FT 20 Powerpak
FT 20 Powerpak
FT 20 Powerpak
FT-20
Portable PowerPak
FTI Part #2720-015, Log #01212
Revision M
Original Instruction
The detailed tooling information in this manual was compiled and written by FTI. The tooling was designed
specifically for use with FTI’s Cold Expansion Systems. FTI cannot be held responsible for damage or injury as a
result of operating this equipment if it is used for other than the process intended, with any other tooling not
provided by FTI, or not used in accordance with the instructions contained in this manual. To avoid personal
injury, please observe all safety precautions and instructions. If you have any questions about the use or
serviceability of this equipment, please contact our Sales Department.
FTI’s Cold Expansion systems and processes are the subject matter of one or more of the following patents:
4,809,420; 4,885,829; 4,934,170; 5,083,363; 5,096,349; 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 specifications or controlling documents. To ensure proper results
from FTI’s cold expansion systems and to be licensed to use FTI’s patented processes, it is essential that FTI’s
complete integrated system of tooling be purchased and utilized. The use of tooling purchased from other than a
licensed supplier could jeopardize fatigue life enhancement and may constitute patent infringement.
FTI reserves the right to change the specifications or configurations of tooling detailed in this manual as part of its
ongoing technical and product information program. Should inconsistencies occur between your tooling and this
manual, please contact our Sales Department.
Fatigue Technology Inc. (FTI) has provided innovative solutions to the aerospace industry since 1969. Our
products are used worldwide to reduce manufacturing and maintenance flow time and costs.
The FTI staff of professionals provides a full range of support services including:
• Application engineering
The Sales Department is always available to assist with special fatigue enhancement requirements. Please contact
FTI with questions at any time.
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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
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TABLE OF CONTENTS (CONTINUED)
SECTION DESCRIPTION PAGE
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; 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
Figure 7.4-1 FT-20 Basic Pump Assembly; Top View ......................................................................................... 21
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SECTION 1.0: INTRODUCTION
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.
The FT-20 is a portable PowerPak that supports the FTI system of tooling. Because of its small size and light
weight, the FT-20 is particularly useful for work in areas with difficult or restricted access. It may be used to
operate FTI hydraulic puller units in the Little Brute and Medium Brute family. The FT-20 may also be used with
the Big Brute (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 Section 6.0 for
PowerPak configuration and schematics.
NOTE: The FT-20 is shipped with hydraulic fluid already in the unit. The FT-20 is shipped with a non-
vented cap on the reservoir. This must be replaced with the supplied vented cap and dipstick prior to
operation. If there is a need to fill the FT-20 with hydraulic fluid or drain the fluid for reshipment, please
refer to Section 4.3 for instructions.
There are three different models in the FT-20 series. The primary identification method is identified on the decal on
the side of the manifold.
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1.3 GENERAL SPECIFICATIONS
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SECTION 2.0: SAFETY
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. Many of these are noted in
this section. Ultimately, the operator is responsible for personal safety; however, the following general safety
precautions should be observed. Also see Figure 2.0-1.
CAUTION: Set the FT-20 PowerPak on a level surface. If the surface is out of plane, there is a risk of the
FT-20 PowerPak unit vibrating off the surface.
Read manual before using Always wear eye protection Always wear ear protection
Figure 2.0-1
Safety Stickers
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 your hands to grasp a leaking
hose under pressure. The force of escaping hydraulic fluid can cause serious injury.
4. DO NOT attempt to disconnect the hydraulic hose while the pump is running.
5. DO NOT expose hoses to potential hazards, such as extreme heat or cold, sharp surfaces, heavy impact, or
vehicular traffic.
6. DO NOT allow hoses to kink, twist, curl, or bend so tightly that the oil flow within the hose is blocked or
reduced.
7. Periodically inspect the hose for wear or damage which could cause premature failure of the hose and possibly
result in injury.
8. Hose material and coupler seals must be compatible with the hydraulic fluid used.
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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. Creating pressure beyond rated capacities may result in personal injury and/or damage to the
PowerPak.
11. DO NOT exceed the recommended air pressure of 90 to 120 psi (6.2 to 8.3 bar).
12. Before operating the pump, tighten all hose connections using the proper tools. Do not overtighten the
connections. Connections need only be tightened 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 replenishing the oil level, retract all cylinders to prevent overfilling the pump reservoir. Overfilling
may cause personal injury due to excess reservoir pressure created when the cylinders are retracted.
15. Do not use the hose to move attached equipment. Stress may damage the hose and cause personal injury.
IMPORTANT: FTI completed a risk assessment on this unit at our factory. Any modifications done by a third
party or the final user are excluded from that risk assessment. As a result, modifications done by a third party or the
final user nullify the CE marking.
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SECTION 3.0: FT-20 OPERATING INSTRUCTIONS
Become familiar with these instructions before operating the FT-20.
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.
NOTE: Clean the top plate of the pump before removing the filler cap and dipstick to prevent
contaminants from entering the oil supply.
