Huck POWERIG 940 User manual

August 6, 2015
HK496
InstructIon Manual
Model 940
POWERIG®Hydraulic unit
Makers of Huck®, Marson®, Recoil®
Brand Fasteners, Tools & Accessories

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
2
NOTICE
This manual applies to 940
serial number 3927 and above.
For any other serial numbers, please contact a Huck customer
service representative.

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
3
Contents
Safety ............................................4
Description........................................5
Specications .....................................5
Principle of Operation...............................6
Preparation for Use.................................6
Checking and Adjusting Pressures. . . . . . . . . . . . . . . . . . . . 7
Operation .........................................7
Maintenance.......................................8
Assembly Reference Drawings .................... 9-11
Powerig Options and Accessories . . . . . . . . . . . . . . . . . . . 12
Troubleshooting ..................................12

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
4
1. Ahalfhourlonghands-ontrainingsessionwithqualied
personnel is recommended before using Huck equipment.
2. Huck equipment must be maintained in a safe working
condionatallmes.Toolsandhosesshouldbeinspected
atthebeginningofeachshi/dayfordamageorwear.Any
repairshouldbedonebyaqualiedrepairmantrainedonHuck
procedures.
3. Repairman and Operator must read manual prior to using
equipment.WarningandCauonsckers/labelssuppliedwith
equipmentmustbeunderstoodbeforeconnecngequipmentto
anyprimarypowersupply.Asapplicable,eachoftheseconsin
thismanualhavespecicsafetyandotherinformaon.
4. ReadMSDSSpecicaonsbeforeservicingthetool.MSDS
Specicaonsareavailablefromtheproductmanufactureror
yourHuckrepresentave.
5. WhenrepairingoroperangHuckinstallaonequipment,always
wearapprovedeyeprotecon.Whereapplicable,refertoANSI
Z87.1 - 2003
6. OnlygenuineHuckpartsshallbeusedforreplacementsor
spares.Useofanyotherpartscanresultintoolingdamageor
personalinjury.
7. Ifapartaxedwithwarninglabelsisreplaced,orlabelsare
missingordamaged,theenduserisresponsibleforreplacement.
Refertoassemblydrawingandpartslistforreplacementpart
number and proper placement.
8. Disconnectprimarypowersourcebeforeperforming
maintenanceonHuckequipmentorchangingNoseAssembly.
9. Toolsandhosesshouldbeinspectedforleaksatthebeginningof
eachshi/day.Ifanyequipmentshowssignsofdamage,wear,
orleakage,donotconnectittotheprimarypowersupply.
10.Mounnghardwareshouldbecheckedatthebeginningofeach
shi/day.
11.Makesureproperpowersourceisusedatallmes.
12.Releasetooltriggerifpowersupplyisinterrupted.
13.Toolsarenottobeusedinanexplosiveenvironmentunless
specicallydesignedtodoso.
14.Neverremoveanysafetyguardsorpintaildeectors.
15.Whereapplicable,ensuredeectororpintailcollectorisinstalled
andoperangpriortouse.
16.Neverinstallafastenerinfreeair.Personalinjuryfromfastener
ejecngmayoccur.
17.Whereapplicable,alwaysclearspentpintailoutofnose
assemblybeforeinstallingthenextfastener.
18.Thereispossibilityofforcibleejeconofpintailsorspent
mandrels from front of tool.
19. Check clearance between trigger and work piece to ensure there
isnopinchpointwhentoolisacvated.Remotetriggersare
availableforhydraulictoolingifpinchpointisunavoidable.
20.Unsuitableposturesmaynotallowcounteracngofnormal
expectedmovementoftool.
21. 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installaontoolsbyoperatorsisanimportant
factorinmaintainingtooleciency,eliminangdownme,and
inprevennganaccidentwhichmaycauseseverepersonal
injury.
22.Neverplacehandsbetweennoseassemblyandworkpiece.Keep
hands clear from front of tool.
23.ThereisariskofcrushingiftooliscycledwithoutNoseAssembly
installed.
24.Toolswithejectorrodsshouldneverbecycledwithoutnose
assemblyinstalled.
25.Whentwopiecelockboltsarebeingusedalwaysmakesurethe
collarorientaoniscorrect.Seefastenerdatasheetforcorrect
posioning.
26.Toolisonlytobeusedasstatedinthismanual.Anyotheruseis
prohibited.
27.Thereisariskofwhippingcompressedairhoseiftoolis
pneudraulicorpneumac.
28.Releasethetriggerincaseoffailureofairsupplyorhydraulic
supply.
29.Useonlyuidsorlubricantsrecommended.
30.Disposalinstrucon:Disassembleandrecyclesteel,aluminum
andplascparts,anddrainanddisposeofhydraulicuidin
accordancewithlocallawfulandsafepracces.
31. Iftoolisxedtoasuspensiondevice,ensurethatthedeviceis
securepriortooperangthetool.
safety InstruCtIons
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.

