PCC FTI MB-30 Betriebsanleitung

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

FTI OPERATIONS, MAINTENANCE, AND REPAIR MANUAL

Medium Brute Puller Unit

Part #2720-007, Log #01204

Revision K

December 12, 2023

401 Andover Park East

Seattle, Washington 98188-7605

USA (206) 246-2010

Original Instruction

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-2868 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

ABOUT FATIGUE TECHNOLOGY INC.

Fatigue Technology Inc. (FTI) is a world-leading aerospace engineering and manufacturing company.

FTI pioneered Cold Expansion (Cx™) 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. Use of

tooling procured from other than a licensed source may constitute patent infringement.

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. FTI reserves the right to change specifications or configurations of

equipment detailed in this manual as part of our ongoing technical and product improvement programs. 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.

Fatigue Technology Inc. (FTI) has provided innovative solutions to fatigue problems in metal structures since 1969.

Complete systems of tooling are used worldwide to enhance the fatigue life of holes in airframes, turbine engines,

and other critical structures.

The FTI staff of professionals provides a full range of support services including:

*Application engineering.

*Detailed project planning, implementation, and management.

*On-site assistance, including training and tool room setup.

The Sales Department is always available to assist with special fatigue enhancement requirements. Please contact

FTI with questions at any time.

This manual can be made available in other languages. Please contact the Sales Department to request a copy.

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 Introduction......................................................................................................................................... 1

1.1 About the Medium Brute Puller Unit ...................................................................................... 1

1.2 General Specifications............................................................................................................. 1

1.3 General Description................................................................................................................. 2

2.0 Safety .................................................................................................................................................. 4

2.1 Hydraulic Hose Safety............................................................................................................. 6

3.0 Puller Unit Operating Instructions ...................................................................................................... 7

3.1 Puller Unit Setup Procedure .................................................................................................... 7

3.2 Actuation of the Puller............................................................................................................. 8

4.0 Maintenance........................................................................................................................................ 9

4.1 General Cleaning..................................................................................................................... 9

4.2 Preventative Maintenance ....................................................................................................... 9

4.3 Lubrication .............................................................................................................................. 9

4.4 Inspection ................................................................................................................................ 9

4.5 Assembly and Disassembly................................................................................................... 10

4.6 Medium Brute Seal Kit (MB-SK) ......................................................................................... 12

5.0 Troubleshooting ................................................................................................................................ 13

5.1 PowerPak Will Not Build Full Hydraulic Pressure ............................................................... 13

5.2 Puller Retracts on Trigger Actuation, But Will Not Return to Start Position ....................... 14

5.3 Mandrel Sticks in Hole When Puller Is Activated................................................................. 15

6.0 Illustrated Parts Breakdown.............................................................................................................. 16

6.1 Medium Brute Assembly Diagrams ...................................................................................... 16

6.2 Medium Brute Part Lists ....................................................................................................... 18

6.3 BMB-10 Assembly Diagram................................................................................................. 37

6.4 BMB-10 Parts List................................................................................................................. 38

Appendix A Legacy Units ..................................................................................................................................... 39

A.1 Trigger Rework (FTI-CT-RK and MB-CT-RK) ................................................................... 39

A.2 Previous Trigger Assembly ................................................................................................... 41

A.3 Handle Revisions................................................................................................................... 42

Appendix B E.C. Declaration of Conformity........................................................................................................ 43

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-2868 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

TABLE OF CONTENTS (Continued)

SECTION DESCRIPTION PAGE

FIGURES

Figure 1.3-1 Medium Brute Puller Unit Parts.......................................................................................................... 2

Figure 2.0-1 Safety Labels....................................................................................................................................... 4

Figure 2.0-2 Location of Air Disconnect................................................................................................................. 5

Figure 2.1-1 Strain Reliever .................................................................................................................................... 6

Figure 2.1-2 Example Hydraulic Hose Identification.............................................................................................. 6

Figure 3.1-1 PowerPak Connection Ports................................................................................................................ 7

Figure 3.1-2 Hydraulic Coupler Connection ........................................................................................................... 7

Figure 4.5-1 Transfer Tube.................................................................................................................................... 10

Figure 4.6-1 Medium Brute Seal Locations .......................................................................................................... 12

Figure 5.2-2 Enerpac CT-604 Pressure Relief Tool .............................................................................................. 14

