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PCC FTI FT-20 Operation, Maintenance, And Repair Manual

Portable powerpak
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401 Andover Park East
Seattle, Washington 98188-7605 USA
(206) 246-2010
FATIGUE TECHNOLOGY INC.
OPERATIONS, MAINTENANCE, AND REPAIR MANUAL
FT-20
Portable PowerPak
FTI Part #2720-015, Log #01212
Revision M
April 15, 2022
Original Instruction
49050-Revision M, Log #01212

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Summary of Contents for PCC FTI FT-20

  • Page 1 401 Andover Park East Seattle, Washington 98188-7605 USA (206) 246-2010 FATIGUE TECHNOLOGY INC. OPERATIONS, MAINTENANCE, AND REPAIR MANUAL FT-20 Portable PowerPak FTI Part #2720-015, Log #01212 Revision M April 15, 2022 Original Instruction 49050-Revision M, Log #01212...
  • Page 2 Fatigue Technology Inc. (FTI) is a world-leading aerospace engineering and manufacturing company. pioneered cold expansion technology (which provides solutions to fatigue problems associated with holes in metal structures) back in 1969 and has 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 Inc.

  • Page 3: Table Of Contents

    ABLE OF ONTENTS ECTION ESCRIPTION Introduction ............................1 About the FT-20 PowerPak ....................1 Identification of FT-20 Series PowerPaks ................1 General Specifications ......................2 Safety ..............................3 FT-20 Operating Instructions ......................5 Hydraulic PowerPak Setup Procedure and Operation ............5 Actuation of PowerPak ......................
  • Page 4 ABLE OF ONTENTS ONTINUED ECTION ESCRIPTION FIGURES Figure 2.0-1 Safety Stickers ............................ 3 Figure 3.1-1 FT-20 PowerPak ..........................5 Figure 5.6-1 Enerpac CT-604 Pressure Relief Tool ....................13 Figure 6.1-1 FT-20A External Fittings; Side View ....................14 Figure 6.2-1 FT-20A External Fittings; Top View ....................15 Figure 6.3-1 FT-20A Basic Pump Assembly;...

  • Page 5: Introduction

    1.0: I ECTION NTRODUCTION This instruction manual contains information on the operation and maintenance of the FT-20 portable hydraulic PowerPak. To obtain optimum performance and many years of trouble-free service, operate the PowerPak properly and follow maintenance procedures carefully. Read this manual before operating the PowerPak and retain it for future reference. If requested, FTI will provide this manual in the language of the end-user.

  • Page 6: General Specifications

    GENERAL SPECIFICATIONS Dimensions: ............In the box: 10” x 5.1” x 10.2” Operational: 10” x 5” x 9.7” Weight: ..............15.5 lbs. dry; 18.25 lbs. shipping weight Operating Hydraulic Pressure: ......10,000 psi maximum; 4,000 psi maximum for the FT-20-4K Air Supply: ............

  • Page 7: Safety

    2.0: S ECTION AFETY 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-20 is safe and easy to use. All general safety precautions associated with hydraulic and pneumatically operated power tools should be observed.
  • Page 8 9. Hoses must not come in contact with toxic materials, such as creosote-impregnated objects and some paints. Keep clean and never paint couplers or hoses. Hose deterioration due to chemical degradation may cause the hose to fail under pressure. 10. DO NOT exceed the hydraulic pressure (psi) rating recommended or tamper with the internal high-pressure relief valve.

  • Page 9: Operating Instructions

    3.0: FT-20 O ECTION PERATING NSTRUCTIONS Become familiar with these instructions before operating the FT-20. HYDRAULIC POWERPAK SETUP PROCEDURE AND OPERATION See Section 6.0 for parts identification. Conduct the following procedures BEFORE actuation: 1. Remove the pipe plug and attach the main air hose quick disconnect to the air inlet fitting. The air supply must be clean and dry, and 90 to 120 psi at a minimum flow of 20 cfm.

