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

Page 1: ...ATIGUE TECHNOLOGY INC OPERATIONS MAINTENANCE AND REPAIR MANUAL 401 Andover Park East Seattle Washington 98188 7605 USA 206 246 2010 FT 20 Portable PowerPak FTI Part 2720 015 Log 01212 Revision M April 15 2022 Original Instruction ...

Page 2: ...49 5 103 548 5 127 254 5 129 253 5 218 854 5 245 743 5 305 627 5 341 559 5 380 136 5 405 228 5 433 100 5 468 104 6 077 010 6 183 180 6 487 767 6 792 657 6 990 722 7 024 908 1 061 276 513 898 692015124 581 385 69310828 468 598 69105390 643 231 69414946 696 686 785 366 1032769 and other patents pending These systems and processes are tooling critical and must be performed in accordance with FTI s sp...

Page 3: ... 5 2 Mandrel Will Not Pull Back into the Barrel of the Puller Unit 10 5 3 PowerPak Builds Hydraulic Pressure but Cannot Maintain Pressure 11 5 4 PowerPak Will Not Build Full Pressure 12 5 5 Air Rushes Out around the Trigger 12 5 6 Puller Retracts But Will Not Return 13 5 7 PowerPak Will Not Stop When Trigger is Released 13 6 0 FT 20A and FT 20 4K Illustrated Parts Breakdown 14 6 1 External Fitting...

Page 4: ... 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 Front View 16 Figure 6 4 1 FT 20A Basic Pump Assembly Top View 17 Figure 7 1 1 FT 20 External Fittings Side View 18 Figure 7 2 1 FT 20 External Fittings Top View 19 Figure 7 3 1 FT 20 Basic Pump Assembly Front View 20...

Page 5: ... BB 30 puller unit though its operation will be slow when compared to the larger FT 200 PowerPak The FT 20 contains an air operated hydraulic pump that generates up to 10 000 pounds per square inch psi hydraulic pressure 4 000 psi for the FT 20 4K The air motor is driven by compressed air at 90 to 120 psi and 20 cubic feet per minute cfm flow through a 3 8 inch minimum inside diameter air hose See...

Page 6: ...nthetic oil Hydraulic Fluid Capacity 1 2 US gallons Hydraulic Fluid Characteristics Power Team Hydraulic Oil ASTM 215 Viscosity Index 100 minimum Viscosity 48 SUS at 210 F 215 SUS at 100 F Specific Gravity at 60 F 0 88 Flash Point degrees 400 F Fire Point degrees 430 F Pour Point degrees 30 F Aniline Point degrees 210 F 220 F Paraffinic Base Color ASTM 2 0 Suitable Substitutes for Hydraulic Fluid ...

Page 7: ...tection Always wear ear protection Figure 2 0 1 Safety Stickers 1 Wear eye and ear protection when operating the FT 20 2 Disconnect the air supply when Maintenance is to be performed Hydraulic hose is disconnected PowerPak is not in use 3 In the event of a ruptured or leaking hydraulic hose IMMEDIATELY RELEASE THE TRIGGER AND DISCONNECT THE AIR LINE from the PowerPak at the air input Never use you...

Page 8: ...ghtened securely and leak free Overtightening may cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities 13 Periodically pump clean oil through the entire length of the hose then pressurize the hose and check for leaks at the crimped connectors between the hose material and the fitting and between the fitting and coupler 14 Before replenish...

Page 9: ...th the reservoir unvented the oil level should be 3 4 inch from the filler plug If the oil level is low replenish the hydraulic fluid per the instructions in Section 4 3 4 Inspect all threads and fittings for signs of wear or damage and replace them if necessary 5 Uncoil the hose assembly from the puller unit to be used and inspect all threads couplings and hoses for damage and degradation Replace...

Page 10: ...on 3 1 2 Activate the FT 20 by depressing the trigger on the handle of the puller unit An air logic valve opens allowing the main air supply into the air motor which drives the hydraulic pump Hydraulic pressure is transmitted through the hose to the cylinder of the puller unit which then retracts the hydraulic piston 3 Releasing the trigger allows the air logic valve to shift and air pressure in t...

Page 11: ...ap and dipstick and visually check the oil level in the reservoir after every 40 hours of use 2 The proper oil level is within 5 16 inch of the top of the reservoir when the puller unit s mandrel is in its normal starting position mandrel extended and trigger released The fill line on the reservoir is 5 16 inch from the top 4 3 FILLING HYDRAULIC FLUID RESERVOIR 1 Disconnect the puller unit from th...

