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FTI OPERATIONS, MAINTENANCE, AND REPAIR MANUAL
Original Instruction
Fatigue Technology
401 Andover Park East
830959-REV A
FT-B100 Series Cordless PowerPak
Part #2720-129, Log #36592
Revision A
June 17, 2020
Seattle, WA • USA 98188-7605
401 Andover Park East
Seattle, Washington 98188-7605
USA (206) 246-2010
© C O P Y R I G H T 2020
F A T I G U E T E C H N O L O G Y
A L L R I G H T S R E S E R V E D
Tel: (206)246-2010
Fax: (206)244-9886
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Table of Contents
Summary of Contents for PCC FTI PowerPak FT-B100 Series
- Page 1 401 Andover Park East Seattle, Washington 98188-7605 USA (206) 246-2010 FTI OPERATIONS, MAINTENANCE, AND REPAIR MANUAL FT-B100 Series Cordless PowerPak Part #2720-129, Log #36592 Revision A June 17, 2020 © C O P Y R I G H T 2020 F A T I G U E T E C H N O L O G Y A L L R I G H T S R E S E R V E D Original Instruction...
- Page 2 Fatigue Technology (FTI) is a world-leading aerospace engineering and manufacturing company. FTI pioneered cold expansion technology (which provides solutions to fatigue problems associated with holes in metal structures) back in 1969 and have advanced this science to develop innovative bushing and fastener products. These proprietary products and associated tooling may be covered by patents or agreements owned by, or exclusively licensed to Fatigue Technology.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction ............................1 About the FT-B100 Series Cordless PowerPaks ..............1 General Specifications ......................1 Safety ..............................2 Safety Symbols and Definitions ..................... 2 General Hydraulic Safety Precautions ................... 3 Battery Operated Pump Safety Precautions ................4 Major Features and Components ...................... - Page 4 TABLE OF CONTENTS (Continued) SECTION DESCRIPTION PAGE TABLES Table 3.0-1 Pump Features and Components ......................5 Table 3.1-1 Pump Specifications ..........................6 Table 3.2-1 Pump Specifications - Key Dimensions ....................7 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
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Page 5: Introduction
1.0: I ECTION NTRODUCTION This instruction manual contains information on the operation and maintenance of the FT-B100 Series Cordless Hydraulic PowerPaks. To obtain optimum performance and many years of trouble-free service, operate the PowerPak properly and follow maintenance procedures carefully. The key to trouble-free operation is maintaining a clean air supply and clean hydraulic oil. -
Page 6: Safety
2.0: S ECTION AFETY Read all instructions carefully. Follow all recommended safety precautions to avoid personal injury as well as damage to the pump and/or damage to other property. Fatigue Technology cannot be responsible for any damage or injury from unsafe use, lack of maintenance or incorrect operation. Do not remove warning labels, tags, or decals. In the event any questions or concerns arise, contact Fatigue Technology for clarification. -
Page 7: General Hydraulic Safety Precautions
GENERAL HYDRAULIC SAFETY PRECAUTIONs ⚠ WARNING Failure to observe and comply with the following precautions could result in death or serious personal injury. Property damages could also occur. Do not remove or disable the pressure relief valve. Never set the pressure relief value to a higher pressure than the maximum rated pressure of the pump. ... -
Page 8: Battery Operated Pump Safety Precautions
BATTERY OPERATED PUMP SAFETY PRECAUTIONS ⚠ WARNING Failure to observe and comply with the following precautions could result in death or serious personal injury. Property damage could also occur. Do not use the pump if the remote pendant rocker switch cannot turn the pump on or off. Have the remote pendant repaired before using the pump. -
Page 9: Major Features And Components
3.0: M ECTION AJOR EATURES AND OMPONENTS Table 3.0-1 Pump Features and Components Replacement Part Number Key: 1199-499 1. Remote Pendant 2. Carrying Handle/Roll bar 3. Hydraulic Reservoir Sight Glass 4. Hydraulic Reservoir Drain Plug 1125-024 (shipping and operation plugs as one part number) 5. -
Page 10: Product Data
PRODUCT DATA Table 3.1-1 Pump Specifications Pump Sound For Use With Operating Temp Range Motor Rating Model Pressure RailTec Puller 40 to 120 F FT-B100 1.4HP 1.0kW 75 dBA Unit +4 to +49C Pump Maximum Flow Rate Flow Rate Flow Rate Reservoir Pump Hydraulic... -
Page 11: External Dimensions
EXTERNAL DIMENSIONS Table 3.2-1 Pump Specifications - Key Dimensions Dimension Item 25.48 14.00 9.69 8.09 4.22 5.66 16.28 10.92 Figure 3.2-1 Pump Key Dimensions Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... -
Page 12: Prior To Pump Operation
PRIOR TO PUMP OPERATION Consult the appropriate puller unit manual for safety precautions before installing a puller unit onto a PowerPak. When used in accordance with these instructions, the FT-B100 PowerPak is safe and easy to use. All general safety precautions associated with hydraulic operated power tools should be observed. Many of these are noted in this section. -
Page 13: Figure 3.3-2 Safety Labels