  • Page 10: Actuation Of Powerpak

    CAUTION It is suggested that an automatic air line oiler/filter be installed as close to the pump as possible. Set oiler to feed 1 to 3 drops per minute into the system. Use No. 10 SAE non-detergent oil. NOTE: An oiler package (including gage, filter, lubricator, and fittings) is NOT included with the FT-20 but is available from FTI.

  • Page 11: Maintenance

    4.0: FT-20 M ECTION AINTENANCE The FT-20 requires routine checking of the unit and periodic preventative maintenance to ensure safe, trouble-free operation. No special maintenance is required. The following actions are suggested. CAUTION: Disconnect the PowerPak from air supply before performing maintenance or repair. GENERAL CLEANING 1.

  • Page 12: Changing The Hydraulic Fluid

    CHANGING THE HYDRAULIC FLUID 1. After approximately 200 to 500 hours of use, the hydraulic fluid should be changed. The frequency of oil changes will depend upon the general working conditions, severity of use, overall cleanliness, and care given the PowerPak. 2.

  • Page 13: Troubleshooting

    5.0: T ECTION ROUBLESHOOTING This section provides some basic steps to identify possible causes of trouble, together with troubleshooting solutions. The FT-20 is a sealed unit. If there are any problems with the PowerPak which go beyond the scope of these instructions, contact Fatigue Technology Inc.

  • Page 14: Mandrel Will Not Pull Back Into The Barrel Of The Puller Unit

    PROBLEM CAUSE SOLUTION MANDREL WILL NOT PULL BACK INTO THE BARREL OF THE PULLER UNIT (a) Inadequate air pressure or (a) Obtain air pressure at 90 to 120 psi and flow at flow. 20 cfm with a hose diameter of 3/8-inch minimum inside diameter.

  • Page 15: Powerpak Builds Hydraulic Pressure But Cannot Maintain Pressure

    PROBLEM CAUSE SOLUTION POWERPAK BUILDS HYDRAULIC PRESSURE BUT CANNOT MAINTAIN PRESSURE CAUTION: Operation of the pump motor with it lifted from the reservoir (Step 5.3c) may result in oil spray. Please shroud the assembly accordingly. (a) Insufficient volume of air. (a) Check the air supply.

  • Page 16: Powerpak Will Not Build Full Pressure

    PROBLEM CAUSE SOLUTION POWERPAK WILL NOT BUILD FULL HYDRAULIC PRESSURE (a) Inadequate air pressure or air (a) Increase air pressure and/or hose diameter. flow. (b) Faulty pressure gage. (b) Calibrate the gage. (c) External fitting leakage. (c) Replace the leaking pipe fitting. (d) Faulty internal pressure (d) Lift the pump from the reservoir but keep the regulator.

  • Page 17: Puller Retracts, But Will Not Return

    PULLER RETRACTS ON FIRST TRIGGER ACTUATION, BUT WILL NOT RETURN TO START POSITION. (a) The new puller unit requires (a) Cycle the trigger several times to introduce lubrication through the piston hydraulic fluid to the cylinder. If piston fails to and cylinder.

  • Page 18: Ft-20A And Ft-20-4K Illustrated Parts Breakdown

    6.0: FT-20A FT-20-4K I ECTION LLUSTRATED ARTS REAKDOWN Note: There are three configurations of the FT-20 PowerPak: the original FT-20, the revised FT-20A, and the reduced pressure FT-20-4K. The style of pump is identified on Decal #2 in the figure below. Section 6.0 describes the FT-20A, while Section 7.0 describes the original FT-20.

  • Page 19: External Fittings: Ft-20A Top View; Parts List

    FT-20A EXTERNAL FITTINGS: FT-20A, TOP VIEW; PARTS LIST Item Number Number Part Number Part Number Required Description 1125-010 250026 1/4-Inch Straight Nipple Fitting 1125-012 208699 1/4-Inch Tee Fitting 1125-039 15426 1/4-Inch Straight Nipple Fitting 1125-021 250024 Quick Coupler (Air Outlet to Puller Unit) 1125-013 208218 1/8-Inch Straight Fitting...

