PCC FTI PowerPak FT-B100 Series Operating instructions

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A
FTI OPERATIONS,MAINTENANCE, AND REPAIR MANUAL
FT-B100 Series Cordless PowerPak
Part #2720-129, Log #36592
Revision A
June 17, 2020
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401 Andover Park East
Seattle, Washington 98188-7605
USA [phone]
Original Instruction

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A
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. 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 (Cx) 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 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, 7,100,264; 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.
ABOUT FATIGUE TECHNOLOGY
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 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1.0 Introduction......................................................................................................................................... 1
1.1 About the FT-B100 Series Cordless PowerPaks..................................................................... 1
1.2 General Specifications............................................................................................................. 1
2.0 Safety .................................................................................................................................................. 2
2.1 Safety Symbols and Definitions............................................................................................. 2
2.2 General Hydraulic Safety Precautions................................................................................... 3
2.3 Battery Operated Pump Safety Precautions........................................................................... 4
3.0 Major Features and Components........................................................................................................ 5
3.1 Product Data............................................................................................................................ 6
3.2 External Dimensions ............................................................................................................... 7
3.3 Prior to Pump Operation.......................................................................................................... 8
4.0 Operating Instructions....................................................................................................................... 10
4.1 Introduction, Hydraulic PowerPak Setup Procedure and Operation..................................... 10
4.2 Operation............................................................................................................................... 13
5.0 Maintenance...................................................................................................................................... 15
5.1 Transportation and Shipment................................................................................................. 16
6.0 Troubleshooting................................................................................................................................ 17
7.0 Material Safety Data Sheets.............................................................................................................. 23
E.C. Declaration of Conformity........................................................................................................ 29
FIGURES
Figure 3.1-1 Pump Features and Components......................................................................................................... 5
Figure 3.2-1 Pump Key Dimensions ....................................................................................................................... 7
Figure 3.3-1 FT-B100.............................................................................................................................................. 8
Figure 3.3-2 Safety Labels....................................................................................................................................... 9
Figure 4.1-1 Battery and Charger.......................................................................................................................... 10
Figure 4.1-2 Battery Capacity Indicator................................................................................................................ 11
Figure 4.1-3 Battery Installation............................................................................................................................ 12
Figure 4.1-4 Remote Pendant................................................................................................................................ 13
Figure 5.0-1 Hydraulic Reservoir.......................................................................................................................... 16
Figure 6.0-1 Enerpac CT-604 Pressure Relief Tool.............................................................................................. 18
Figure 6.0-2 Overall System Hydraulic Circuit Diagram...................................................................................... 19
Figure 6.0-3 Hydraulic Piston Circuit Showing “Pull” Action ............................................................................. 20
Figure 6.0-4 Hydraulic Piston Circuit Showing “Stop” Action............................................................................. 21
Figure 6.0-5 Hydraulic Piston Circuit Showing “Return” Action ......................................................................... 22

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A
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

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 1
SECTION 1.0: INTRODUCTION
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. Before operating the PowerPak, read this manual and retain it for
future reference.
1.1 ABOUT THE FT-B100 SERIES CORDLESS POWERPAKS
The FT-B100 Series A PowerPak is the hydraulic pump that best supports the FTI Rail Tec system of tooling.
It is used to operate the FTI RailTec family of puller units.
The FT-B100 contains a battery operated hydraulic pump that generates up to 10,000 ± 500 psi (689.5 ± 34.5
bar) hydraulic pressure.
1.2 GENERAL SPECIFICATIONS
Dimensions:...................................................... 24.5 x 16.3 x 14 inches (64.3 cm x 41.4 cm x 35.6 cm)
Weight:............................................................. 65.5lbs. - 29.7 Kg
Operating Hydraulic Pressure: ......................... 10,000 psi maximum
Operating Temperature Range ......................... 40°F to 120°F (4.4°C to 48.8°C)
Hydraulic Fluid Capacity:................................ 1.75 US gallons 6.6 L
Hydraulic Fluid Characteristics:....................... Enerpac HF
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:......... Power Team Hydraulic Oil #9637; or
U.S. MIL-SPEC #5606; MIL-PRF-83282; or meets ISO 46:
FTI Part Number 1045-154; Aeroshell 41; ASTM 215

