
CHECKING OUTPUT PRESSURES USING T124833CE
1. Close the valve (turn handle clockwise). Press and hold
auxiliary trigger switch. Read the PULL pressure on right
gauge. Release trigger switch.
2. Open valve by a few counterclockwise handle turns.
3. Press and Release auxiliary trigger switch to set the unit’s
internal valve. Hydraulic uid is directed out RETURN
pressure port.
4. SLOWLY close the valve. The pressure will rise, and then
sharply drop. Read the RETURN pressure on the left gauge
just before the pressure drops.
5. Open the valve. Turn OFF the Powerig.
6. Disconnect auxiliary trigger, then pressure setting gauge.
7. Refer to installation tool’s instruction manual for specic
PULL and RETURN pressures.
ADJUSTING OUTPUT PRESSURES
The POWERIG Hydraulic Unit should be prepared for
operation as described in PrEParation for uSE. Use Gauge
T-124833CE to check pressures before and after adjusting
PULL and RETURN pressures.
ADJUSTING COMBINATION VALVE P/N 119740
The 918 and 918-5 POWERIG Hydraulic Units are equipped
with valves that can be set at specic PULL and RETURN
pressures (see the applicable instruction manual for your
tool). There is a socket-head screw to adjust PULL pressure
and a dierent one to adjust RETURN pressure. See Figure 7.
PULL PRESSURE ADJUSTMENT
Use 5/16” hex key for PULL pressure adjusting screw.
Turn adjusting screw clockwise to increase pressure.
b. Turn adjusting screw counterclockwise to decrease
pressure.
c. Check resulting PULL pressure setting with Gauge
T-124833CE.
RETURN PRESSURE ADJUSTMENT
Use 5/16” hex key for RETURN pressure adjusting screw.
a. Turn adjusting screw clockwise to increase pressure.
b. Turn adjusting screw counterclockwise to decrease
pressure.
c. Check resulting RETURN pressure setting with Gauge
T-124833CE.
WARNINGS:
Turn OFF the Powerig prior to connecting
or disconnecting tools. If it is necessary to
connect or disconnect a tool while the unit
is running, use the following procedure for
maximum safety.
Connect tool’s hydraulic hoses to unit before
connecting tools switch control cord to unit.
If a malfunctioning cord switch is connected
rst, hydraulic unit may begin to cycle
unexpectedly. Unexpected cycling may lead
to serious injury. When connecting hoses,
switch MUST be connected last. Just as
important: When disconnecting hoses, switch
MUST be disconnected rst.
Maximum PULL pressure is 8400 psi (648
bar). Refer to specic tool instruction manual
for PULL and RETURN pressures for Huck
installation equipment. Severe personal injury
may occur if excessive pressures cause
violent failure of equipment.
WARNING: Turn OFF the hydraulic unit.
Accidental cycling of the unit may cause
severe injury when disconnecting couplings.
Fluid may unexpectedly spray.
CAUTION: The following check must be
completed quickly. Sustained high pressure
will cause premature wear on the unit.
CAUTION: Whenever possible, set Powerig
pressures to the lowest recommended
pressure to minimize wear on the equipment.
T-124833CE
Pressure Gauge

8
918 series Powerig Hydraulic Units (HK786)
Operating Instructions
1. Connect power cable to proper power source.
2. Turn DISCONNECT SWITCH to ON.
3. To start unit, push START button and then release.
4. Push STOP button to stop unit.
5. Press tool trigger to cycle tool. (When trigger is pressed,
tool piston will retract. When trigger is released, tool
piston will return.)
ALWAYS BE ALERT FOR:
(a) leaks at hose connections,
(b) damage to hoses, and
(c) hydraulic uid level.
WARNING: Severe personal injury may
result if connections or hoses fail.
Assembly of NPTF Threaded Components
AIR FITTINGS
1) Apply TEFLON®stick to male threads which do not have
pre-applied sealant per manufacturer’s recommendations.
(Proceed to All Fittings step 2)
HYDRAULIC FITTINGS
1) Apply Threadmate™to male and female threads which
do not have pre-applied sealant per manufacturer’s
recommendations. (Proceed to All Fittings step 2)
ALL FITTINGS:
2) Tighten to nger-tight condition.
3) Wrench tighten to 2-3 turns past nger-tight condition.
4) Final thread engagement can be checked (optional) by
measuring the dimension from the ange of male tting
to the end of the thread before assembly and subtracting
the distance under the ange after assembly.
THREAD SIZE FINAL THREAD ENGAGEMENT AT FULL MAKEUP
1/8-27 NPTF .235 inch (.59 cm)
1/4-18 NPTF .339 inch (.86 cm)
3/8-18 NPTF .351 inch (.89 cm)
Before operating the Powerig®Hydraulic Unit, make sure unit has been prepared for service as described
in PrEParation for uSE. Connect hoses and control cords as shown in connEcting inStallation toolS to
PowErig hydraulic unit.

