Huck ERT1D User manual

Form HK 1039
04-16-2004
INSTRUCTION MANUAL
EBBERT RIVET TOOL MODELS
ERT1D, ERT2D, ERT4D,
ERT1DL AND ERT2DL

3
ERT D Series Tooling Alcoa Fastening Systems
SAFETY
This instruction manual must be read with particular
attention to the following safety guide lines, by any
person servicing or operating this tool.
1. Safety Glossary
WARNINGS - Must be understood
to avoid severe personal injury.
CAUTIONS - show conditions that will dam-
age equipment and or structure.
Notes - are reminders of required proce-
dures.
Bold, Italic type and underlining - empha-
sizes a specific instruction.
2. Huck equipment must be maintained in a safe
working condition at all times and inspected on a
regular basis for damage or wear. Any repair
should be done by a qualified repairman trained
on Huck procedures.
3. Repairman and Operator must read manual prior
to using equipment and understand any Warning
and Caution stickers/labels supplied with equip-
ment before connecting equipment to any pri-
mary power supply. As applicable, each of the
sections in this manual have specific safety and
other information.
4. See MSDS Specifications before servicing the
tool. MSDS Specifications are available from
you Huck representative or on-line at
www.huck.com. Click on Installation Systems
Division.
5. When repairing or operating Huck installation
equipment, always wear approved eye protec-
tion. Where applicable, refer to ANSI Z87.1 -
1989
6. Disconnect primary power source before doing
maintenance on Huck equipment.
7. If any equipment shows signs of damage, wear,
or leakage, do not connect it to the primary
power supply.
8. Make sure proper power source is used at all
times.
9. Never remove any safety guards or pintail
deflector.
10. Never install a fastener in free air. Personal
injury from fastener ejecting may occur.
11. When using an offset nose always clear spent
pintail out of nose assembly before installing the
next fastener.
12. If there is a pinch point between trigger and
work piece use remote trigger. (Remote trig-
gers are available for all tooling).
13. Do not abuse tool by dropping or using it as a
hammer. Never use hydraulic or air lines as a
handle. Reasonable care of installation tools by
operators is an important factor in maintaining
tool efficiency, eliminating downtime, and in pre-
venting an accident which may cause severe
personal injury.
14. Never place hands between nose assembly and
work piece.
15. Tools with ejector rods should never be cycled
with out nose assembly installed.
16. When two piece lock bolts are being used
always make sure the collar orientation is cor-
rect. See fastener data sheet of correct posi-
tioning.
!
Product complies with requirements
set forth by the relevant European
directives.
Read manual prior to using
equipment.
Eye protection required while
using this equipment.
Hearing protection required while
using this equipment.

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TOOL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
ERT1D & ERT2D SERIES SERVICE PROCEDURES
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
ERT4D SERVICE PROCEDURES
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
RIVET TOOL HANDLE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
AIR BLEEDING THE RIVET TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
ASSEMBLY DRAWINGS AND PARTS LISTS . . . . . . . . . . . . . . . . . . .13 - 16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
KITS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4
ERT D Series Tooling Alcoa Fastening Systems
CONTENTS

This manual contains operating and service procedures for
the Ebbert Rivet Tool models ERT1D, ERT2D, ERT3D,
ERT4D, and their optional tool configurations. It is suggest-
ed that close attention be directed to the recommended
service procedures contained in this manual.
Specific instructions for each tool are given under that tool
model number heading. While they may appear to be simi-
lar, each tool contains parts not used on other models and
removal and replacement methods may vary.
5
ERT D Series Tooling Alcoa Fastening Systems
1.) Incoming non-oiled plant air is regulated at 90psi
through the Air Filter/Regulator to the Four-Way Valve,
and also through the Red Air Line to the valve in the
rivet tool handle. When air is initially applied to the
power unit, the Pull Stroke Power Booster is retracted
and the Return Stroke Power Booster is advanced.
2.) When the tool trigger is pulled, a trigger/plunger
unseats a valve ball and directs air from the tool handle
back through the Green Air Line to the Four-way Valve.
3.) The Four-way Valve is shifted, directing air pressure
through the Blue Air Line into the Pull Stroke Power
Booster and through the Red Air Line to the Exhaust
Valve of the Return Stroke Power Booster.
4.) As the Power Boosters air/hydraulic pistons advance,
hydraulic fluid is forced through the black Pull Stroke
Hydraulic Line into the tool, forcing the tool to retract.
This delivers the necessary force to install the fastener
and break the pintail.
5.) At the same time, the Four-Way Valve supplies air to
the Return Stroke Power Booster, forcing it to the
returned position.
6.) When the trigger is released, the Four-way Valve shifts
to its normal position. The normally open outlet of the
Four-Way Valve (labeled CYL1) directs 90psi pushing
both Power Booster air pistons to their original posi-
tions. The cycle is now completed. (In the EPS2V and
EPS2VL, the pintail would then travel through the pintail
collection tube from the tool into the Pintail Collection
Box.)
Hydraulic
Fluid
Reservoir
PULL
STROKE
Power
Booster
Pull Stroke Hydraulic
Pressure 4,000 PSI
Non-Oiled
Plant Air 0
PSI
Red Line
Green Line
Vacuum
RETURN
STROKE
Power
Booster
25
PSI
Exhaust
Valve
Return Stroke Hydraulic
Pressure 562 PSI
GENERAL INFORMATION
PRINCIPLE OF OPERATION