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 2
SECTION 2.0: SAFETY
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.
If you have never been trained on high-pressure hydraulic safety, contact FTI for training.
2.1 SAFETY SYMBOLS AND DEFINITIONS
This manual follows a system of safety alert symbols, signal words and safety messages to warn the user of
specific hazards. Failure to comply with these warnings could result in death or serious personal injury, as
well as damages to the equipment or other property.
The Safety Alert Symbol appears throughout this manual. It is used to alert you to potential
physical injury hazards. Pay close attention to Safety Alert Symbols and obey all safety messages
that follow this symbol to avoid the possibility of death or serious personal injury.
Safety Alert Symbols are used in conjunction with certain Signal Words that call attention to safety messages
or property damages messages and designate a degree or level of hazard seriousness. The Signal Words used
in this manual are WARNING, CAUTION, and NOTICE.
⚠WARNING
Indicates a hazardous situation that, if not
avoided, could result in death or serious personal
injury.
⚠CAUTION
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
personal injury.
NOTICE
Indicates information considered important, but
not hazard related (e.g. messages relating to
property damages). Please note that the Safety
Alert symbol will not be used with this signal
word.

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 3
2.2 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.
Stay clear of loads supported by hydraulics. To avoid personal injury, keep hands and feet away from
puller unit and work piece during operation.
Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin. If oil is injected
under the skin, see a doctor immediately.
Use only rigid pieces to hold loads. Carefully select steel or wood blocks that are capable of supporting
the load. Never use a hydraulic cylinder as a shim or spacer in any lifting or pressing application.
The system operating pressure must not exceed the pressure rating of the lowest rated component in the
system. Refer to the installed pressure gage on the pump outlet. It is your window to see what is
happening in the system.
Wear personal protective equipment (P.P.E.) when operating hydraulic equipment. Always wear eye
protection. Safety equipment such as dusk mask, non-skid safety shoes, hard hat, or hearing protection
should be used in appropriate conditions and will reduce personal injuries.
Immediately replace worn or damaged parts with genuine Fatigue Technology parts. Standard grade
parts will break causing personal injury and property damages.
Do not operate in an explosive environment.
⚠CAUTION
Failure to observe and comply with the following precautions could result in minor or moderate
personal injury. Property damage could also occur.
Do not use or repair damaged hydraulic hose. Avoid sharp bends and kinks when routing hydraulic
hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will
internally damage the hose, leading to premature hose failure.
Do not drop heavy object on hose. A sharp impact may cause internal damage to hose wire strands.
Applying pressure to a damaged hose may cause it to rupture.
Do not lift hydraulic equipment by the hoses or swivel couplers. Use the carrying handle or strap.
Keep hydraulic equipment away from flames and heat. Excessive heat will soften packings and seals,
resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance, do
not expose equipment to temperatures of 150 ˚F [65˚C] or higher. Protect all hydraulic equipment from
weld spatter.
Immediately replace worn or damaged parts with genuine Fatigue Technology parts. Fatigue
Technology parts are designed to fit properly and to withstand high loads. Non-Fatigue Technology
parts may break or cause the pump to malfunction.
Hydraulic equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact Fatigue Technology.
NOTICE

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 4
2.3 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.
Do not operate the pump near combustible materials, such as flammable liquid, gases or dust.
Remove the battery from the pump before making any adjustments, performing maintenance or storing
the pump.
Do not attempt to disable or modify the safety key interlock feature.
Remove safety key when pump is unattended to prevent unauthorized persons from operating pump.
Do not probe the battery or battery charger when conductive materials.
Do not allow metal items or material such as steel wool, aluminum foil or other foreign objects into the
battery or battery charger cavity or charger terminal.
Do not use the pump if the motor assembly is loose or damaged. Have the motor assembly inspected
and repaired by Fatigue Technology before using the pump.
Do not attempt to charge the non-specified batteries in the charger.
Do not expose the battery or battery charger to wet conditions or excessive humidity.
Do not immerse the battery or battery charger.
Use the Fatigue Technology pump only with the specified Briggs & Stratton 82V LI-ION batteries.
Refer to Section 3.1 for approved battery model number.
Recharge battery only with the charger specified by Briggs & Stratton for the battery being used.
Do not deliberately short circuit battery or battery charger.
If battery liquid leaks and contact occurs, flush with water and seek medical help.
Do not attempt to disassemble, repair or modify the battery or battery charger.
Unplug battery charger when cleaning or not in use.
Do not burn, crush or damage battery.
Do not cover ventilation slots in the top of the charger or sides of the battery.
Do not place battery charger on a soft surface, such as a blanket or pillow.
Do not allow battery or battery charger to become too warm. Allow these item to cool before
attempting to charge the battery.
Store battery and battery charger in a cool, dry place. Keep these items in a secured area, away from
children and pets.
Battery and battery charger may not be opened under any circumstances. If the cover is damaged, then
these items should no longer be used and must be replaced.
Pump motor assembly (“powerhead”) in not serviceable and should not be opened. Electric shock may
result.

