Huck Model 911D

911D Powerig SeriesAlcoa Fastening SystemsPressures - definitionsPull Pressure:This is the maximum hydraulic pressure ofthe Pump which is set and adjusted withthe Main Pressure Relief Valve (5). Inparticular, it controls the maximumhydraulic pressure applied to the front ofthe Tool Piston during the “Pull” stroke(Pulling on the Fastener Pintail), enablingthe complete Fastener installation.Swage Pressure:Sometimes called Cut-Off Pressure, this isthe hydraulic pressure which is applied tothe front of the Tool Piston, enablingswaging of the Collar during theinstallation of Bobtail Fasteners whenusing IT type Bobtail Tools. This pressureis set using the Digital Pressure Switch (6)and is adjusted to ensure completeswaging of the Collar when the value ofthe set Swage Pressure is reached. Thispressure will always be set lower than thePull Pressure.Return Pressure:This is the hydraulic pressure applied tothe rear of the Tool Piston and is set andadjusted with the Pressure Switch (7). Inparticular, it controls the maximumhydraulic pressure applied to the rear ofthe Tool Piston during the return stroke,enabling the Tool/Nose Assembly to ejectfrom the installed Fastener.Servicing PowerigOnly an appropriately qualified and competent person should service any Diesel Enginehydraulic or electrical components.A SEPARATE Manual is provided for the Diesel Engine.Alcoa Fastening Systems Account Managers and Systems Engineers are located in yourarea to offer assistance you require in solving your installation problems.If you need assistance by telephone, please call Alcoa Fastening Systems CustomerServices at Telford UK. tel 44 1952 290011

911D Powerig SeriesAlcoa Fastening SystemsPrinciple of Operation with Bobtail ToolsNon Bobtail ToolsWhen the tool trigger is depressed :Relay R2 is energised which alsoenergises Relay R1 via contact R2-1(latched in by the Digital Return PressureSwitch 7).Normally open Relay contacts R2-3 closesto operate the HDV 3 solenoid, allowingfluid through the HDV via outlet port PNormally closed Relay contacts R2-2open, preventing the Return PressureHDV solenoid from operating while thepull pressure HDV solenoid is energised.The Installation Tool Piston movesrearwards to begin the Fastenerinstallation cycle.When the Installation Tool trigger isreleased, Relay R2 is de-energised,contacts R2-3 open to de-energise theHDV Pull Pressure solenoid. relaycontacts R2-2 close to energise theReturn Pressure solenoid, allowing fluidthrough the HDV via outlet port R.The Installation Tool piston movesforward.When the Piston reaches the fully forwardposition, pressure in the return lineincreases and opens the Digital ReturnPressure Switch 7 contacts, which deenergises Relay R1. This also deenergises the HDV Return Pressuresolenoid and the Digital Return PressureSwitch then recloses (re-closes-sets).The installation cycle is now complete.Bobtail Tools (when connected to thePowerig via the Multi-Pin Lemo Plug)When the Bobtail Tool Limit Switch isactivated (LED Light on ), and the Tooltrigger is pressed, Relay R3 is energised(and latched - see Note 1). which alsoenergises relay R1 via contact R3-1(latched in by the Digital Return Pressureswitch). Normally open Relay contacts R3-3 close to operate the HDV 3 PullPressure solenoid, allowing fluid throughthe HDV via outlet port P. Normally closedRelay contacts R3-2 open, preventingReturn Pressure HDV solenoid fromoperating while the pull pressure HDVsolenoid is energised.The Installation Tool Piston movesrearwards to begin the Fastenerinstallation cycleWhen the Swage Pressure reaches thepressure set on the Digital SwagePressure Switch 6 Relay R4 energisesand latches in via Relay R1-3 and RelayR4-2 contacts.Normally closed Relay R4-1 contactsopen and de-energises Relay R3.R3-3 contacts open to de-energise theHDV Pull Pressure solenoid.Relay R3-2 contacts close to energise theHDV Return Pressure solenoid allowingfluid through the HDV outlet port RThe Installation Tool Piston movesforward.When the Piston reaches the fully forwardposition, pressure in the return lineincreases and opens the Digital ReturnPressure Switch 7 which de-energisesRelay R1. This also de-energises the HDVReturn Pressure solenoid. The DigitalReturn Pressure Switch then recloses (recloses-sets).The installation cycle is now completeNotes:1. The latching of Relay R3, allows thefastener installation to continue even if theLimit Switch contacts in the Tool openafter activating the Tool Trigger.