10. Use caution when operating the PowerPak near electric power sources. The PowerPak is not generally insulated for coming into contact with electric power sources. 11. Do not use in potentially explosive atmospheres. 12. Two ISO safety labels have been placed on machinery to alert the operator of certain precautions that must be met to ensure proper and safe operation of the machinery. -
Page 14: Operating Instructions
4.0: O ECTION PERATING NSTRUCTIONS INTRODUCTION, HYDRAULIC POWERPAK SETUP PROCEDURE AND OPERATION The FTI-B100 combines the high performance of an electric AC-powered pump with the convenience of a cordless, battery powered pump. It is ideal solution for remote locations, where electrical or pneumatic power sources are not available. -
Page 15: Figure 4.1-2 Battery Capacity Indicator
4.1.4 Important Receiving Instructions Visually inspect all components for shipping damage. Shipping damage is not covered by warranty. If shipping damage is found, notify carrier at once. The carrier is responsible for all repair and replacement cost resulting from damage in shipment. Note: Personnel should read this and associated puller unit manuals prior to use. -
Page 16: Figure 4.1-3 Battery Installation
4.1.8 Battery Installation 1. Ensure that remote pendant switch is in the OFF (O) position. 2. Lift battery door and hold it open. 3. Align ribs on battery and battery bracket. Then, slide the battery fully into the battery compartment until it stops. -
Page 17: Operation
4.1.11 Additional Battery and Charger Information The battery is not shipped fully charged. It is recommended that battery be fully charged before first use to ensure maximum run time can be achieved. For best result, the battery should be charged in a location with a temperature between 43˚ F [61˚ C] and 104˚... - Page 18 4.2.4 Operating Precautions ⚠ WARNING Failure to observe the following precautions and instructions could allow load to drop on persons working in the area. Death or serious personal injury could result. Keep persons away from area under load during lifting, lowering and whenever the control value lever is moved.
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Page 19: Maintenance
5.0: M ECTION AINTENANCE 5.0.1 Check Oil Level Be sure hydraulic cylinder or other tool is fully retracted. Remove the battery from the pump. Place the pump on a level surface. Visually check the oil level by looking through the hydraulic reservoir sight glass. Reservoir is FULL when oil level is about halfway between the top and bottom of the sight glass. -
Page 20: Transportation And Shipment
Figure 5.0-1 Hydraulic Reservoir TRANSPORTATION AND SHIPMENT 1. A PowerPak will leak if tipped or inverted. Therefore, it is essential to DRAIN ALL HYDRAULIC FLUID prior to shipment. This is especially important because many federal and international regulations restrict shipment of containers that may leak fluids. Seattle, WA •... -
Page 21: Troubleshooting
6.0: T ECTION ROUBLESHOOTING This section provides some basic steps to identify possible causes of trouble, together with troubleshooting solutions. If you cannot solve your maintenance or operation problem with the information provided in this section, contact the nearest FTI representative. Failure to observe and comply with the following precautions could result in death or serious personal injury. -
Page 22: Figure 6.0-1 Enerpac Ct-604 Pressure Relief Tool
TROUBLESHOOTING GUIDE (continued) Symptom Possible Cause Solution A. Pump element piston is sticking. Noisy and/or vibrating Contact Fatigue Technology. pump operation. B. Motor is damaged. A. Oil level low. Add oil until reservoir is full. To prime the pump. Be sure that the pump reservoir is filled with oil. -
Page 23: Figure 6.0-2 Overall System Hydraulic Circuit Diagram
Figure 6.0-2 Overall System Hydraulic Circuit Diagram Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... -
Page 24: Figure 6.0-3 Hydraulic Piston Circuit Showing "Pull" Action
Figure 6.0.3 Hydraulic Piston Circuit Showing “Pull” Action Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... -
Page 25: Figure 6.0-4 Hydraulic Piston Circuit Showing "Stop" Action
Figure 6.0-4 Hydraulic Piston Circuit Showing “Stop” Action Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... -
Page 26: Figure 6.0-5 Hydraulic Piston Circuit Showing "Return" Action
Figure 6.0-5 Hydraulic Piston Circuit Showing “Return” Action Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... -
Page 27: Material Safety Data Sheets
7.0: M ECTION ATERIAL AFETY HEETS Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A... - Page 28 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
- Page 29 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
- Page 30 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
- Page 31 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
- Page 32 Seattle, WA • USA 98188-7605 Fatigue Technology 401 Andover Park East Tel: (206)246-2010 Fax: (206)244-9886 830959-REV A...
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Page 33: Declaration Of Conformity
FATIGUE TECHNOLOGY 401 Andover Park East Seattle, Washington 98188-7605 E.C. DECLARATION OF CONFORMITY Manufacturer: Fatigue Technology 401 Andover Park East Seattle, WA 98188-7605 Telephone: (206) 246-2010 Fax: (206) 244-9886 Responsible Person in E.C.: Jean-Michel Derisson 4 rue d’Austerlitz 31490 Léguevin FRANCE Telephone: 33 5-34-559-916 Fax:...