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1
Safety Instructions
2
Instruction Manual Description
3
940-220AUS Specifications
3
Powerig® Hydraulic Unit Preparation for Use
5
Checking Pressures &
Adjusting Pressures
5
Operating Instructions
6
Maintenance
6
Troubleshooting
7
Spare Parts & Accessories
9
NOTICE
THIS MANUAL APPLIES TO MODEL
940-220AUS POWERIG®
SERIAL NUMBER 2009 AND ABOVE
1
940-220AUS POWERIG® Hydraulic Unit
Safety Instructions
This instruction manual must be read with particular attention 11. If there is a pinch point between trigger and work piece use
to the following safety guidelines, by any person servicing or remote trigger. (Remote triggers are available for all tooling.)
operating this tool.
12. Do not abuse tool by dropping or using it as a hammer.
Never use hydraulic or air lines as a handle. Reasonable
GLOSSARY OF TERMS AND SYMBOLS:
care of installation tools by operators is an important factor
- Product complies with requirements set forth by the in maintaining tool efficiency, eliminating downtime, and in
relevant European directives. preventing an accident which may cause severe personal
injury.
- READ MANUAL prior to using equipment.
13. Never place hands between nose assembly and work piece.
- EYE PROTECTION IS REQUIRED while using this 14. Tools with ejector rods should never be cycled without nose
equipment. assembly installed.
- HEARING PROTECTION IS REQUIRED while using 15. When two piece lock bolts are being used always make
this equipment. sure the collar orientation is correct. See fastener data sheet
of correct positioning.
WARNINGS: Must be understood to avoid
severe personal injury.
2
940-220AUS POWERIG® Hydraulic Unit
Description
Model 940-220AUS POWERIG® Hydraulic Unit is a portable, The four-way directional valve is operated by a 24 volt AC control
electrically operated power source designed to operate all Huck circuit. The high pressure relief valve controls PULL pressure
Hydraulic equipment excluding HUCK-SPIN tools. (maximum pressure of the unit) and is adjustable by the operator.
Pleaser refer to Figure 1. Bold text in this section of the manual An internal relief valve is preset at the factory to protect the
indicates a part identified in Figure 1. Model 940-220AUS operator and equipment. The internal relief is not adjustable by
operates on 230 volt AC, 50 Hz single phase electrical power. The the operator.
POWERIG® Hydraulic Unit requires 10amp (minimum) circuit with
A pressure switch controls RETURN pressure and turns off the
a common 10amp GPO (General Power Outlet).
POWERIG® Hydraulic Unit at the end of an installation cycle.
An electrical Enclosure contains a motor Contactor, a
Pressure are adjustable to match Huck equipment being used. See
transformer, a relay and a circuit breaker. See also Figure 2.
applicable tool instruction manual for pressure settings for other
Solenoid contactor should not be accessed by an unqualified
Huck installation equipment.
personnel.
Hydraulic fluid is stored in the reservoir which also serves at the
Hydraulic pressure is developed by a two-stage, gear piston
base. Remove the filler cap to check fluid level and to add fluid.
pump driven by a 1 1/8” horsepower universal electric motor.
Hydraulic quick disconnect couplers are furnished for
Pressurized fluid is directed by a four-way directional valve
connecting hoses from installation equipment.
to either the PULL port or the RETURN port of the installation
equipment.
Specifications
WIDTH: 16.1 inches (409mm) PRESSURE SETTING AS SHIPPED
LENGTH: 13.9 inches (354mm) RETURN: 2,200 - 2,400 psi (15,200 - 16,500 kPa)
HEIGHT: 18.5 inches (470mm) PULL: 7,400 - 7,800 psi (51,021 - 53,779 kPa)
WEIGHT: (w/o Hyd. Fluid) 66 pounds (30Kg) RESERVOIR CAPACITY: 2.6 gallons (10 Litres)
ELECTRICAL SYSTEM: 230 volts, 50/60 Hertz, Single Phase, AC MINIMUM OPERATING TEMPERATURE: (ambient) 0o F (18o C)
CONTROL SYSTEM: Solenoid Operated Directional Valve MAXIMUM HYDRAULIC FLUID TEMPERATURE: 150o F (65o C)
MOTOR: 12,000 RPM, 1-1/8 HP, 20 amps. nominal
NOTE: Hydraulic Fluid will be supplied by Arconic Fastening
PUMP: 2 Stage. Gear-Piston type, 70 cu. In./min. @ 5,000 psi Systems and Rings only if shipped in Australia.
out pressure (Output pressure adjustable to 10,000 psi) 940-220AUS POWERIG® supplied with oil and ready to use.