911D Powerig SeriesAlcoa Fastening Systems6 Digital PressureSwitch(Swage Pressure)5 MainPressure ReliefValve(Pull Pressure)15/15A Oil ReturnLine Filter &Condition GaugeFuel TankFiller Cap14 Filler/Strainer41 Handle Screw in,removable)7 Digital PressureSwitch(Swage Pressure)16 OilLevel/TempGauge1 Diesel Engine19 Hydraulic QuickDisconnect Coupling(Return Pressure)18 Hydraulic QuickDisconnectCoupling (PullPressure)40 Main Wheel 34 12 VDC ElectricalConnector(non Bobtail Tools orremote Triggers)35 12 VDC ElectricalConnector(Bobtail Tools)Key StartSwitch (StarterMotor) Diesel EngineIndicatorLightsMain ComponentsFIG. 1

911D Powerig SeriesAlcoa Fastening SystemsThrottle ControlLever LockThrottle ControlLeverStop Lever(shown in Enginerun position)Stop Lever(stop Engineposition)Engine ControlsMain ComponentsFIG. 1A

911D Powerig SeriesAlcoa Fastening SystemsInstallation ToolPR673515/15A21LEGENDRef. N0.1235671515APart 11D/15AItemLombardini 15LD-350 Diesel EnginePumpHydraulic Directional ValveMain Pressure Relief Valve (Pull Pressure)Digital Pressure Switch (Swage Pressure)Digital Pressure Switch (Return Pressure)Hydraulic Oil Return Line FilterOil Filter Condition Gauge911D Hydraulic SchematicFIG. 2

42 FuseR2R3 - 1R1R2 - 1R1 - 1911D Electrical Schematic42 Fuse3HDV PULLPRESSURESOLENOID42 FuseR3 - 3R3R4 - 1B O B TAILTO O LTRIGGERB O B TAIL TO O LLIMIT SWITCHNOTE: R1 TO R4 ARE RELAYS REF. 37R2 - 33 HDV RETURNPRESSURESOLENOIDR3 - 2R2 - 2R1 - 27 DIGITAL P R E S S U R ESWITCH(RETURN PRESSURE)R4 - 2R1 - 3R46 DIGITAL P R E S S U R ESWITCH(PULL PRESSURE)DIGITAL P R E S S U R ESWITCH(PULL PRESSURE)HDV PULL P R E S S U R ESOLENOIDHDV RETURNPRESSURE SOLENOIDDIGITAL P R E S S U R ESWITCH(RETURN PRESSURE)24 VDC SUPPLYLEMO PLUG/SOCKETC O N N E C TOR (BOBTAIL TOOLS)911D Powerig SeriesAlcoa Fastening Systems