9
918 series Powerig Hydraulic Units (HK786)
Maintenance
PREVENTIVE MAINTENANCE
An eective preventive maintenance program includes
scheduled inspections to detect and correct minor troubles:
1. Inspect hydraulic and electrical ttings to be sure they are
secure.
2. Inspect hoses frequently for signs of damage. Replace
hoses if damage is detected.
3. Inspect during operation to detect any abnormal heating,
vibration or leakage.
4. Inspect hydraulic uid periodically and replace if
contamination is detected. Clean sump lter if uid is
dirty and being replaced. NOTE: Light on bulkhead will
come on when lter is dirty and oil should be replaced.
5. Keep hood in place and keep all exterior surfaces clean.
6. Replace oil lter every six months or if oil lter light on
bulkhead comes on. A lter element can be ordered from
Huck, part number 507089.
7. Do not block ventilation louvers at end of unit. Maintain a
minimum of 4 inches of clearances from louvers to wall or
solid object.
COMBINATION VALVE OVERHAUL
Combination valves should be returned to the nearest repair
facility shown on the inside of the back cover of this manual
if a major overhaul is necessary. Minor overhaul includes
cleaning and replacing seals, perishable parts and high wear
components. Huck recommends only minor overhaul by the
user.
One spare combination valve should be kept on hand for
each POWERIG Hydraulic Unit.
Smear LUBRAPLATE 130AA, or hydraulic uid, on O-rings and
other components when reassembling combination valve.
Follow Figure 7 for proper position of all components.
OUTPUT PRESSURES
To prevent malfunctions, check and adjust PULL and
RETURN pressures of POWERIG® Hydraulic Unit. Check
pressures when:
• Unit is being used for the rst time.
• Any part of combination valve is repaired.
• Combination valve is replaced.
• Troubleshooting is to be performed.
• Before any tool is connected.
• Whenever tool does not perform as expected.
• Whenever unsure of the pressure setting.
LUBRIPLATE is a registered trademark of Fiske Brothers Rening Co.
CAUTION: Do not operate POWERIG if line
voltage is lower than 5 percent below normal.
WARNING: Only a qualied electrician
is to install the power cable, according
to local electrical codes, and service the
electrical control and disconnect panel.
ALWAYS DISCONNECT PRIMARY POWER
SOURCE FROM HYDRAULIC UNIT WHEN
PERFORMING MAINTENANCE. This includes
opening panels and access doors. SEVERE
ELECTRICAL BURNS OR ELECTROCUTION
MAY RESULT IF THIS PRECAUTION IS NOT
TAKEN. Other serious injuries may occur
from mechanical components, such as the
fan, if the motor unexpectedly starts.
WARNING: After overhauling combination
valve, PULL and RETURN pressures must be
checked. Serious personal injury may occur
if excessive pressure causes violent hose or
installation equipment failure.
WARNING: Excessive pressures may cause
violent rupture of some part of the fastening
system. Exploding components may cause
severe or fatal injuries to personnel in the
vicinity. If the system does not rupture,
continuous higher than normal pressure will
cause premature wear of equipment.