Motor Pressure
and Switch
Pump
Quick
Disconnect
Coupler
High Pressure
Relief Valve
Quick
Disconnect
Coupler
Power Cord
Four-Way
Reservoir Directional
Valve
3
940-220AUS POWERIG® Hydraulic Unit
TOOL
TRIGGER CONTACTOR K1
K1/ 4
K1/3 CONTACTOR K2
K2/4
PRESSURE
K2/3 SWITCH
CIRCUIT
BREAKER
3 A
24 VAC
230 VAC
A N
K 1 /1 SOLENOID 1 K1 / 2
K2 /1 MOTOR K2 /2
INDUCTIVE FILTER
CORCOM 20VW1
A
N
4
940-220AUS POWERIG® Hydraulic Unit
Checking Pressures
Checking PULL Pressure and RETURN Pressure
WARNINGS: Maximum PULL pressure is 8400
Checking pressures before use, before troubleshooting, and psi.
after overhauling. See pressures given in the specific tool
instruction manual.
Refer to specific tool instruction manual for PULL and RETURN
For Checking pressures, use T-124833 PRESSURE GAUGE and pressures. Severe personal injury may occur if excessive pressures
PRESSURE GAUGE INSTRUCTION MANUAL. cause violent failure of equipment. Higher than normal pressures
will also cause premature wear of equipment.
For Adjusting pressures, see ADJUSTING PRESSURES in this
manual.
Adjusting Pressures
NOTE: Use “T” gauge T-124833 to check pressures during Adjusting RETURN Pressure
adjustment, see the CHECKING PRESSURES section of this
manual. Set pressures according to the specific installation 1. Loosen the jam nut on pressure switch.
equipment manual. 2. Turn the adjusting screw clockwise to increase RETURN pres
sure OR counter-clockwise to decrease RETURN pressure.
Adjusting PULL Pressure 3. Tighten the jam nut on pressure switch after return pressure
NOTE: PULL pressure is the maximum POWERIG pressure. Do has been adjusted.
not exceed the pressure rating of the installation equipment. See 4. Check RETURN pressure. Follow instructions in the
the installation equipmen manual for pressure rating. appropriate section of this manual.
WARNINGS: If recommended maximum pres-
sure is exceeded, violation failure of fasten-
ing system may occur. This may cause severe
personal injury.
5
940-220AUS POWERIG® Hydraulic Unit
Operating Instructions
Each time before using the POWERIG® Hydraulic Unit WARNINGS: Must be understood before
1. Check the fluid level in the reservoir and add hydraulic fluid as checking pressures.
required.
2. Inspect hoses for damage and wear. If hoses show wear Connect a Huck hydraulic tool to the POWERIG® Hydraulic Unit
that has removed more than the surface texture, they must using a hose kit. See TABLE 2 for hose kit part numbers.
be replaced.
Be sure that:
3. Check the entire system and repair any leaks.
4. Check electrical cord and extension for abrasion and replace 1. Hose from PULL PRESSURE on the control panel runs to the
as required. port stamped with a letter “P” on the tool.
2. Hose from RETURN PRESSURE on the control panel runs to
Operating Tools the port stamped with the letter “R” on the tool.
Plug the power cord into a grounded wall outlet. If an extension is Plug the control cable from the tool into the two-prong socket on
used, it should be UL type SO or STO, 660 volt, 12/3 if 25 feet long the POWERIG® Hydraulic Unit control panel.
and 10/3 if 50 feet long. Depress the tool trigger switch and let the POWERIG® Hydraulic
Never drag POWERIG by cord, use a two man lift. Unit operate for a dew minutes to circulate fluid and remove air
from the system.
Check pressures and adjust as necessary. See the appropriate
sections in this manual. Attach a nose assembly to the installation equipment. Fasteners
may now be installed. Follow instructions in the tool manual.
Maintenance
Parts List Troubleshooting
See Figures 3 for part numbers reference. Always check the simplest possible cause of malfunction first. For
example, blown fuse, tripped circuit breaker, defective switch or
Preventative Maintenance control cord. Eliminate each possible cause until the defective
circuit or part is located. Where possible substitute known good
An effective preventative maintenance program includes parts for suspected bad parts. A qualified electrician should check
scheduled inspections to detect and correct minor troubles. out the electrical system. Use the TROUBLESHOOTING GUIDE
Perform the following steps monthly during normal use: as an aid in locating trouble and correcting it.
1. Inspect hydraulic and electrical fittings to be sure they are
secure.
2. Inspect hoses for signs of damage. Replace hoses if abrasion is
deeper than the surface texture.
3. Inspect hydraulic fluid. If contamination (particles, water,
sludge, etc) is detected, clean the reservoir and replace fluid.
4. Clean exterior surfaces.
5. Check supply voltage. Do not operate the POWERIG®
Hydraulic Unit if the line voltage is more than 5 percent above
or below 230 Volts.