911D Powerig SeriesAlcoa Fastening SystemsPreparation for First Time Use (Refer to FIG. 1 )1. Check the dieselengine oil level byusing the dipstick.The oil level shouldbe near themaximum.If necessary addclean oil via the fillercap.Note:Refer to the DieselEngine maintenanceManual for correctgrade of oil.2. Open air cleanerand remove element.CAUTIONTo avoid explosions or fire outbreaks, donot smoke or use naked flames duringoperations. Fuel vapours are highlytoxic.Only carry out operations outdoors or ina well ventilated area.Keep face well away from the filler capand fuel tank to prevent inhalation ofharmful vapours.Dispose of fuel in accordance withapplicable laws and regulations as it ishighly polluting.Use the same type of fuel as used incars as use of other types could damagethe engine. The cetane rating of the fuelmust be higher than 45 to preventdifficult starting.Do not use dirty fuel of mixtures ofdiesel fuel and water, since this wouldcause serious engine damage5. Check that there is sufficient enginediesel fuel for the time intended to operatethe Powerig. A full tank of fuel will run theengine for approx. 4 hours at 2400 r.p.m.Do not fill the fuel tank completely but justup to 1 cm (0.39”) from the top of the fueltank. This allows space for fuel movement.Only use clean fuel and wipe any fuelspillage from the engine before starting.6. Using the Oil Level/Temp Gauge 16,check that the hydraulic fluid (oil) level is atthe top of the glass. To avoid overheatingof the fluid, the level should not be allowedto fall lower than half way down the glass. .3. Fill with engine oilup to the level mark.4. Reassemble air cleaner. Ensure that theair filter is mounted the correct wayotherwise dust and other impurities couldenter the intake ducts.7. If necessary, remove Filler Cap 14 and fillPowerig Oil Reservoir with recommendedhydraulic fluid, (refer to page 28) to the topof the glass.CAUTIONFor filling the reservoir, only use cleanfluid and a clean funnel with a maximumof a 60 micron filter. Failure to do thiswill cause malfunction and componentdamage.8. Reinstall Filler Cap.

911D Powerig SeriesStarting & stopping the engine.9. Apply the brakeon the CastorWheel to avoidunexpectedmovement of thePowerig duringoperation.Push down withfoot to operatebrake.Throttle LeverLockAlcoa Fastening SystemsNote:If there is not enough battery power tooperate the electric starter motor, the enginemaybe started with the recoil starter. Referto page 53 of the Diesel EngineMaintenance Manual for instructions.13. Move throttle lever to the idle positionand allow engine to run at idle for a fewminutes before increasing speed andputting under load.Note:During the first 50 hours of running theengine, do not exceed 70% of maximumload.Stopping.Throttle LeverStarting.10. Set the throttleat 50% maximum speed.11. Turn the key clockwiseto position 1 as shownbelow. The warning lightshould illuminate.12. Continue to turn thekey clockwise to position2 to operate the electricstarter motor. Releasethe key once the enginehas started. The key willnow return to position 1and should be left in this position whilst theengine is running.CAUTIONDo not operate the starter for more than20 seconds at a time. If the engine doesnot start, wait 1 minute before tryingagain.If the engine does not start after twoattempts, trace the cause according tothe Diagnosis Chart (page 75 - 77) of theDiesel Engine Maintenance Manual.All warning lights should stay off whenthe engine is running.14. Move throttle lever to the idle positionand allow engine to run at idle for a fewminutes.15. Move the stop leverfully to the left until theengine stops.16. Rotate the key anticlockwise to the stopposition.