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
5
CSA CERTIFIED
WIDTH: 16.1 inches (40.9 cm)
LENGTH: 13.9 inches (35.4 cm)
HEIGHT: 18.5 inches (47 cm)
WEIGHT: 66 pounds (30 kg) (with empty reservoir)
ELECTRICAL SYSTEM:
115VAC (25A), 50/60hz, single phase
CONTROL SYSTEM:
Solenoid operated directional valve, 24V
MOTOR:
12000 RPM, 1-1/8 HP, 25 amps. nominal
PUMP:
2-stage, gear-piston type, 70 in3/min @5,000 psi out pres-
sure (Output pressure adjustable to 10,000 psi)
RESERVOIR CAPACITY: 2.6 gallons (9.8 liters)
PRESSURE SETTING AS SHIPPED:
RETURN: 2,200-2,400 psi (15,200-16,500 kPa)
PULL: 5,400 - 5,700psi (37,200 - 39,300 kPa)
Minimum Operating Temperature (ambient): 0° (18°C)
Maximum Hydraulic Fluid Temperature: 150°F (65°C)
HYDRAULIC FLUID: Hydraulic uid shall meet DEXRON®
III, DEXRON VI, MERCON, Allison C-4 or equivalent ATF
specications.
Fire resistant uid may be used if it is an ester based uid
such as Quintolubric HFD or equivalent. Water based uid
shall NOT be used as serious damage to equipment will
occur.
DEXRON is a registered trademark of General Motors Corporaon.
speCIfICatIons
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fIgure 1
See Figures 1 & 5. Model 940 POWERIG®Hydraulic Unit
is a portable, electrically operated power source designed
to operate all Huck hydraulic installation equipment exclud-
ing Huck-Spin®tools. Model 940 operates on 115 volt AC,
50-60 Hz, one-phase electrical power. The power cord is a
10/3 SJTO cord with a NEMA L5-30 plug. The motor on the
Powerig is rated at 115V, 50/60Hertz, 25A.
An electrical enclosure contains a motor contactor, trans-
former, relay and circuit breaker. Hydraulic pressure is
developed by a two-stage, gear-piston pump driven by a 1
1/8 horsepower universal electric motor. Pressurized uid is
directed by a four-way directional valve to either the PULL
or RETURN port of the installation equipment. The four-way
directional valve is operated by a 24 volt AC control circuit.
The high pressure relief valve controls PULL pressure
(maximum pressure of the unit) and is adjustable by the
operator. An internal relief valve is preset at the factory to
protect the Operator and equipment. The internal relief is
not adjustable by the operator. A pressure switch controls
RETURN pressure and turns off the POWERIG Hydraulic
Unil at the end of an installation cycle. Pressures are adjust-
able to match Huck equipment being used. See applicable
tool instruction manual for pressure settings for other Huck
installation equipment.
Hydraulic uid is stored in the reservoir which also serves
as the base. Remove the ller cap/dipstick to check uid
level and to add uid. Hydraulic quick disconnect cou-
plers are furnished for connecting hoses from installation
equipment.
DesCrIptIon
Main Components