6
ERT D Series Tooling Alcoa Fastening Systems
(ERT1D only)
(ERT1D only)
2.44 62.0
.6 17.5
. 7
24.6
2.00
50.8
3.00
76.2 5.02
127.4
6.0
154.7
8.60 218.4
7.54 1 1.5
INCHES
mm
ERT1D, ERT1DL
Weight: ERT1D: 2.13 lbs.
ERT1DL: 1.63 lbs
Stroke: 15/16”
Rated Pull Force: 2,062 lbs.
Fastener Sizes: 3/32” through 3/16”
(ERT2D only)
(ERT2D only)
1. 4 4 .2
.88 22.2
5.23
132.
6.31
160.3
2.00
50.8
3.50
88.
.16 232.8
7. 1
201.0
2.05
52.0
INCHES
mm
ERT2D, ERT2DL
Weight: ERT2D: 2.92 lbs.
ERT2DL: 2.36 lbs
Stroke: 1-1/32”
Rated Pull Force: 4,454 lbs.
Fastener Sizes: 1/8” through 1/4”
TOOL SPECIFICATIONS
Fig. 1
Fig. 1A

7
ERT D Series Tooling Alcoa Fastening Systems
12.67
321.
.81
24 .1 8.73
221.7
1.37 34.7
2.05 52.0
3. 4 100.0
3.50
88.
2.00
50.8
INCHES
mm
ERT4D
Weight: 3.89 lbs.
Stroke: 1-1/32”
Rated Pull Force: 4,454 lbs.
Fastener Sizes: 1/8” through 1/4”
TOOL SPECIFICATIONS (CONTINUED)
Fig. 1B

Disassembly of ERT1D & ERT2D
(Figure 2)
1. Unscrew the two Socket Head Screws for ERT1D or
four screws for ERT2D which secure the Piston Rod
Guide to the front of the tool, and remove the Piston
Rod Guide.
2. Loosen the Hose Clamp/Sleeve at the rear of the tool,
and pull it back far enough to allow clearance for the
removal of the End Cap. From the rear of the tool,
remove the two Socket Head Screws (ERT1D) or four
screws (ERT2D) and the Support Loop Assembly.
3. To remove the End Cap/Guide Tube Assembly, Piston
and Piston Forward Stop, push the Piston toward the
rear of the Cylinder.
4. Remove the remaining Seal from the front of the
Cylinder.
5. The Cylinder is now stripped of parts except the
Retaining Ring . For normal tool service it is not neces-
sary to remove this Retaining Ring. If it is removed,
when replacing, be sure to relocate the retaining ring
ears at the bottom of the Cylinder, allowing clearance
for the hydraulic inlet port.
6. ERT1D
Remove the Retaining Ring, Piston Forward Stop,
Piston Seal Retainer, and all Seals from the Piston, and
the Piston Rod Wiper from the Piston Rod Guide.
ERT2D
Remove the Retaining Ring, Front Seal Retainer and all
Seals from the Piston, and the O-ring, Back-up Ring,
Seal, and Piston Rod Wiper from the Piston Rod Guide.
NOTE: Whenever servicing the tool to this extent,
the Piston Rod Wiper must be replaced with a new
one.
7. Remove the O-ring from the End Cap.
8. Clean the disassembled parts in cleaning solution.
8
ERT D Series Tooling Alcoa Fastening Systems
SERVICE PROCEDURES
Step 1:
Socket Head Screws
and Piston Rod Guide
Step 3:
End Cap/Guide
Tube Assy, Piston,
& Piston Forward Stop
Push rearward
Step 4:
Remove
this Seal
Step 6:
Piston Rod
Wiper must
be replaced.
Step 6:
Remove three
Seals, Piston
Forward Stop,
Piston Seal Re-
tainer, and Retaining
Ring from Piston.
Step 5:
This Retaining
Ring may be
left in place.
Step 2:
Socket Head Screws
and Support Loop
Assembly
Step 7:
Remove
this O-ring
Fig. 2