6
940-220AUS POWERIG® Hydraulic Unit
Troubleshooting Guide
Trouble Probable Cause
1. Motor fails to start when tool switch is depressed 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
2. Motor runs, but tool will not reciprocate a) Hoses not coupled properly
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
3. Pintail of fasteners 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
f) Worn seals in hand tool
4. Tool will not return when switch is released a) RETURN pressure set too low
(Tool will not push nose assembly off swaged fastener) b) Hoses not coupled properly
c) Worn or defective solenoid
d) Worn or defective pilot valve
5. Motor fails to shut-off when installation cycle is a) RETURN pressure switch set too high
completed b) Hydraulic fluid viscosity not proper or level is low
c) Hydraulic fluid overheated
d) Defective limit switch in pressure switch assembly
6. Pump making noise throughout entire cycle a) Pump is cavitating-fluid level may be low or fluid viscosity too
heavy
b) Strainer is dirty and clogged
7. Tool operation slow - entire cycle does occur a) Pump is cavitating-fluid level may be 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
7
940-220AUS POWERIG® Hydraulic Unit
500071
Screws (10)
107317
Filler/Breather
Cap
9625
111415 Pressure
Motor Brush Switch Assembly
Set
106397
External
Relief Valve
Pilot Valve
Adapter Plate
Micro-Switch
103918 Pump-to-
Motor Coupling &
112117 1-1/8 HP .020
220V Motor .030
Platen
500067
Screws (4)
103596 Directional
111364 Valve
Cover Plate
107217 Adapter Union
111357 Cover
Plate Gasket 503165 Back-up Ring &
504408 O-Ring
111355 103904
Filter Assy Return Line
8
940-220AUS POWERIG® Hydraulic Unit
Spare Parts
The quantity of spare parts that should be kept on hand varies Other parts should be available to the service technician as
with the application and number of the POWERIG Hydraulic Units required.
in service.
Pump Overhaul
If pump requires overhaul return it, or the complete unit, to the
nearest repair facility shown on the inside of the back cover.
Hose and Control Cord Kits - Hose and control kits are available 26 118309-26, 111955 110839, 110839C
as shown in table.
52 118309-52, 112176
9
940-220AUS POWERIG® Hydraulic Unit
Set Screw
Spring Retainer
Locknut .020
.030
Platen
Sealant to
Plug Screw
Spring Retainer
Switch
Adjusting Screw Adjusting
Screw
Switch Switch
Button Mounting
Bracket
10
940-220AUS POWERIG® Hydraulic Unit
Industrial Fasteners Division Industrial Distribution Group Industrial Fasteners Division Industrial Fasteners Division
Group Headquarters 14300 Clay Terrace Blvd. 1508 Centre Road Unit C, Stafford Park 7
8001 Imperial Drive Suite 250 Clayton, Victoria 3168 Telford, Shropshire TF3 3BQ
Waco, TX 76712, USA Carmel, IN 46032, USA Australia United Kingdom
PO BOX 8117 Tel: 800 826 2884 Tel: +61 3 8545 3333 Tel: +44-1952-2900-11
Waco, TX 76714-8117, USA Fax: 800 573 2645 Toll Free: 1800 363 049 Fax: +44-1952-2904-59
Tel: 800 388 4825 Fax: +61 3 8545 3390
Tel: 254 776 2000 Industrial Fasteners Division Fasteners Division
Fax: 254 751 5259 Avenida Parque Lira Industrial Fasteners Division 9 rue de Cressonnieres
79-402 Tacubaya Unit No. 28, Chowringhee Court 72110 Saint Cosme en Vairais
Fasteners Division Mexico C P 11850 55/1, Chowringhee Road France
1 Corporate Drive Tel: +52 55 5515 1776 Kolkata - 700071 Tel: +33 0 243 314100
Kingston, NY 12401, USA Fax: +52 55 5277 7564 India Fax: +33 0 243 314141
Tel: 800 278 4825 Tel: +91 33 4069 9170/80
Tel: 845 331 7300 Industrial Fasteners Division Fax: +91 33 4069 9184 Fasteners Division
Fax: 845 334 7333 Av. NacÕes Unidas, 12.901 Industriestrasse 6
Torres Oeste, 3° andar Industrial Fasteners Division D-65779 Kelkheim
Industrial Distribution Group São Paulo - SP - Brasil Arconic Japan Ltd. Germany
1925 North MacArthur Drive Tel: 04578 000 #1013 NBF Hibiya Bldg. Tel: +49 0 6195 8050
Tracey, CA 95376, USA Fax: +55 11 5509 0200 Uchisaiwai-cho, Chiyoda-ku Fax:+ 49 0 6195 2001
Tel: 800 826 2884 Tokyo 100-1011
Fax: 800 573 2645 Japan
Tel: +81 3 3539 6577
Fax: +81 3 3539 6585
Fasteners Division
58 Yinsheng Road, Shengpu
Suzhou Industrial Park
Suzhou Jiangsu 215126
China
Tel: 0512 6286 3800-8888
Fax: 0512 6286 3810
Huck is Forever, For the Long Haul, The Future of Fastening with regard to properties of the products shown and/
Technology, The Future of Assembly Technology, and Tools or the means for selecting such products, and is not
of Productivity are service marks of AFS. AFS provides intended to create any warranty, express, implied, or
technical assistance regarding the use and application of statutory; all warranties are contained only in AFS’s
Huck fasteners and tooling. written quotations, acknowledgements, and/or purchase
orders. It is recommended that the user secure specific,
NOTICE: The information contained in this publication is up-to-date data and information regarding each
only for general guidance application and/or use of such products.