10
918 series Powerig Hydraulic Units (HK786)
918 & 918-5 Front View
Electrical Control Panel Assembly
(Figure `12)
130650
Diconnect
Switch
Indicator
Light
CAUTION
CAUTION
502961
Power Cable
Strain Relief
START
Button
STOP
Button
24V Control
Circuit
Receptacles
Circuit
Breakers
107752
Reservoir
Base
TOOL 1 Return
Pressure Port TOOL 1 Pull
Pressure Port
TOOL 2
Return
Pressure
Port
TOOL 2
Pull
Pressure
Port
503419
Fluid Level
Gauge
Hydraulic Fluid
Heater Ports
Models 918 and 918-5
Front View
TOOL 3
Return Pressure Port
(918-5 ONLY)
TOOL 3
Pull Pressure Port
(918-5 ONLY)
110144 (918)
114176 (918-5)
Hood
Figure 1

11
918 series Powerig Hydraulic Units (HK786)
Top View with Cover Removed
Return Line Assy
100047 Oil Filler Assy
Bulkhead
Electrical Control Panel Assy
TOOL 1 & TOOL 2
Front Bracket Assy
Motor
107768 (220V & 440V)
506635 (380V)
110635 (550V)
Oil Cooler
107754
Grommet
502939
(must be replaced together)
Fan 101999
Suction Line
Assembly 506495
Pressure
Lines
Bulkhead
Electrical Control Panel Assy
TOOL 1 & TOOL 2
Front Bracket Assy
TOOL 3
Electrical Enclosure Assy
100047 Oil Filler
Assy
Return Line Assy
See Figure 10
See Figure 10
See Figure 11
See Figure 12
See Figure 12
See Figure 14
See Figure 15
See Figure 16
Pump
110217
114200
Pump
Fan 101999
Oil Cooler 107754
Grommet 502939
(must be replaced together)
Pump-to-Motor
Coupling 110572
Pump-to-Motor
Coupling 110572
506495
Pressure
Lines
Suction Line
Assembly
See Figure 14
Motor
107768 (220V & 440V)
506635 (380V)
110635 (550V)
Model 918
Top View
Cover Removed
Model 918-5
Top View
Cover Removed
Figure 2

12
918 series Powerig Hydraulic Units (HK786)
918 & 918-5 Electrical Schematic
NOTE: The graphics identified below
appear in RED printing on the schematic.



Figure 3

13
918 series Powerig Hydraulic Units (HK786)
918-380 & 918-5/380 Electrical Schematic
NOTE: The graphics identified below
appear in RED printing on the schematic.



 

Figure 4

14
918 series Powerig Hydraulic Units (HK786)
918 & 918-5 Hydraulic Diagram
Figure 5

15
918 series Powerig Hydraulic Units (HK786)
Typical Hose and Control Cord Hook-up
Figure 6

16
918 series Powerig Hydraulic Units (HK786)
120073 Combination Valve Service Kit



















































