Instruction Manual Huck Model 911D Diesel Engine Hydraulic Powerig Manufacturer: Alcoa Fastening Systems Ltd; Telford, United Kingdom Form No. 911D ENG Rev. 24.11.
911D Powerig Series Alcoa Fastening Systems (911D)
911D Powerig Series Alcoa Fastening Systems 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
911D Powerig Series Alcoa Fastening Systems HUCK FASTENING SYSTEMS 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.
911D Powerig Series Alcoa Fastening Systems 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.
911D Powerig Series Alcoa Fastening Systems 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.
911D Powerig Series Alcoa Fastening Systems 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.
911D Powerig Series 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 Alcoa Fastening Systems 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.
11D Powerig Series Alcoa Fastening Systems Utilisation Non-Bobtail Tools Huck Tool Series/Model Pull Pressure Max. bar/psi Return Pressure Max.
911D Powerig Series Alcoa Fastening Systems Pressures - definitions 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.
911D Powerig Series Alcoa Fastening Systems 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).
911D Powerig Series Alcoa Fastening Systems 6 Digital Pressure Switch (Swage Pressure) 5 Main Pressure Relief Valve (Pull Pressure) 15/15A Oil Return Line Filter & Condition Gauge Fuel Tank Filler Cap 14 Filler/Strainer 41 Handle Screw in, removable) 7 Digital Pressure Switch (Swage Pressure) 16 Oil Level/Temp Gauge 1 Diesel Engine 19 Hydraulic Quick Disconnect Coupling (Return Pressure) 18 Hydraulic Quick Disconnect Coupling (Pull Pressure) 40 Main Wheel 34 12 VDC Electrical Connector (non Bobta
911D Powerig Series Alcoa Fastening Systems Throttle Control Lever Lock Throttle Control Lever Stop Lever (shown in Engine run position) Stop Lever (stop Engine position) Engine Controls Main Components FIG.
911D Powerig Series Alcoa Fastening Systems Installation Tool P R 6 7 3 5 15/15A 2 1 LEGEND Ref. N0. 1 2 3 5 6 7 15 15A Part Number 911D/1 911D/2 911D/3 911D/5 911D/6 911D/7 911D/15 911D/15A Item Lombardini 15LD-350 Diesel Engine Pump Hydraulic Directional Valve Main Pressure Relief Valve (Pull Pressure) Digital Pressure Switch (Swage Pressure) Digital Pressure Switch (Return Pressure) Hydraulic Oil Return Line Filter Oil Filter Condition Gauge 911D Hydraulic Schematic FIG.
42 Fuse R2 R3 - 1 R1 R2 - 1 R1 - 1 911D Electrical Schematic 42 Fuse 3 HDV PULL PRESSURE SOLENOID 42 Fuse R3 - 3 R3 R4 - 1 B O B TAIL TO O L TRIGGER B O B TAIL TO O L LIMIT SWITCH NOTE: R1 TO R4 ARE RELAYS REF.
911D Powerig Series Alcoa Fastening Systems Preparation for First Time Use (Refer to FIG. 1 ) 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. CAUTION To avoid explosions or fire outbreaks, do not smoke or use naked flames during operations. Fuel vapours are highly toxic.
911D Powerig Series 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. Throttle Lever Lock Throttle Lever 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.
911D Powerig Series 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.
911D Powerig Series Alcoa Fastening Systems Adjustment Screw Clockwise to increase Pull Pressure Anti-clockwise to decrease Pull Pressure Lock Nut 7 Digital Pressure Switch (Swage Pressure) 6 Digital Pressure Switch (Swage Pressure) 5 Main Pressure Relief Valve (Pull Pressure) FIG.
911D Powerig Series Alcoa Fastening Systems 6. Consecutive pressing of S1 will change the value of the digit over the cursor from 1 to 9 and then 0. 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.
911D Powerig Series Swage Pressure (FIG 4 (only applicable when using IT type tools. Refer to Utilisation (page 6) for correct setting) Note: When using IT type Bobtail Installation Tools, fitted to the Powerig connector 35 with the electrical 8 pin Lemo Plug, the Digital Pressure Switch (Swage Pressure) 6, controls the hydraulic pressure to the tool during the pull cycle. This in turn controls the amount (length) of Bobtail fastener Collar swage. The higher the pressure, the more the Collar is swaged.
911D Powerig Series Alcoa Fastening Systems Connecting and testing a Bobtail Tool (after completing previous steps 1 to 17). 7. Prepare a sample joint with the Bobtail Fastener. Place the Collar (see note below), onto the Pin. IT type Bobtail Tools.... Note: Only Bobtail Fasteners of 12 mm (1/2”) diameter or larger, have thread form locking grooves into which a tab on the Collar locates. Rotating the Collar will enable it to be screwed hand tight to the joint face. 1.