Figure 6.1-1 Medium Brute Exploded View ......................................................................................................... 16

Figure 6.1-2 Medium Brute Section View............................................................................................................. 17

Figure 6.3-1 BMB-10 Assembly Diagram ............................................................................................................ 37

Figure A.1-1 FTI-CT-RKT Tool Kit Pieces........................................................................................................... 39

Figure A.1-2 Diagram of Cartridge Trigger Assembly .......................................................................................... 40

Figure A.2-1 Diagram of Previous Trigger Assembly ........................................................................................... 41

Figure A.3-1 Handle Revisions .............................................................................................................................. 42

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

TABLE OF CONTENTS (Continued)

SECTION DESCRIPTION PAGE

TABLES

Table 1.3-1 Medium Brute Specifications ............................................................................................................. 3

Table 4.6-1 Medium Brute Seal Kit ..................................................................................................................... 12

Table 6.2-1 MB-30 Parts List............................................................................................................................... 19

Table 6.2-2 MB-30A Parts List............................................................................................................................ 20

Table 6.2-3 MB-30B Parts List ............................................................................................................................ 21

Table 6.2-4 MB-30-H25 Parts List....................................................................................................................... 22

Table 6.2-5 MB-30A-H25 Parts List.................................................................................................................... 23

Table 6.2-6 MB-30C Parts List ............................................................................................................................ 24

Table 6.2-7 MB-30-V Parts List........................................................................................................................... 25

Table 6.2-8 MB-70 Parts List............................................................................................................................... 26

Table 6.2-9 MB-70A Parts List............................................................................................................................ 27

Table 6.2-10 MB-70B Parts List ............................................................................................................................ 28

Table 6.2-11 MB-70-H25 Parts List....................................................................................................................... 29

Table 6.2-12 MB-70A-H25 Parts List.................................................................................................................... 30

Table 6.2-13 MB-70-H20 Parts List....................................................................................................................... 31

Table 6.2-14 MB-70-V Parts List........................................................................................................................... 32

Table 6.2-15 MB-70-H20-V Parts List .................................................................................................................. 33

Table 6.2-16 MB-10 Parts List............................................................................................................................... 34

Table 6.2-17 MB-10A Parts List............................................................................................................................ 35

Table 6.2-18 MB-10B Parts List ............................................................................................................................ 36

Table 6.4-1 BMB-10 Parts List ............................................................................................................................ 38

Table A.1-1 FTI-CT-RKT Trigger Assembly Replacement Tool Kit .................................................................. 39

Table A.1-2 FTI-CT-RK Trigger Rework Kit....................................................................................................... 40

Table A.1-3 MB-CT-RK Medium Brute Rework Kit........................................................................................... 40

Table A.2-1 Parts List for Previous Trigger Assembly......................................................................................... 41

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-2868 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K

This page intentionally left blank for two-sided printing.

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K 1

SECTION 1.0: INTRODUCTION

This instruction manual contains information on the operation and maintenance of the Medium Brute Puller Unit. To

obtain optimum performance and many years of trouble-free service, operate the puller unit properly and carefully

follow maintenance procedures. Read this manual before operating the puller unit and retain the manual for future

reference. If requested, FTI will provide this manual in the language of the end-user.

1.1 ABOUT THE MEDIUM BRUTE PULLER UNIT

The Medium Brute hydraulic puller unit is a powerful, moderately sized, lightweight tool specifically

designed for use with Fatigue Technology Inc. (FTI) patented Split Sleeve Cold Expansion™ (SsCx™)

process. The Medium Brute is designed to pull a mandrel through a hole with the pre-lubricated stainless

steel split sleeves used in this process. The puller is also compatible with other FTI processes including

ForceMate®, FleXmate®, GromEx®, etc.

Medium Brute (MB) pullers have a maximum pull force of 24,000 pounds (1.1 x 105N) at 10,000 psi (689.5

bar) pump pressure. The MB is available in sizes (models) capable of cold expanding holes up to 7 inches

(177.8 mm) deep, and 15/16-inch (23.8 mm) diameter in aluminum, and up to 3/4-inch (19.1 mm) diameter

in steel and titanium. Larger diameters may be evaluated on a case by case basis, contact FTI Sales for

application assistance.

The Medium Brute is available in various models to accommodate multiple material stack-ups, hose options,

and mandrel adapters:

MB-xx where ‘-xx’ relates to material stack (see Table 1.3-1).