911D Powerig SeriesChecking & Adjusting Pull,Return & Swage Pressures.Pull Pressure (FIG.4)(refer to Utilisation (page 6) for correctsetting)1. With the engine running at operatingspeed, observe the display on the DigitalPressure Switch (Swage Pressure). Thiswill show the unit of measurement set andwill periodically show “bAr” or “PSI”.Note:When facing the hydraulic connectors, theDigital Pressure Switch (Swage Pressure),is on the right hand side.2. Connect a remote electrical trigger (or theplug/cable from a non-Bobtail InstallationTool), to the Powerig electrical connector34.3. Operate theremote Triggermomentarily andnote pressurereading displayed onthe Digital PressureSwitch.CAUTIONComplete this test as quickly as possibleto prevent overload of hydrauliccomponents.4. Refer to FIG. 4 and adjust the PullPressure to suit the Installation Tool beingused. Refer to Utilisation (Page 6) and/orthe Installation Tool Instruction Manual forcorrect Pull Pressure setting. Only makesmall adjustments (1/4 turn) at one time. Donot remove any pre-installed washers orlocknut from the adjusting screw.5. Check the Pull Pressure again asdescribed above. Repeat adjustment ifnecessary until correct value is obtained.Alcoa Fastening Systems6. Once the Pull Pressure has been set,tighten the Lock Nut on the AdjustmentScrew to ensure setting is retained. Checkthe pressure one more time to ensure it hadnot changed whilst tightening the Lock Nut.Return Pressure (FIG 4)(refer to Utilisation (page 6) for correctsetting)Notes:a) The diesel engine does not have to berunning during checking or adjustment ofthe return pressure but the key must be inposition 1.b) When facing the hydraulic connectors,the Digital Pressure Switch (ReturnPressure), is on the left hand side.c) The Digital Pressure Switches are able tomeasure two SEPARATE pressure switchpoints; S1 & S2. Only the S1 is used andfor the Return Pressure, the normallyclosed (N/C) switch contacts are utilised. Ifthe left hand indicator light is on, then theN/C contacts are closed.d) The reset pressures r1 & r2 should left atthe factory setting of 50 bar (725 psi).e) The S1 button is used to change to thedifferent menu items. The S2 button isused to access the menu items and the S1button used again to change the settings ofthose menu items.1. Press both the S1 & S2buttons at the same timeand the display will showthe first menu item.2. Press the S2 buttonand the current unitsetting will be displayed.

911D Powerig SeriesAlcoa Fastening SystemsAdjustment ScrewClockwise to increase PullPressureAnti-clockwise to decreasePull PressureLock Nut7 Digital PressureSwitch(Swage Pressure)6 Digital PressureSwitch(Swage Pressure)5 Main Pressure Relief Valve(Pull Pressure)FIG. 4

911D Powerig SeriesAlcoa Fastening Systems6. Consecutive pressing of S1 will changethe value of the digit over the cursor from 1to 9 and then 0.3. To keep this setting,press S2 again and thedisplay will return to“Unit”. Pressing S1 nowwill change the display tothe next menu item (S1);continue from step 5.To change themeasurement units, pressS1. Consecutive pressingof S1 will change theunits between bAr andPSI.When the required unit isshown, press S2 againand the display will returnto “Unit”4. Press S1 to continue tothe next menu item. Thedisplay will show “S1”.This is switch point 1, thevalue of this is the ReturnPressure.5. Press the S2 buttonand the current ReturnPressure setting will bedisplayed.To keep this setting, press S2 several timesuntil “S1” is displayed again.Pressing S1 now will change the display tothe next menu item (r1); continue from step9.To change the settings, note theflashing/blinking cursor under the space forthe first digit of Return Pressure setting.Note:The display is able to show 4 digit numbers.In this example a value of 350 bar is shownand therefore the space for the first digit isblank. 4 digit numbers are only used if themeasurement units are set to PSI. TheReturn Pressure must always be lowerthan the Pull Pressure by at least 6.9 bar(100 psi), to ensure correct Powerig7. When the required value shown, pressS2 and the cursor will move to the rightunder the next digit.8. Continue adjusting each digit in turn.Pressing S2 after adjusting the last digit willchange the display back to “S1”.9. Pressing the S1 buttonwill change the display tothe next menu item.r1 is the value at whichthe Return Pressure (S1),resets to zero and shouldbe set at 50 bar (725 psi).Press S2 to check thesetting. If it is necessary to change thesetting then follow the procedure as in steps6 & 7.10 Press S1 to continueto the next menu itemwhich is S2.The S2 & r2 switch pointsare not used.The next steps will savethe settings.11. Press the S2 buttonseveral times until thedisplay shows “Stor”.12. Press the S2 buttonand the display will show“no”. Press the S1 buttonto change the display to“yes”.13. Press the S2 button tosave the settings. Thedisplay will return to zero.