  • Page 20: Basic Pump Assembly: Ft-20A Front View; Parts List

    FT-20A BASIC PUMP ASSEMBLY: FT-20A, FRONT VIEW; PARTS LIST Item Number Description Number Part Number Part Number Required Cap and Gasket Assembly (red plug and black operations plug without dipstick [units prior to 1125-024 209375 compliance with European Union Machinery Directive 2006/42/EC]) Aluminum cap with dipstick (units compliant with 1125-064...

  • Page 21: Basic Pump Assembly: Ft-20A Top View; Parts List

    FT-20A BASIC PUMP ASSEMBLY: FT-20A, TOP VIEW; PARTS LIST Item Number Number Part Number Part Number Required Description 1125-030 29992 Foam Tube 1125-048 420293 Piston Release Valve Body 1125-045 58682 Release Valve Body 1125-034 11151 Socket Head Cap Screw (Torque to 50/60 in-lbs) 1125-046 420965-BK2 Cover Plate...

  • Page 22: Illustrated Parts Breakdown

    7.0: FT-20 I ECTION LLUSTRATED ARTS REAKDOWN Note: There are three configurations of the FT-20 PowerPak: the original FT-20, the revised FT-20A, and the reduced pressure FT-20-4K. The style of pump is identified on Decal #2 in the figure below. Section 6.0 describes the FT-20A, while Section 7.0 describes the original FT-20.

  • Page 23: External Fittings: Ft-20 Top View; Parts List

    FT-20 EXTERNAL FITTINGS: FT-20 TOP VIEW; PARTS LIST Item Number Number Part Number Part Number Required Description 1125-010 250026 1/4-Inch Straight Nipple Fitting 1125-012 208699 1/4-Inch Tee Fitting 1125-011 250027 1/4-Inch Straight Nipple Fitting 1125-021 250024 Quick Coupler (Air Outlet to Tool) 1125-013 208218 1/8-Inch Straight Fitting...

  • Page 24: Basic Pump Assembly: Ft-20 Front View; Parts List

    FT-20 BASIC PUMP ASSEMBLY: FT-20 FRONT VIEW; PARTS LIST Item Number Number Part Number Part Number Required Description Cap and Gasket Assembly (red plug and black operations plug without dipstick [units prior to 1125-024 209375 compliance with European Union Machinery Directive 2006/42/EC]) Aluminum cap with dipstick (units compliant with 1125-064...

  • Page 25: Basic Pump Assembly: Ft-20 Top View; Parts List

    FT-20 BASIC PUMP ASSEMBLY: FT-20 TOP VIEW; PARTS LIST Item Number Number Part Number Part Number Required Description 1125-030 29992 Foam Tube 1125-032 34759 Piston Release Valve Body 1125-028 14280 90-Degree Fitting 1125-033 41598 Release Valve Body 1125-034 11151 Socket Head Cap Screw (Torque to 50/60 in-lbs) 1125-029 45840-BK2 Cover Plate...

  • Page 26: Safety Data Sheet

    8.0: S ECTION AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 27 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 28 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 29 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 30 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 31 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 32 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 33 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 34 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 35 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 36 AFETY HEET Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 37 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 38 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 39 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 40 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 41 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 42 Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 43 This page intentionally left blank. Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...
  • Page 44 FATIGUE TECHNOLOGY INC. 401 Andover Park East Seattle, Washington 98188-7605 E.C. DECLARATION OF CONFORMITY Manufacturer: Fatigue Technology Inc. 401 Andover Park East Seattle, WA 98188-7605 Telephone: (206) 246-2010 Fax: (206) 244-9886 Responsible Person in E.C.: KALISTRUT AEROSPACE COUDRIN, Jerome 1 Av. Marc Seguin 26240 Saint-Vallier France Telephone: 33 (0)6-72-28-66-54...
  • Page 45 This page intentionally left blank. Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886 49050-REV M...

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