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 5
SECTION 3.0: MAJOR FEATURES AND COMPONENTS
Table 3.0-1
Pump Features and Components
Key:
Replacement Part Number
1. Remote Pendant
1199-499
2. Carrying Handle/Roll bar
N/A
3. Hydraulic Reservoir Sight Glass
N/A
4. Hydraulic Reservoir Drain Plug
N/A
5. Oil Fill Plug
1125-024 (shipping and operation plugs as one part number)
6. Hydraulic Reservoir
N/A
7. Pump Motor
N/A
8. Battery Door
N/A
9. Battery Release Button
N/A
10. Battery
1199-497 North America, 1199-513 CE version
11. Safety Key
N/A
12. Male Hydraulic Plug
1047-013
13. Female Hydraulic Plug
1047-072
14. Fitting Nipple
1047-071
Figure 3.1-1
Pump Features and Components
8
9
10
11
2
3
4
7
5
6
12
14
13
1

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 6
3.1 PRODUCT DATA
Table 3.1-1
Pump Specifications
Pump
Model
For Use With
Operating Temp Range
Motor Rating
Sound
Pressure
FT-B100
RailTec Puller
Unit
40 to 120 F
+4 to +49C
1.4HP 1.0kW
75 dBA
Pump
Model
Number
Maximum
Hydraulic
Pressure
Flow Rate
No Load
Flow Rate
4,000psi
276 bar
Flow Rate
10,000psi
700bar
Reservoir
Size
Pump
Weight
Hydraulic
Oil Type
Pump
Model
Number
10,000psi
700bar
310 in3/min
5.0 l/min
80 in3/min
1.3l/min
32 in3/min
.52l/min
1.75gal
6.6l
65.5lbs
29.7kgs
Enerpac
HF
Pump Series
Pump
Model #
Includes Charger
Charger Model Numbers
FTI
Briggs & Stratton
FT-B100
Series
FT-B100-
120V
Battery Charger, 120V AC, 50/60 Hz
Input NA
1199-495
1760263
FT-B100-
220V
Battery Charger, 220V AC, 50/60 Hz
Input EU/AU CE certified
1199-494
1760264
Pump
Model #
Battery
FTI Part Number
FTI
CE Certified
Briggs &
Stratton
North America
Briggs & Stratton
CE Certified
FT-B100-120V
1199-496
N/A
1760265
N/A
FT-B100-220V
1199-513
Yes
N/A
1760515
Pump Series
Pump
Model #
Includes Charger
Pressure Relief Tool
FTI
Enerpac #
FT-B100
Series
FT-B100-
120V
Battery Charger, 120V AC, 50/60 Hz
Input NA
1187-770
CT-604
FT-B100-
220V
Battery Charger, 220V AC, 50/60 Hz
Input EU/AU CE certified
1187-770
CT-604

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
830959-REV A 7
3.2 EXTERNAL DIMENSIONS
Table 3.2-1
Pump Specifications - Key Dimensions
Figure 3.2-1
Pump Key Dimensions
Item
Dimension
In
mm
A
25.48
647
B
14.00
356
C
9.69
246
D
8.09
205
E
4.22
107
F
5.66
144
G
16.28
414
H
10.92
277
H
G
A
F
B
E
D
C

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
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3.3 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. Ultimately, the operator is responsible for personal safety; however, the following
general safety precautions should be observed.
Note that the FT-B100 series pumps are not sealed units and must not be tipped or shipped wet. Tipping the
unit while filled will result in oil leaks, and cause operational issues. A shipping cap is included and can be
put back in place for shipping.
1. Wear eye and ear protection when operating the FT-B100 PowerPak.
2. Disconnect the remove battery 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 TURN OFF. Never use your
hands to grasp a leaking hose under pressure. The force of escaping hydraulic fluid could cause serious
injury. If hydraulic oil should penetrate the skin, medical attention must be sought immediately.
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 and fittings for wear or damage
that could cause premature failure of the hose or fittings and
possibly result in injury. Replace damaged hoses or fittings
prior to use.
8. Hose material and coupler seals must be compatible with the
hydraulic fluid used (see Section 1.2 for hydraulic fluid
requirements). Hoses and fittings must have a minimum
working pressure of 10,000 psi with a minimum burst pressure
of 20,000 psi. Note: Hydraulic hoses supplied by FTI meet
these requirements.
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.
Figure 3.3-1
FT-B100