2. Remove the shipping plug from the reservoir fill port and replace with the supplied vented cap.
3. The fill line on the reservoir is 5/16 inch from the top. Visually inspect the oil level in the reservoir. When
operating, make sure the reservoir vented cap is in place. The oil level should be within 5/16 inch of the filler
plug; if the pump is to be operated with 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 if necessary.
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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.
Please contact our Sales Department for details.
CAUTION: Set the FT-20 PowerPak on a level surface. If the surface is out of plane, there is a risk of the
FT-20 PowerPak unit vibrating off the surface.
1. The PowerPak is an air-driven hydraulic unit and can be activated only when connected to a FTI puller unit or
remote trigger as described in Section 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 the puller unit barrel returns the puller
piston to the start position.
4. If actuation fails to take place, the trigger response valve may need to be adjusted. This is done by loosening
the brass nut on the trigger response valve. Connect the pump main air supply and the puller unit. Then, with
the puller unit trigger depressed, adjust the pilot screw in (clockwise) or out (counterclockwise). Turning the
pilot screw in makes the trigger more sensitive, while adjusting it out makes it less sensitive. Once the desired
sensitivity is achieved, retighten the brass nut. Different puller units may require this valve to be readjusted.
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SECTION 4.0: FT-20 MAINTENANCE
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.
1. Periodically clean the outer surfaces of the FT-20 and equipment used with the FT-20.
2. When not in use, ensure that the dust cap is reinstalled on the hydraulic coupler.
3. Keep all hose connections free of metal chips, dirt, and grime.
4. Keep the breather hole in the vented filler cap and dipstick clean and unobstructed.
5. The hydraulic oil should be replaced every 200 to 500 hours of use, depending on severity of use and
environmental conditions.
6. Always clean the hydraulic and air couplers prior to making connections.
1. Clean the top plate, remove the filler cap 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.
1. Disconnect the puller unit from the PowerPak and the air supply when adding oil to the reservoir.
2. Clean the entire area around the vented filler cap and dipstick before removing the filler plug located to the right
and slightly behind the hydraulic quick coupler.
3. Remove the filler cap and dipstick. Insert a clean funnel with a flexible tube and strain the new oil through a
paper filter. If a flexible tube is not available, the pump shroud may need to be removed for access.
4. Fill with hydraulic fluid to within 5/16 inch of the top of the filler hole. The fill line on the reservoir is 5/16
inch from the top. See Section 1.3 for hydraulic fluid specifications.
5. Replace the filler cap and dipstick and make sure the breather hole in the filler cap and dipstick is open. Cycle
the PowerPak (with the puller unit attached) several times, and recheck the oil level in the PowerPak reservoir.
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4.4 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. To drain the FT-20, remove the shroud and cover retainer screws and expose the reservoir. (If a drain plug is
present, unscrew the plug and drain the oil through the port.)
3. Drain the hydraulic fluid by 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.
1. The air supply must be clean and dry, and provided at 90 to 120 psi. Volume must be a minimum of 20 cfm,
and a 3/8-inch inside diameter air hose is recommended.
2. FTI recommends that an automatic air line filter/oiler be installed in the air inlet line as close to the PowerPak
as possible. Set the oiler to feed 1 to 3 drops of oil per minute (one drop for every 50 to 75 cfm of air) into the
system. Use SAE No. 10 non-detergent oil.
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SECTION 5.0: TROUBLESHOOTING
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. or an FTI Representative who can provide you with the nearest
authorized service center.
WARNING:
To prevent injuries, any repair work or troubleshooting must be done by qualified personnel familiar with
this equipment. Use proper equipment and tools when troubleshooting.
IMPORTANT: Refer to the parts lists (Section 6.0) when using the Troubleshooting Guide.
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 (a) While squeezing the trigger of the puller unit,
properly adjusted. loosen the brass nut on the trigger response
valve. Adjust the valve pilot in or out until the
desired sensitivity is obtained. Retighten the
brass nut.
(b) Air logic valve is stuck in (b) The air logic valve is located on top of the pump
position. just under the shroud. Remove the shroud and
disassemble the valve. Remove the valve spool
and inspect the O-rings and spool body. If the
valve is a Versa brand valve (gold body),
replace the O-rings as required and remove any
contaminates. If the valve is an I.S.I. brand valve
(black body), the spool will most likely need to
be replaced. Clean any contaminates from the
valve body. Refer to Section 6.0 for valve part
numbers.
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PROBLEM CAUSE SOLUTION
5.2 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.
(b) Trigger response valve is not (b) While squeezing the trigger of puller unit, loosen
properly adjusted. the brass nut on the trigger response valve.
Adjust the valve pilot in or out until the desired
sensitivity is obtained. Retighten the brass nut.
(c) Loose oil coupling to the (c) Check the quick-disconnect couplings on the
puller unit. hose and pump. Inspect couplers to ensure that
they are completely tightened.
(d) Oil level too low. (d) Refer to Section 4.2, Checking Hydraulic Fluid
Level.
(e) Hydraulic line from the puller (e) Connect the hydraulic line to the hydraulic quick-
unit is not attached to the coupler.
