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11

940 Powerig® 

(HK496)

    

Troubleshooting

1. Motor fails 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 fastener 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.

4. Tool will not return when switch is released. (Tool will 

not push nose assembly off swaged fastener.):

  (a) RETURN pressure set too low.

    (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 

completed:

  (a) RETURN pressure switch set too high.

  (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 is 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.

Always check the simplest possible cause of malfunction first. For example, blown fuse, tripped circuit breaker, 

defective switch or control cord. Eliminate each possible cause until the defective circuit or part is located. Where 

possible, substitute known good parts for suspected bad parts. A qualified electrician should check out the 

electrical system. Use this section as an aid in locating trouble and correcting it.

OPTIONS

940T-1

 

(Special Version of 940)

The 940T-1 is part of Huck’s revised aftermarket Truck 

Kits, which contain different pressure installation tools. 

This hydraulic unit will be shipped from the factory with 

output pressures set as follows: 

PULL: 5700-5800 psi 

RETURN: 4400-4600 psi

ACCESSORIES:

Auxiliary Switch and Control Cord 113056

An auxiliary switch is available for use when checking and 

adjusting pressures and when troubleshooting.

 

Gauge T-124833CE

A “T” gauge is available for use when checking and 

adjusting pressures, and troubleshooting.

 

Hose and Control Cord Kits

 of various lengths

Please contact your HUCK representative.

Directional Valve Kit 129437

Includes seals necessary to service Directional Valve 

103596.

Rig Transport Dolly 129703

Heavy duty steel dolly for easy movement of powerig 

throughout the work area.

Motor 111346

Motor and Pump Assembly 111345

Motor Service Kit 115770

includes: 

Motor Brushes Set  111415

  115V Armature 

115764

  Upper Bearing 

115766

  Lower Bearing 

115767

   115V Motor Field 

115768

   Brush  Holder 

115784

   Brush Holder Cap  115785

 Gasket 

115786

Options & Accessories

Содержание HK496

Страница 1: ...l Brand Fasteners Tools Accessories Serial Number Notice 2 Safety Instructions 3 Description 4 Principle of Operation 4 Preparation for Use 4 Specifications 5 Checking and Adjusting Pressures 5 Operation 5 Maintenance 6 Components Drawings 7 10 Options and Accessories 11 Troubleshooting 11 ...

Страница 2: ...2 940 Powerig HK496 NOTICE This manual applies to 940 serial number 3927 and above For any other serial numbers please contact a Huck customer service representa tive ...

Страница 3: ...for hydraulic tooling if pinch point is unavoidable 20 Unsuitable postures may not allow counteracting 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 installation tools by operators is an important factor in maintaining tool efficiency eliminating downtime and in...

Страница 4: ...ipstick to check fluid level and to add fluid Hydraulic quick disconnect couplers are furnished for connecting hoses from installation equipment Description FIGURE 2 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 o...

Страница 5: ... 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 instructio...

Страница 6: ...m 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 actuat...

Страница 7: ...7 940 Powerig HK496 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 ...

Страница 8: ...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 Re...

Страница 9: ...o 1A red transformer lower right circuit breaker 1 red CR12 CR9 1 red circuit breaker MCL3 1 red MCL1 MCL3 1 red MCL3 CR9 2 white MCL2 transformer lower left 2 white MC terminal MCL2 3 red MCT3 CR5 6 blue transformer upper left trigger 7 blue trigger CR14 8 blue transformer upper right CR13 ...

Страница 10: ...e and install as a unit into the motor shell Apply Loctite 277 Threadlocker or equivalent between outer race and bore Place motor in an upright position while Loctite cures 2 Brush Holders must be installed with slot and dimple facing the open end of the Motor Shell Apply Loctite 680 Retaining Compound or equivalent between Brush Holder and bore 3 Insert Flag Terminals into adjacent Brush Holders ...

Страница 11: ... cycle does occur a Pump is cavitating fluid level may be low or fluid viscosity is 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 Always check the simplest possible cause of malfunction first For example blown fuse tripped circuit breaker defective switch or control cord Eliminate each possible cause un...

Страница 12: ...12 940 Powerig HK496 Record your own notes here ...

Страница 13: ... complete overhaul Determination is made on a case by case basis upon return of parts to Huck International Inc for evaluation Tooling Part s and Other Items not manufactured by Huck HUCK makes no warranty with respect to the tooling part s or other items manufactured by third parties HUCK expressly disclaims any warranty expressed or implied as to the condition design operation merchantability or...

Страница 14: ...t C Stafford Park 7 Telford Shropshire England TF3 3BQ 01952 290011 FAX 0952 290459 Us Operations BP4 Clos D Asseville 95450 Us par Vigny France 33 1 30 27 9500 FAX 33 1 34 66 0600 AUSTRALIA Melbourne Operations 11508 Centre Road Clayton Victoria Australia 3168 03 764 5500 Toll Free 008 335 030 FAX 03 764 5510 Huck is Forever For the Long Haul The Future of Fastening Technology The Future of Assem...

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