Figure 7
Used on Combination
Valve, P/N 119740

17
918 series Powerig Hydraulic Units (HK786)
Hydraulic Pumps
For parts identification, see Figures 8 & 9 on the
following pages.
The hydraulic pumps that are used on POWERIG®Hydraulic Unit
models 918-2 and 918-3 are similar, except for the covers. The
918-2 pump cover has two outlets; the 918-3 pump cover has
three outlets.
For major overhaul, return pumps to the address shown on the
inside back cover of this manual. These pumps will be returned
to the manufacturer for overhaul and test, and will be returned
with a new warranty.
Minor servicing (clearing and replacing perishable and high-wear
components) can be done if replacement parts (shown in Figure
8) are available.
An extra pump for each POWERIG should be kept on hand.
TO REMOVE PUMP FOR OVERHAUL
For parts identification, see Figures 1, 2, 8, & 9.
1. Disconnect the electrical power supply from POWERIG and
remove the hood.
2. Disconnect the solenoid wires in the electrical panel or
remove the solenoids from the combination valves.
3. Disconnect the pressure hoses from the combination
valves.
4. Disconnect the return line hose.
5. Remove the six socket-head cap screws holding bracket and
combination valves. Lift bracket and valves, and set them
aside.
6. Loosen the pipe coupling in suction-line assembly. See
Figure 14, Item 6.
7. Remove two socket-head cap screws holding the pump to
the motor.
8. Support weight of pump and slide out of motor housing.
9. Pump to motor coupling (P/N 110572) comes out with the
pump. Remove the coupling only if necessary.
10. Remove six socket-head cap screws (Figure 8, Item 7) to
remove the cover when replacing O-rings, seats, balls, or
springs. (If this is the only service being performed, omit
steps 5, 6, 7, 8, and 9).
11. Remove the six socket-head screws (Figure 8, Item 6)
to remove the barrel for replacement of O-ring, piston
assemblies, or springs. (If this is the only service being
performed, omit steps 5, 6, 7, 8, and 9).
12. A worn shaft seal can be removed using a pointed rod.
13. Use the Pump Seal Kit listed in K & A.
14. Smear LUBRIPLATE®130-AA (Huck P/N 502723), or
hydraulic fluid, on O-rings when reassembling.
15. Tighten socket-head screws (Figure 8, Items 6 & 7) to 30–35
ft.-lbs. torque.
16. If pump to motor coupling was removed, reassemble with
coupling positioned 5/16" - 3/8" from pump flange.
17. Reassemble pump to motor. Tighten two socket-head
screws to 90 ft.-lbs. torque if plated and 120 ft.-lbs. if un-
plated.
18. Reassemble solenoids, pressure hoses, return hose, and
suction line. Use Threadmate®thread compound (P/N
508517) on pipe threads of fittings and hoses.
LUBRIPLATE is a registered trademark of Fiske Brothers Rening Co.
Threadmate is a registered trademark of Parker Intangibles LLC..
CAUTION: Pumps must be primed after
overhaul. See First-time Start-up. Check
output pressures. See CheCking & Adjusting
Output pressures.

18
918 series Powerig Hydraulic Units (HK786)
Hydraulic Pumps (continued)


110572 
5/16”-3/8”
Figure 9



   



Figure 8
Exploded View of
Split Flow Hydraulic
Pump
ITEM 918 918-5 DESCRIPTION QTY
1 110931 110931 Shaft Seal 1
2 109404 109404 Piston Assembly 6
3 109405 109405 Piston Return Spring 6
4 504649 504649 O-ring 1
5 110509 114195 Cover & Pin Assembly 1
5a 109615 114199 Cover 1
5b 109407 109407 Spring 6
5c 109413 109413 Ball 6
5d 109406 109406 Seat 6
5e 504617 504617 O-ring 6
6 500090 500090 Socket Head Screw 1” 6
7 500095 500095 Socket Head Screw 2.25” 6
8 * * Woodru Key 2
Pump and Coupling
POWERIG PUMP NO. TYPE
918, all voltages 110217 2-Port
918-5, all voltages 114200 3-Port

19
918 series Powerig Hydraulic Units (HK786)
Front Bracket Assembly
503706 2 Pipe Plug 21 590265 1 Hydraulic Diagram Sticker20 590260 1 Change Filter Sticker 19 590258 2 Caution Sticker (ref) 18 590136 2 TOOL 2 Sticker 17 590135 2 TOOL 1 Sticker 16 590133 2 Return Pressure Sticker 15 590132 2 Pull Pressure Sticker 14 590012CSA 1 Nameplate 13 504058 2 Elbow 12 504057 2 Hex Nipple 11 503683 2 Hex Nipple 10 503680 2 Street Elbow 9 505930 1 Indicator Light 8 500170 6 Flat Washer 7 502992 4 Drive Screw 6 501236 6 Socket Head Screw 5 110439 2 Coupler Body 4 110438 2 Coupler Nipple 3 119740 2 Combination Valve 2 113922 1 Front Bracket 1
12
20
19
12
9
5 7
(6) (6)
10
(2)
4
(2)
3
(2)
11
(2)
8
(2)
21 (2)
(2)
18 16
15
(2)
14
17
(4)
6 13
  Description Item


918 & 918-5
See Figure 11 for additional components of 918-5 series.
Solenoid Assy 115833 available for service contains Solenoid Tube 115832 and Solenoid Coil 115831
Figure 10

20
918 series Powerig Hydraulic Units (HK786)
Electrical Enclosure Assembly 918-5 series
 - Electrical Enclosure Assembly
918-5, Tool 3
123

4
6
5
7
8
9


10
11
12 13
14
15
16
17
18




19
Figure 11