Page 12: ...y pouring the oil over and out one corner of the reservoir 4 Refill the reservoir with hydraulic fluid See Section 1 3 for hydraulic fluid specifications 5 Replace the pump on the reservoir torquing the cover plate retaining screws to 25 30 in lbs Make sure the reservoir gasket is in place 6 Replace the shroud 4 5 LUBRICATION AND AIR REQUIREMENTS 1 The air supply must be clean and dry and provided...

Page 13: ...roubleshooting Guide PROBLEM CAUSE SOLUTION 5 1 PUMP WILL NOT START OR WILL NOT STOP REGARDLESS OF TRIGGER POSITION NOTE This is common for new pumps or different puller unit pump combinations a Trigger response valve is not properly adjusted a While squeezing the trigger of the puller unit loosen the brass nut on the trigger response valve Adjust the valve pilot in or out until the desired sensit...

Page 14: ...level too low d Refer to Section 4 2 Checking Hydraulic Fluid Level e Hydraulic line from the puller unit is not attached to the hydraulic quick coupler e Connect the hydraulic line to the hydraulic quick coupler f Vacuum in reservoir f Check for a plugged vent in the vented filler cap and dipstick Loosen the filler cap 1 to 2 turns g Flow check valve in coupler does not stay open when coupler is ...

Page 15: ...r a Check the air supply Hoses should be 3 8 inch inside diameter b External oil leaks b Replace leaking pipe fittings Reseal or replace any faulty line fittings If no oil leakage is visible the problem may be internal c Pressure control valve leaks c To test for a leaking control valve lift the pump from the reservoir but keep the intake filter in the oil Remove the drain line to see if the oil i...

Page 16: ...erent puller unit the first puller unit is defective If another puller unit is unavailable look for oil leaks and their locations Refer to the appropriate puller unit manual for instructions f Leaks in the pressure valve f Clean and reseal or replace the valve g Piston packing or valve seats are damaged g Return the pump to FTI for repair 5 5 AIR RUSHES OUT AROUND THE TRIGGER OF THE PULLER UNIT WH...

Page 17: ...roke b 1 Disconnect the air supply from the FT 20 2 Disconnect the coupler from the FT 20 3 Connect Enerpac CT 604 to the coupler and bleed off hydraulic oil to relieve the build up Figure 5 6 1 shows the Enerpac CT 604 Pressure Relief Tool 4 Once pressure is relieved the coupler may be tightened and reinstalled onto the PowerPak 5 Reattach the air lines to get the puller unit to return 6 Check th...

Page 18: ...se the FT 20A section for the FT 20 4K 6 1 EXTERNAL FITTINGS FT 20A SIDE VIEW PARTS LIST Item Number FTI Part Number SPX Part Number Applicable Model No Number Required Description 1 1125 003 14726 or 15883 FT 20A 0 4 foot Tubing 2 FT 20A 1 Decal 3 1047 013 FT 20A 1 Hydraulic Quick Coupler 1047 090 FT 20 4K 4 1125 005 61243 FT 20A 1 Plastic Reservoir 5 1125 007 33853 FT 20A 1 Reservoir Gasket 6 11...

Page 19: ...ick Coupler Air Outlet to Puller Unit 5 1125 013 208218 1 1 8 Inch Straight Fitting 6 1125 014 19463 1 1 8 Inch Tee Fitting 7 1125 020 213343 1 Quick Plug Coupler Air Inlet from Puller Unit 8 1125 022 213346 1 Speed Control Muffler Trigger Response Valve 9 1125 016 14680 1 90 Degree Elbow Fitting 10 1125 040 10807 3 Hex Socket Head Cap Screw 11 1125 018 211060 6 Plastic Screw Torque to 25 30 in lb...

Page 20: ...ired Description 1 1125 024 209375 1 Cap and Gasket Assembly red plug and black operations plug without dipstick units prior to compliance with European Union Machinery Directive 2006 42 EC 1 1125 064 1 Aluminum cap with dipstick units compliant with European Union Machinery Directive 2006 42 EC 2 1125 043 64767 1 Pump Body 3 1125 025 17428 4 Cos Head Cap Screw Torque to 85 95 in lbs Figure 6 3 1 ...