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.
(h) Dirt in pump or filter plugged. (h) The oil pick-up strainer should be cleaned; if
necessary, the PowerPak should be dismantled
and all parts inspected and cleaned. Replace the
hydraulic oil.
(i) Leak in the air circuit. (i) Ensure there are no air leaks from any fittings.
Tighten fittings to eliminate the leaks. NOTE:
Leaks from the puller unit trigger are acceptable.
(j) Relief valve or low pressure (j) Readjust as needed. Because this adjustment is
unloading valve is out of complex, contact FTI about procedures for return
adjustment. or repair.
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PROBLEM CAUSE SOLUTION
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. 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 is
leaking from the valve. If the control valve is not
leaking, the internal check valve could be
leaking.
(d) Piston packing or valve seats (d) Return the pump to FTI for repair.
are damaged.
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PROBLEM CAUSE SOLUTION
(a) Inadequate air pressure or air (a) Increase air pressure and/or hose diameter.
flow.
(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. filter immersed in oil. Note the pressure reading
when the relief valve begins to open. If it is
functioning normally, the pressure should start
to bleed off at 9,500 to 10,000 psi (4,000 psi for
the FT-20-4K).
(e) Internal leakage in puller unit. (e) Disconnect the puller unit. Use a different
puller unit to test the PowerPak; if it builds to
full pressure using a different 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 (g) Return the pump to FTI for repair.
are damaged.
5.5 AIR RUSHES OUT AROUND THE TRIGGER OF THE PULLER UNIT WHEN ACTUATED AND
PUMP DOES NOT OPERATE.
NOTE: Minor air leakage from the trigger is normal.
(a) An air line from the puller unit (a) Connect the air line.
is not connected.
(b) The trigger response valve is (b) While squeezing the trigger of the puller unit,
not properly adjusted. loosen the brass nut on the trigger response
valve. Adjust the valve pilot in or out until the
desired sensitivity is obtained. Retighten the
brass nut.
(c) Hose fittings from the puller (c) Check all hose fitting configurations in the
unit or PowerPak are reversed. puller unit manual.
(d) Air logic control valve is stuck (d) Refer to 5.1 (b).
in position.
PROBLEM CAUSE SOLUTION
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5.6 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. return, proceed to 5.6 (b).
(b) The hydraulic quick coupler (b) 1) Disconnect the air supply from the FT-20.
has not been completely 2) Disconnect the coupler from the FT-20.
tightened at the PowerPak 3) Connect Enerpac CT-604 to the coupler
manifold. This allows the and bleed off hydraulic oil to relieve the
check valve in the puller build-up. Figure 5.6-1 shows the Enerpac
unit’s hydraulic quick coupler CT-604 Pressure Relief Tool.
to close on the return stroke. 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 the oil level in the PowerPak
reservoir.
Figure 5.6-1
Enerpac CT-604 Pressure Relief Tool
(a) Puller unit retracts and will (a) Trigger response valve is not properly adjusted.
not return because hydraulic See 5.1 (a).
pump will not shut off, or
there is a delay in PowerPak
shutoff.
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SECTION 6.0: FT-20A AND FT-20-4K ILLUSTRATED PARTS BREAKDOWN
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. Use the FT-20A section for the
FT-20-4K.
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FT-20A
6.2 EXTERNAL FITTINGS: FT-20A, TOP VIEW; PARTS LIST 8
6
11 9
10 12
13
14
1 2 3
13
Figure 6.2-1
FT-20A External Fittings; Top View
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FT-20A
6.3 BASIC PUMP ASSEMBLY: FT-20A, FRONT VIEW; PARTS LIST
Figure 6.3-1
FT-20A Basic Pump Assembly; Front View
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FT-20A
6.4 BASIC PUMP ASSEMBLY: FT-20A, TOP VIEW; PARTS LIST
Figure 6.4-1
FT-20A Basic Pump Assembly; Top View
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SECTION 7.0: FT-20 ILLUSTRATED PARTS BREAKDOWN
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. Use the FT-20A section for the
FT-20-4K.
Figure 7.1-1
FT-20 External Fittings; Side View
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FT-20
7.2 EXTERNAL FITTINGS: FT-20 TOP VIEW; PARTS LIST
Figure 7.2-1
FT-20 External Fittings; Top View
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FT-20
7.3 BASIC PUMP ASSEMBLY: FT-20 FRONT VIEW; PARTS LIST
Figure 7.3-1
FT-20 Basic Pump Assembly; Front View
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FT-20
7.4 BASIC PUMP ASSEMBLY: FT-20 TOP VIEW; PARTS LIST
Figure 7.4-1
FT-20 Basic Pump Assembly; Top View
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SECTION 8.0: SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
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SAFETY DATA SHEET
Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
32 49050-REV M
Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
34 49050-REV M
Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
36 49050-REV M
Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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FATIGUE TECHNOLOGY INC.
401 Andover Park East
Seattle, Washington 98188-7605
USA
Telephone: 33 (0)6-72-28-66-54
Type:
Serial Number:
Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
40 49050-REV M
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Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886
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