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
6
FIGURE 2 shows the electrical schematic diagram of
the POWERIG®Hydraulic Unit.
Pressure switch (PS) contacts are normally
closed. Increasing pressure opens contacts.
When the tool trigger switch is depressed, 24 volts
AC is applied between relay terminals CR13 and
CR14 activating the relay coil and closing two sets
of contacts, CR9-CR5 and CR12-CRS. Closing con-
tacts CR9-CR5 starts the motor. Closing contacts
CR12-CR8 activates the solenoid coil of the pilot
valve. The pilot valve shifts the directional valve
spools.
Pressurized uid is directed to the PULL pressure
port of the installation equipment.
When the tool trigger switch is released, the relay
contacts open. The solenoid coil is dc-activated and
the spring return of the pilot valve shifts the direction-
al valve spools. Pressurized uid is directed to the
RETURN pressure port of the installation equipment.
The motor contactor is held closed until the preset
RETURN pressure is reached and pressure switch
(PS) contacts open. The motor turns off, the pres-
sure drops, and pressure switch returns to the closed
(normal) position.
Service
Introduction of foreign material into Hydraulic Unit will
result in poor performance and down time for repair.
To avoid this, observe the following good practices:
Clean the area around the ller cap before adding
hydraulic uid.
Use a clean funnel with a lter.
Keep quick-disconnect couplers clean by keeping
them off the oor. Wipe off quick-disconnect couplers
before connecting them.
Before Use
Fill the reservoir with hydraulic uid, approximately
2.6 gallons (9.8 liters), until the uid level is between
the grooves of the dipstick.
The POWERIG Hydraulic Unit is shipped without
hydraulic uid.
prInCIple of operatIon
preparatIon for use
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fIgure 2
Electrical Schematic Diagram

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
7
CHECKING PRESSURES
Check PULL and RETURN pressures before use,
before troubleshooting, and after overhauling.
See pressures given in the specic tool
instruction manual. For checking pressures, use
T-124833CE PRESSURE GAUGE and PRESSURE
GAUGE INSTRUCTION MANUAL.
ADJUSTING PRESSURES
NOTE: Use “T” gauge T-124833CE to check pres-
sures during adjustment. Set pressures according to
the specic installation equipment manual.
ADJUSTING PULL PRESSURE
NOTE: PULL pressure is the maximum POWERIG®
pressure. Do not exceed the pressure rating of the
installation equipment. See the installation equipment
manual for pressure rating.
1) Loosen the jam nut of the high pressure
relief valve.
2) Turn the adjusting screw clockwise to increase
PULL pressure OR counterclockwise to decrease
PULL pressure.
3) Tighten the jam nut after PULL pressure has
been adjusted.
4) Check PULL pressure. Follow instructions in the
appropriate section of this manual.
ADJUSTING RETURN PRESSURE
1) Loosen the jam nut on pressure switch.
2) Turn the adjusting screw clockwise to increase
RETURN pressure OR counterclockwise to
decrease RETURN pressure.
3) Tighten the jam nut on pressure switch after
return pressure has been adjusted.
4) Check RETURN pressure. Follow instructions in
the appropriate section of this manual.
CheCkIng anD aDjustIng pressures
WARNING: Maximum PULL pressure is
8400 psi. Refer to specic tool instruction
manual for PULL and RETURN pressures.
Severe personal injury may occur if
excessive pressures cause violent failure
of equipment. Higher than normal pres-
sures will also cause premature wear of
equipment.
WARNING: If recommended maximum
pressure is exceeded, violent failure of
fastening system may occur. This may
cause severe personal injury.
operatIon
Before each use:
1) Check the uid level in the reservoir and add
hydraulic uid as required.
2) Inspect hoses for damage and wear. If hoses
show wear that has removed more than the sur-
face texture, they must be replaced.
3) Check the entire system and repair any leaks.
4) Check electrical cord and extension for abrasion
and replace as required.
Be sure that:
1) Hose from PULL PRESSURE on the control panel
runs to the port stamped with a letter P on the
tool.
2) Hose from RETURN PRESSURE on the control
panel runs to the port stamped with letter R on the
tool.
Plug the control cable from the tool into the two-prong
socket on the POWERIG Hydraulic Unit control panel.
Depress the tool trigger switch and let the POWERIG
Hydraulic Unit operate for a few minutes to circulate
uid and remove air from the system.
Attach a nose assembly to the installation equipment.
Fasteners may now be installed. Follow instructions in
the tool manual.
Operating Tools
Plug the power cord into a grounded wall outlet.
Check pressures and adjust as necessary. See the
appropriate sections in this manual. WARNINGS must
be understood before checking pressures.
Connect hydraulic hoses from a HUCK hydraulic tool
to the Powerig Hydraulic Unit.