Page 21: ...rt Number Number Required Description 1 1125 030 29992 1 Foam Tube 2 1125 048 420293 1 Piston Release Valve Body 3 1125 045 58682 1 Release Valve Body 4 1125 034 11151 4 Socket Head Cap Screw Torque to 50 60 in lbs 5 1125 046 420965 BK2 1 Cover Plate 6 1125 047 250463 2 90 Degree Elbow Fitting 7 1125 031 15499 3 Pipe Plug 8 1125 035 14423 2 Socket Head Cap Screw Figure 6 4 1 FT 20A Basic Pump Asse...

Page 22: ... FT 20A while Section 7 0 describes the original FT 20 Use the FT 20A section for the FT 20 4K 7 1 EXTERNAL FITTINGS FT 20 SIDE VIEW PARTS LIST Item Number FTI Part Number SPX Part Number Number Required Description 1 1125 001 15044 1 90 Degree Elbow Fitting 2 1125 009 14281 0 4 foot Tubing 3 1125 004 46269 1 Decal 4 1047 013 1 Quick Socket Coupler 5 1125 005 61243 1 Plastic Reservoir 6 1125 007 3...

Page 23: ...1 250024 1 Quick Coupler Air Outlet to Tool 5 1125 013 208218 2 1 8 Inch Straight Fitting 6 1125 014 19463 1 1 8 Inch Tee Fitting 7 1125 020 213343 1 Quick Plug Coupler Air Inlet from Tool 8 1125 013 208218 1 1 8 Inch Straight Fitting 9 1125 022 213346 1 Speed Control Muffler 10 1125 016 14680 1 90 Degree Elbow Fitting 11 1125 017 10020 3 Hex Socket Head Cap Screw 12 1125 018 211060 6 Plastic Scre...

Page 24: ...red Description 1 1125 024 209375 1 Cap and Gasket Assembly red plug and black operations plug without dipstick units prior to compliance with European Union Machinery Directive 2006 42 EC 1 1125 064 1 Aluminum cap with dipstick units compliant with European Union Machinery Directive 2006 42 EC 2 1125 026 50494 1 Pump Body 3 1125 025 17428 4 Cos Head Cap Screw Torque to 85 95 in lbs Figure 7 3 1 F...

Page 25: ...Required Description 1 1125 030 29992 1 Foam Tube 2 1125 032 34759 1 Piston Release Valve Body 3 1125 028 14280 1 90 Degree Fitting 4 1125 033 41598 1 Release Valve Body 5 1125 034 11151 6 Socket Head Cap Screw Torque to 50 60 in lbs 6 1125 029 45840 BK2 1 Cover Plate 7 1125 027 15045 1 90 Degree Elbow Fitting 8 1125 031 15499 3 Pipe Plug 9 1125 035 14423 2 Socket Head Cap Screw Figure 7 4 1 FT 20...

Page 26: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 22 49050 REV M SECTION 8 0 SAFETY DATA SHEET ...

Page 27: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 23 SAFETY DATA SHEET ...

Page 28: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 24 49050 REV M SAFETY DATA SHEET ...

Page 29: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 25 SAFETY DATA SHEET ...

Page 30: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 26 49050 REV M SAFETY DATA SHEET ...

Page 31: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 27 SAFETY DATA SHEET ...

Page 32: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 28 49050 REV M SAFETY DATA SHEET ...

Page 33: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 29 SAFETY DATA SHEET ...

Page 34: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 30 49050 REV M SAFETY DATA SHEET ...

Page 35: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 31 SAFETY DATA SHEET ...

Page 36: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 32 49050 REV M SAFETY DATA SHEET ...

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 33 ...

Page 38: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 34 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 35 ...

Page 40: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 36 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 37 ...

Page 42: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 38 49050 REV M ...

Page 43: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 39 This page intentionally left blank ...

Page 44: ...dersigned declares that the machinery described Type Serial Number Conforms to the following directives Council Directive 2006 42 EC the Machinery Directive ISO 11148 1 Hand Held Non Electric Power Tools Safety Requirements Part 1 ISO 4413 Hydraulic fluid power General rules and safety requirements for systems and their components ISO 4414 Pneumatic fluid power General rules and safety requirement...

Page 45: ...Fatigue Technology Inc 401 Andover Park East Seattle WA USA 98188 7605 Tel 206 246 2010 Fax 206 244 9886 49050 REV M 41 This page intentionally left blank ...