MB-xx-V where ‘-V’ represents high visibility hoses.

MB-xx-Hxx where ‘-Hxx’ represents a unique hose length other than the standard 10 feet.

MB-xxA comes with a MB-CA-8 mandrel adapter.

MB-xxB comes with a MB-CA-11 mandrel adapter.

BMB-10 is a special puller with a BB barrel and BMB-CA-13 mandrel adapter.

The Medium Brute has a fail-safe air control system that causes the puller retraction cycle to be interrupted

and return the puller unit to its original position whenever the operator releases finger pressure on the trigger

or in the event of an air hose failure. All puller units operate in conjunction with either of FTI’s PowerPak

air-hydraulic power units, the standard FT-200D, FT-200C, or portable FT-20 (and are compatible with older

units FT-200B, IW100MF, and IW10MF). The MB has proven to be very reliable and requires minimal

maintenance.

Use the puller unit only with FTI tooling and accessories. Refer to the FTI Tooling Catalog for more

information or contact the FTI Sales department for assistance.

1.2 GENERAL SPECIFICATIONS

Hydraulic Fluid Requirements......................................... U.S. MIL-Spec #5606

Stackup Capacity (Grip) ................................................. Material up to 7 inches (177.8 mm)

Actuation / Operation....................................................... Pneumatic / Hydraulic

Compatible PowerPaks .................................................... FT-200D, FTI-200C or FT-20

Replacement Seal Kit....................................................... Medium Brute Seal Kit (MB-SK)

Emission sound pressure level at the work station

(according to EN ISO 11201:1995) on load ................. 83.1 dB(A)

Weighted hand-arm vibration at the handle

(according to EN 28662-1:1993) on load ..................... <2.5 m.S2

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-2868 Tel: (206)246-2010 Fax: (206)244-9886

2358856-REV K

1.3 GENERAL DESCRIPTION

• Air actuated, hydraulic puller capable of cold expanding up to 15/16-inch (23.8 mm) diameter in aluminum and

mild steel, and up to 3/4-inch (19.1 mm) diameter in titanium and high-strength steel.

• Maximum pull force is 24,000 pounds (1.1 x 105Newtons) at 10,000 psi (389.5 bar) hydraulic pressure.

• Includes a hose assembly, spanner wrench, and nosecap pin wrench. Threaded adapter(s), or chuck(s) are also

included depending on model (see Table 1.3.1). All models come packaged in a tool case with foam, except as

noted.

• Available in various lengths depending on the model, up to 7.0 inches (177.8 mm) material stackup capacity.

• Hydraulic pressure provided by the FT-200D, FTI-200C, or FT-20 PowerPak.

Figure 1.3-1

Medium Brute Puller Unit Parts

Trigger

Cylinder

Housing

Barrel

End Cap

Handle

Hose

Assemblies

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: (206)246-2010 Fax: (206)244-9886

358856-REV K 3

Table 1.3-1

Medium Brute Specifications

Model

Number

Maximum

Stackup Length Mandrel

Attachment

Weight*

(Excluding

Hoses)

Stroke Case Hose

MB-30

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

13.0 lbs

(5.9 kg)

5.16 inch

(131 mm)

6575-002

Standard 10 foot

(3.0 m)

MB-30A

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

MB-CA-8 Chuck

13.4 lbs

(6.1 kg)

5.16 inch

(131 mm)

6575-002

Standard 10 foot

(3.0 m)

MB-30B

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

MB-CA-11 Chuck

13.4 lbs

(6.1 kg)

5.16 inch

(131 mm)

6575-002

Standard 10 foot

(3.0 m)

MB-30-H25

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

13.0 lbs

(5.9 kg)

5.16 inch

(131 mm)

6575-002

Standard 25 foot

(7.6 m)

MB-30A-H25

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

MB-CA-8 Chuck

13.4 lbs

(6.1 kg)

5.16 inch

(131 mm)

6575-002

Standard 25 foot

(7.6 m)

MB-30C

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

13.0 lbs

(5.9 kg)

5.16 inch

(131 mm)

N/A

Standard 10 foot

(3.0 m)

MB-30-V

3.3 inch

(83.8 mm)

16.7 inch

(424.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

13.0 lbs

(5.9 kg)

5.16 inch

(131 mm)

6575-002

High-Vis 10 foot

(3.0 m)

MB-70

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

16.1 lbs

(7.3 kg)