Reassembly of ERT1D and ERT2D
1. When replacing seals, make sure they are correctly
positioned as shown on the tool assembly drawings in
this manual. Wipe all seals with a thin film of seal lubri-
cant before reassembly.
2. It is important to inspect the cylinder wall to insure the
surface is free of any gouges or nicks that will damage
a new seal. Small nicks or gouges can normally be
removed using a fine crocus cloth.
3. After all seals, o-rings and back-up rings are replaced,
ERT1D
With the Piston Forward Stop placed on the Piston
shaft, insert the End CapAssembly into the Piston, then
slide the complete assembly into the tool Cylinder.
ERT2D
Insert the End Cap Assembly into the Piston, then slide
the complete assembly into the tool Cylinder.
NOTE: Use caution when inserting this assembly
into the cylinder to keep the piston from "cocking"
in the cylinder and "nicking" the cylinder wall. This
could ultimately cause a seal edge to be cut.
Secure the End Cap and Support Loop Assembly with
two screws (ERT1D) or four screws (ERT2D).
4. At this point, reposition the tool in the vice with the open
front of the cylinder pointing straight up. You can choose
from two options for filling the tool with hydraulic fluid:
a) Gravity fill: Connect the hydraulic line to the power
unit and allow hydraulic fluid to flow from the higher
positioned reservoir into the tool cylinder until it is
level with the front Retaining Ring, then disconnect
the hydraulic line for installation of remaining com-
ponents.
b) Optional fill: Using the Model 300509 Bleed Pump
Assembly, you can save time by pumping from the
hydraulic connector thru the line, filling the tool in
the same manner and to the same level as above.
5. ERT2D
Replace the Front Seal Retainer by positioning the
cutout section so it will clear the two ears of the
Retaining Ring when it is dropped into place. If the
retainer does not lay flat, tap it gently with a screwdriv-
er until it assumes a flat position.
6. Slide the hydraulic seal down over the piston threads
and wrench flats carefully to prevent "nicking" the seal
edges.
ERT1D
Insert the Piston Rod Guide and Wiper assembly, push-
ing the Hydraulic Seal down into the Cylinder. Secure
the Piston Rod Guide with two screws. Torque the
screws at both ends of the tool to 12-15 ft/lbs.
ERT2D
It is not necessary to push the seal all of the way into
the Cylinder. It will assume its position in the Piston Rod
Guide when the guide is next installed and secured with
the two Bearing Plates and four Screws. Torque the
screws at both ends of the tool to 60-80 in./lbs.
8. This method of refilling the tool with hydraulic fluid
relieves any further requirement for bleeding air. The
tool can now be connected to the power unit and be test
cycled. The pulling head assembly can now be
installed.
9
ERT D Series Tooling Alcoa Fastening Systems
SERVICE PROCEDURES (CONT.)

10
ERT D Series Tooling Alcoa Fastening Systems
Disassembly of ERT4D (Figure 3)
1. Remove the Handle from the front of the tool.
2. Loosen the Hose Clamp/Sleeve at the rear of the tool,
and pull it back far enough to allow clearance for the
removal of the End Cap.
3. After removing the Support Loop Assembly, the Piston
and End Cap can be removed by pushing back on the
front of the Piston for removal through the back of the
tool.
4. Remove the O-Ring from the End Cap.
5. The Front Seal Retainer must be removed from the
front of the tool. This retainer is a snug fit and generally
requires a soft hammer blow to the end of a brass dowel
held against the Seal Retainer.
6. The Cylinder is now stripped of parts except the
Retaining Ring . For normal tool service it is not neces-
sary to remove this Retaining Ring. If it is removed,
when replacing, be sure to relocate the retaining ring
ears at the bottom of the Cylinder, allowing clearance
for the hydraulic inlet port.
7. Remove the Retaining Ring, Piston Seal Retainer and
all Seals from the Piston, and the O-ring, Back-up Ring,
and hydraulic Seal from the Front Seal Retainer.
NOTE: Whenever servicing the tool to this extent,
the Piston Rod Wiper must be replaced with a new
one.
8. Clean the disassembled parts in cleaning solution.
SERVICE PROCEDURES (CONT.)
Handle
Piston
Seal
Retainer
Front
Seal
Retainer
Piston
Piston
Rod
Wiper
End Cap/
Guide Tube
Assembly
O-Ring
Back-up
Ring Support Loop
Assembly
Cylinder
Fig. 3