911D Powerig SeriesSwage Pressure (FIG 4(only applicable when using IT type tools.Refer to Utilisation (page 6) for correctsetting)Note:When using IT type Bobtail InstallationTools, fitted to the Powerig connector 35with the electrical 8 pin Lemo Plug, theDigital Pressure Switch (Swage Pressure)6, controls the hydraulic pressure to the toolduring the pull cycle. This in turn controlsthe amount (length) of Bobtail fastenerCollar swage. The higher the pressure, themore the Collar is swaged.This Digital Pressure Switch is checked andadjusted using the same procedure as thatfor the Digital Pressure Switch for theReturn Pressure as previously explained.The indicator will light not be illuminated asthe normally open contacts should be in theopen condition.Set a Swage Pressure just above theminimum required for the Nose AssemblyAnvil to just lightly contact the CollarFlange. A circular witness mark around theCollar flange will indicate the Anvil contact.On most large diameter (12 mm (1/2”) andabove), Bobtail Collars have a series ofraised nodules around the flange which willbe crushed by contact with the Anvil.Do not adjust the Swage Pressure too highas this increases the risk of Bobtail groovesbeing stripped/damaged or the Bobtail beingbroken away from the Pin. In either event,this will prevent a Bobtail Collar Cutter frombeing used to remove the installed fastener.14. Inspect hoses, electrical cords andconnections frequently for signs ofdamage or ageing. If necessary replace.15. Connect both hoses of the InstallationTool, (or if being used with a Hose Set,connect the Hose Set), to the Powerig.Activate the Tool Trigger to fully cycle theTool, or if using an “IT” type Bobtail Tool,then use a remote trigger attached to thePowerig connector 34.Note:Alcoa Fastening SystemsIt is not possible to cycle IT type BobtailTool s using it’s own trigger unless the toolLimit Switch is activated (contacts close).Therefore a remote Trigger as describedabove must be used.CAUTIONBTT series tools do not have a DumpValve to relieve hydraulic pressure fromthe front of the Piston.Therefore, release the triggerimmediately when the tool Piston hasstopped moving.CAUTIONSome types of Installation Tool (e.g. BTTand SFBTT series, extend in lengthduring operation.16. When using tools other than BTT BobtailTools, continue to press the trigger forapprox. 4 seconds when the Tool Piston hasstopped moving. Release the Trigger andand allow the Tool Piston to return to thestarting position. Repeat three times.This will ensure that any air in the hydraulicsystem is removed.Note:New Hose Sets or individual hoses my notcontain any hydraulic fluid and the air mustbe removed. To do this, connect one pair ofcouplings at one end of the Hose set, to thePowerig. Connect the other pair of Hoseset couplings to each other. With thePowerig running, activate the remotetrigger/tool trigger and then release. Waitapprox. 45 seconds, then stop the Powerig.Check the Powerig hydraulic oil level beforecontinuing.17. Check the Pull Pressure again and recloses-adjust if necessary. Tighten the LockNut toensure settings to not change.

911D Powerig SeriesAlcoa Fastening SystemsConnecting and testing a Bobtail Tool(after completing previous steps 1 to17).7. Prepare a sample joint with the BobtailFastener. Place the Collar (see notebelow), onto the Pin.IT type Bobtail Tools.Note:Only Bobtail Fasteners of 12 mm (1/2”)diameter or larger, have thread formlocking grooves into which a tab on theCollar locates. Rotating the Collar

Services desk at Alcoa Fastening Systems Ltd, Telford Shropshire TF3 3BQ. The Producer Identification Number for Alcoa Fastening Systems Ltd, Telford is: WEE/AF0044SY The Waste Electrical & Electronic Equipment Regulations 2006 CAUTION THE HYDRAULIC OUTPUT PRESSURE VALVES (PULL & RETURN