8.86 inch

(225 mm)

6575-003

Standard 10 foot

(3.0 m)

MB-70A

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

MB-CA-8 Chuck

16.5 lbs

(7.5 kg)

8.86 inch

(225 mm)

6575-003

Standard 10 foot

(3.0 m)

MB-70B

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

MB-CA-11 Chuck

16.5 lbs

(7.5 kg)

8.86 inch

(225 mm)

6575-003

Standard 10 foot

(3.0 m)

MB-70-H25

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

16.1 lbs

(7.3 kg)

8.86 inch

(225 mm)

6575-003

Standard 25 foot

(7.6 m)

MB-70A-H25

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

MB-CA-8 Chuck

16.5 lbs

(7.5 kg)

8.86 inch

(225 mm)

6575-003

Standard 25 foot

(7.6 m)

MB-70-H20

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

16.1 lbs

(7.3 kg)

8.86 inch

(225 mm)

6575-003

Standard 20 foot

(6.1 m)

MB-70-V

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

16.1 lbs

(7.3 kg)

8.86 inch

(225 mm)

6575-003

High-Vis 10 foot

(3.0 m)

MB-70-H20-V

7.0 inch

(177.8 mm)

24.1 inch

(612.2 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

16.1 lbs

(7.3 kg)

8.86 inch

(225 mm)

6575-003

High-Vis 20 foot

(6.1 m)

MB-10

1.3 inch

(33.0 mm)

12.7 inch

(322.6 mm)

5/8-18 (Installed)

or 7/8-14 (Included)

11.4 lbs

(5.2 kg)

3.16 inch

(80 mm)

6575-001

Standard 10 foot

(3.0 m)

MB-10A

1.3 inch

(33.0 mm)

12.7 inch

(322.6 mm)

MB-CA-8 Chuck

11.8 lbs

(5.4 kg)

3.16 inch

(80 mm)

6575-001

Standard 10 foot

(3.0 m)

MB-10B

1.3 inch

(33.0 mm)

12.7 inch

(322.6 mm)

MB-CA-11 Chuck

11.8 lbs

(5.4 kg)

3.16 inch

(80 mm)

6575-001

Standard 10 foot

(3.0 m)

BMB-10

1.0 inch

(25.4 mm)

15.7 inch

(398.8 mm)

BMB-CA-13 Chuck

19.2 lbs

(8.7 kg)

3.16 inch

(80 mm)

6575-002

Standard 10 foot

(3.0 m)

*A user-supplied suspension system may be required at the end use site. The requirement for a suspension system is based on

the end user’s workplace lifting and weight standards. A risk analysis for the suspension is necessary to maintain compliance to

end user’s standards or directives. All risks involved with the suspension of the Medium Brute are the responsibility of the end

user. User instructions and training regarding the suspension system are the responsibility of the end user.

Nosecap Selection: The Medium Brute Puller Unit is compatible with standard nosecaps or extension nosecaps

(Refer to Section 2.3 of the FTI Tooling Catalog for more information).

Mandrel Selection: The Medium Brute Puller Unit is directly compatible with standard Type 2 or Type 5 threaded

mandrels (Refer to Section 2.3 of the FTI Tooling Catalog for more information).

Fatigue Technology Inc. 401 Andover Park East Seattle, WA • USA 98188-2868 Tel: (206)246-2010 Fax: (206)244-9886

4358856-REV K

SECTION 2.0: SAFETY

Consult PowerPak manual for safety precautions before connecting the puller unit.

When used in accordance with these instructions, the puller unit 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.

CAUTION: The weight of this unit may require a suspension system per the end user’s workplace lifting

standards.

1. Operators must read this manual in its entirety before using the Medium Brute. Wear eye and hearing protection

when operating the puller unit. Do not strike any part of the tool with a hammer or equivalent object. Keep hands

and fingers clear of the nosecap, as they could be crushed between the nosecap and the workpiece. Safety labels

on the tool act as a reminder to these instructions and are shown in Figure 2.0-1.

Read manual before using Always wear eye protection Always wear hearing protection

Do not strike Keep fingers away from nosecap

Figure 2.0-1

Safety Labels

2. This puller unit must be used with an FT-200D, FT-200C, or FT-20 PowerPak hydraulic pump. This manual

does not cover the use and safety precautions of these accessories. Refer to the PowerPak operator manual for the

specific pump being used.

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