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
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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. These safety labels and
their definitions are shown in Figure 3.3.2.
Notes:
a. Safety labels are not shown actual size. Actual size is Ø0.75 inch (Ø19.05 mm).
b. Actual colors on the safety labels are a white image on a blue background.
Figure 3.3-2
Safety Labels
13. DO NOT exceed the psi hydraulic pressure rating noted on the pump nameplate or tamper with the
internal high relief valve. Creating pressures beyond rated capacities may result in personal injury.
14. Before operating the pump, tighten all hose connections. Do not overtighten the connections.
Connections need only be tightened securely and leak-free. Overtightening may cause premature thread
failure, or cause high-pressure fittings to split at pressures lower than their rated capacities.
15. Periodically pump clean oil through the entire length of 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.
16. Before replenishing the oil level, retract all cylinders to prevent overfilling the pump reservoir. An
overfill may cause personal injury due to excess reservoir pressure created when cylinders are retracted.
17. DO NOT use the hose to move attached equipment. Stress may damage the hose and cause personal
injury.
18. Pump should be placed on a level surface when operated.
19. Pump should not be moved during operation.

Fatigue Technology 401 Andover Park East Seattle, WA • USA 98188-7605 Tel: [phone] Fax: [phone]
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SECTION 4.0: OPERATING INSTRUCTIONS
4.1 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.
Major features include a brushless DC electric motor, three-stage pump element and 1.75 gallon [6.6 liter]
hydraulic reservoir.
The pump is powered by a rechargeable 82V lithium-ion battery, manufactured by Briggs & Stratton
Corporation. The lithium-ion battery is capable of providing impressive run time, even under extreme job site
conditions.
Figure 4.1-1
Battery and Charger
4.1.1 Additional Information - Battery Charger
The Briggs & Stratton logo is trademarked and intellectual property of Briggs & Stratton.
Portions of this publication are subjected to copyright of Briggs & Stratton Corporation and Enerpac
Corporation.
4.1.2 Conformance to National and International Standards
FTI declares that the FT-B100 series cordless electric pump has been tested and conforms to applicable
standards and is approved to carry the CE, TUV C and US certification marks. An EU Declarations of
conformity is enclosed separately. Note: battery and battery charger may be CE certified depending on model
ordered, see Table 3.1-1.
4.1.3 Electromagnetic Compatibility (EMC)
The FT-B100 Series cordless electric pump has been tested and certified to conform to CE-EMC emission
and immunity standards.

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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. Operators should be
trained on the contents of this manual prior to use.
4.1.5 Hydraulic Reservoir Breather
A shipping plug is installed in the breather port on the top of the reservoir. Before using the pump, replace the
shipping plug with the adaptor fitting and breather.
4.1.6 Hydraulic Connections
To ensure proper operation, avoid kinking or tightly bending hoses. If a hose becomes kinked or otherwise
damaged, it must be replaced. Damaged hoses may rupture at high pressure. Serious personal injury may
result.
Installation of a pressure gauge in each hydraulic line is strongly recommended. All hoses and fitting must be
rated to at least 10,000 psi [700 bar].
4.1.7 Battery Capacity Indicator
New Batteries should be charged before use. Each battery contains four indicator lights. The battery capacity
indicator lights show the approximate battery capacity level.
Press the battery capacity indicator button to display the lights. The battery capacity indicator light will stay
lit for two seconds after the button is pressed. Refer to Figure 4.1-2 to determine the level of charge.
Run time between battery charges is dependent on the application, pump run time, pressure setting and other
factors.
If none of the battery capacity indicator lights illuminate when the battery capacity is pressed, place the
battery on the charger and charge as needed.
Figure 4.1-2
Battery Capacity Indicator
When Battery Capacity Indicator
Button is pressed:
Percent Charge:
(approximate)
4 Lights ON
80 - 100%
3 Lights ON
60 - 80%
2 Lights ON
40 - 60%
1 Light ON
25 - 40%
0 Lights ON
< 25%