911D Powerig Series which will be crushed by contact with the Anvil. Do not adjust the Swage Pressure too high as this increases the risk of Bobtail grooves being stripped/damaged or the Bobtail being broken away from the pin. In either event, this will prevent a Bobtail Collar Cutter from being used. ST type Bobtail tools...
911D Powerig Series Anvil, closing around the end of Pin. The Anvil will be forced forward toward the Collar Flange to complete the Collar swaging/forming. 10. Release the tool Trigger when the Collar is fully swaged or the Nose Assembly stops moving. When the Nose Assembly Anvil is free from the Collar, the Puller will release from the end of the Pin and enable the Tool/Nose Assembly to be removed from the installed fastener. 11.
911D Powerig Series Alcoa Fastening Systems 5 Main Pressure 15 Oil Relief Valve Return Line (Pull Pressure) Filter & Condition 14 Filler/Strainer Engine Oil Gauge Filler Cap 6 Digital Pressure Switch (Swage Pressure) Fuel Tank Filler Cap 1 Diesel Engine 7 Digital Pressure Switch (Return Pressure) 19 Hydraulic Quick Disconnect Coupling (Return Pressure) 41 Handle Screw in, removable) 34 12 VDC Electrical Connector (non Bobtail Tools 40 Main Wheel 35 12 VDC Electrical Connector or remote (Bobtail Tools)
Qty. 1 1 1 1 1 1 1 2 1 1 2 1 1 Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 (Oil Reservoir to Pump) 3/4 Hydraulic Hose Assy. 440 mm (Manifold Port P to under Relief valve) 1/4 Hydraulic Hose Assy.400 mm (Manifold Ports A & B to Pressure Switch Outlet) 1/4 Hydraulic Hose Assy.460 mm (Manifold Tee to Male Tee on Relief Tank Port) 3/8 Hydraulic Hose Assy.300 mm 3/8 Hydraulic Hose Assy.
Qty. No. 1 1 1 1 1 1 1 1 3 2 2 4 2 3 4 5 1 Ref.
1 1 1 1 1 1 1 4 1 1 2 2 3 30 31 32 33 34 35 36 37 38 39 40 41 42 No. Ref. Description - - - - Supplier Part No.
911D Powerig Series Alcoa Fastening Systems Preventive Maintenance 1. Before carrying out any maintenance, remove the key from the engine Key Switch to avoid accidental starting and electrical damage. manufacturer. 6. Refer to the engine manuals supplied with this Powerig for preventative maintenance details. 2. Regularly inspect the hydraulic fluid. If contamination particles larger than 20 um are present, then replace fluid.
911D Powerig Series Draining Hydraulic Fluid...... 1. Ensure that equipment is readily available to deal with any spillage of hydraulic fluid. 2. If possible, place the Powerig onto an oil tray or draining sink sufficient to retain 14 ltrs (3.11 Gals.) of fluid. 3. Remove the screws from the rear cover and remove cover. 13 Hose Alcoa Fastening Systems to be made for any leakage from the hose connection. re-closes-tighten the hose connection if any leakage is observed. 8.
911D Powerig Series Alcoa Fastening Systems HYDRAULIC FLUIDS * - <-- 0° C * 0° - 30° C HLP 32 HLP 46 AGIP AGIP OSO 35 AGIP OSO 45 ARAL ARAL Vitam GF 32 ARAL Vitam DE 32 ARAL Vitam HF 32 ARAL Vitam GF 46 ARAL Vitam DE 46 ARAL Vitam HF 46 AVIA AVILUB Hydr.-Oil RSL 32 AVILUB Hydr.-Oil HVI 32 AVILUB Hydr.-Oil RSL 46 AVILUB Hydr.
911D Powerig Series Alcoa Fastening Systems Important Note: The following pages contain the Material Safety Data Sheets (MSDS) for the Shell Tellus 46 Hydraulic Oil & the Esso Diesel Fuel which were both supplied with this Powerig when new. The MSDS for the engine oil is contained in the SEPA R ATE Diesel Engine manuals supplied with the Powerig.
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems
911D Powerig Series Alcoa Fastening Systems LIMITED WARRANTIES Tooling Warranty: Huck warrants that tooling and other items (excluding fasteners, and hereinafter referred as "other items") manufactured by Huck shall be free from defects in workmanship and materials for a period of ninety (90) days from the date of original purchase.
For the Long Haul™ A Global Organization Alcoa Fastening Systems (AFS) maintains company offices throughout the United States and Canada, with subsidiary offices in many other countries. Authorized AFS distributors are also located in many of the world’s industrial and Aerospace centers, where they provide a ready source of AFS fasteners, installation tools, tool parts, and application assistance.