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
8
MaIntenanCe
PARTS LIST
See Figures 3-6 for part numbers.
WIRING
See Figure 6 for wiring diagram and TABLE 1 for wire
list.
PREVENTIVE MAINTENANCE
An effective preventive maintenance program includes
scheduled inspections to detect and correct minor
troubles. Perform the following steps monthly during
normal use:
Inspect hydraulic and electrical ttings 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 heat-
ing, vibration or leakage.
Inspect hydraulic uid. If contamination (particles,
water, sludge, etc.) is detected, clean the reservoir and
replace uid.
Clean exterior surfaces.
Check supply voltage. Do not operate the the
POWERIG®Hydraulic Unit if the line voltage is more
than 5 percent above or below 115 Volts.
SPARE PARTS
The quantity of spare parts that should be kept on
hand varies with the application and number of the
POWERIG Hydraulic Units in service. For directional
valve and pilot valve maintenance, Seal Kit, 124100,
should be kept on hand at all times. This kit contains
O-rings and back-up 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.
DIRECTIONAL VALVE OVERHAUL
If minor overhaul of the directional valve (cleaning and
replacing O-rings and back-up rings) is necessary,
Seal Kit, 124100, is available. If major overhaul is
necessary, return the directional valve to the nearest
repair facility shown on the inside of the back cover.
Clean components in mineral spirits. Smear
LUBRIPLATE 130AA, or equivalent, on O-rings and
mating surfaces to aid assembly and prevent damage
to O-rings. LUBRIPLATE is trademarked and manu-
factured by Fiske Brothers Rening Co. and is avail-
able in most localities. A handy tube of LUBRIPLATE
130AA is available from Huck as part number 502723.
INTERNAL ADJUSTMENT OF PRESSURE SWITCH
1. Remove the top cover of the switch.
2. Loosen two screws located 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 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 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.
REPLACING PUMP TO MOTOR COUPLING
The pump to motor coupling can be replaced
by removing 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 pump requires overhaul return it, or the complete
unit, to the nearest repair facility shown on the inside
of the hack cover.

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
9
Note:
This assembly is purchased
complete. The bill of material
listed is for reference and
replacement part purposes
only.




(10)




























(4)








with











(4)





fIgure 4
111345 puMp, Motor, ValVe asseMbly

940 series Powerig® (HK496) Alcoa Fastening Systems & Rings
10
506362 Contactor
110685 Female Base 508266
Strain
Relief
506365 Relay Socket 502767 Screw 502769 Screw
506366
Relay &
506393
Hold-down
Spring
506363
Circuit
Breaker
128187 Power
Cord Assy
(Includes Strain Relief 508266)
502783 Screw 500693 Lockwasher 500234 Hex Nut
590303 Schematic Sticker
506368 Enclosure Gasket
123479
Enclosure
507293
Transformer
500424
Screw (4)
502767
Screw (2)
502758 Screw (2)
590131
Sticker
(115V AC)
590131
Sticker
(Class 2
Circuit 30V)
123433
Enclosure
Panel
590134
Sticker
(24V AC)
501214 Screw (3)
590012 Nameplate 502992 Screw (4)
Motor Cord
502783
Screw (4)
Pressure Switch Solenoid
123432 Motor Gasket
506364
Strain
Relief
fIgure 5
123490 eleCtrICal enClosure asseMbly