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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.
4. Ensure battery release button snaps in place and that the battery is fully seated and secured before
beginning operation.
5. Close the battery door.
Figure 4.1-3
Battery Installation
To ensure compatibility and proper operation, use only Briggs & Stratton 82V lithium-ion batteries with the
pump. Refer to Table 3.1-1 for battery model number information.
4.1.9 Battery Removal
1. Ensure Pump motor is switched off.
2. Lift the battery door and hold it open.
3. Press the release button located above battery.
4. Slide the battery outwards and remove it from the battery compartment. Refer to Figure 4.1-3.
4.1.10 Battery Management System
The battery management system monitors and controls battery operation:
A low voltage cut-off feature will shut down the battery when the battery voltage drops to below the
acceptable limit.
A high temperature shut down feature will shut down the battery if its internal temperature rises to
above the acceptable limit.
If the low voltage cut-off or high temperature shut down feature is activated while the pump is
operating, the pump motor will emit a beeping sound and the pump will stop.
If the high temperature shut down feature is activated, the battery must cool down to an acceptable
internal temperature before the pump can be restored.
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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˚F [40˚C]. The battery is a lithium-ion device. It will not develop a memory and may be
charged at any time.
If the battery charger light glows green and blinks when the battery is place in the battery charger, this
indicates that the battery is being charged. A solid green light indicates that the battery is fully charged.
If the battery charger light glows solid red when the battery is placed in the battery charger, this
indicated that the battery temperature is above acceptable limits. Leave the battery in the charger and
allow time (up to 30 minutes) for the battery to cool. The charger should resume charging after the
battery has cooled.
If the battery has been stored with little to no charge for a long period of time, the charger goes into
recovery mode, which will take 20 hours to full charge the battery. This will enhance the life of the
battery. Once the battery is fully charged, the next charge will return to standard charging.
4.2 OPERATION
4.2.1 Before start up
1. Check all hydraulic fittings and connections to be sure they are tight and leak free.
2. Install hydraulic reservoir breather. Refer to Figure 3.1-1.
3. Check the hydraulic oil level. Add oil if necessary. Refer to Figure 5.0.
4. Install a fully charged battery on the pump. Refer to Section 4.1.8.
5. Verify safety key is installed.
6. Connect puller unit hydraulic hose(s) to pump as described in Puller unit manual.
4.2.2 Starting the Pump Motor
1. Place RailTec Puller Unit in the neutral (handle centered position).
2. To start the pump motor, press the upper half of the remote pendant rocker switch.
4.2.3 Stopping the Pump Motor
To stop the pump motor, press the lower half of the remote pendant rocker switch.
In an emergency, the pump motor can also be stopped by removing either the safety key or the battery.
Figure 4.1-4
Remote Pendant
1. On Position
2. Off Position
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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.
To prevent the lifted load from dropping, always immediately support it with jack stand or other
mechanical blocking device of adequate rated capacity. Be certain that blocking is fully in place before
moving the control value lever from one position to another. An unsupported load can drop when the
control valve is shifted.

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SECTION 5.0:MAINTENANCE
5.0.1 Check Oil Level
1. Be sure hydraulic cylinder or other tool is fully retracted.
2. Remove the battery from the pump.
3. Place the pump on a level surface.
4. 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. Refer to Figure 5.0-1.
5. If the oil level is low:
a. Add oil as described in Section 5.0.3.
5.0.2 Hydraulic Oil Information
Use only Enerpac HF hydraulic oil when adding additional oil or when performing an oil change. Enerpac HF
hydraulic oil is available from Fatigue Technology.
Recommended use only Enerpac HF hydraulic oil. Use of other oils may result in damage to pump
components. Such damage is not covered under the product warranty.
5.0.3 Adding Oil
1. Be sure hydraulic cylinder or tool is fully retracted.
Disconnect hydraulic hoses.
2. Remove the battery from the pump.
3. Place the pump on a level work surface.
4. Remove SAE #10 plug from cover plate.
5. Slowly fill the reservoir with new oil until level is about halfway between the top and the bottom of
the hydraulic reservoir sight glass. Refer to Section 3.1 for oil requirements.
DO NOT overfill. Be certain that all hydraulic cylinders are fully retracted before adding any oil. Over filling
hydraulic reservoir may cause damage to the pump.
5.0.4 Oil Change
Change the hydraulic oil in the pump reservoir at least once a year or whenever it is suspected that the oil has
become contaminated.
To properly drain and refill the reservoir, change the oil as described in the following steps. Refer to Figure
5.0-1.
1. Be sure hydraulic cylinder or tool is fully retracted.
2. Remove the battery from the pump.
3. Disconnect hydraulic hoses from pump.
FT-B100 Series pumps are equipped with a 1.75 gallon [6.6 liter] hydraulic reservoir. Be sure the pan or
container is large enough to hold all the drained oil.
4. Place a suitable pan or container or appropriate capacity under the hydraulic reservoir drain plug.
5. Remove hydraulic reservoir drain plug.
6. Allow used oil to drain completely from reservoir.
7. Clean hydraulic reservoir drain plug and remove any metal shavings (plug is magnetic).
8. Reinstall hydraulic drain plug.
9. Refill hydraulic reservoir with new oil.
Dispose of used oil in accordance with all applicable laws and regulations.

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Figure 5.0-1
Hydraulic Reservoir
5.1 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.