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INSTRUCTION MANUAL
PORTABLE HYDRAULIC
POWER UNIT
HG3505A / 42303
Read and understand this material before operating
or servicing this equipment. Failure to understand
how to safely operate this tool could result in an
accident causing serious injury or death.
999 1316.0 REV 3
© 1998 Greenlee Textron
2/98
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Table of Contents
Summary of Contents for Greenlee Fairmont HG3505A
- Page 1 INSTRUCTION MANUAL PORTABLE HYDRAULIC POWER UNIT HG3505A / 42303 Read and understand this material before operating or servicing this equipment. Failure to understand how to safely operate this tool could result in an accident causing serious injury or death. 999 1316.0 REV 3 ©...
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Page 2: Table Of Contents
Optional Accessories ... 19 Appendix A - SAE J1273 May 1986 ... 20-21 Description The HG3505A Portable Hydraulic Power Unit is compact, efficient and quiet. Because it is completely portable and self-contained, it can be used at almost any job site. -
Page 3: Safety Information
Safety is a critical factor in the design of Greenlee equipment. The best program starts with a safety-conscious operator. The information highlighted in this bulletin describes operating practices for the benefit of the workers who will use our equipment in their daily jobs. - Page 4 SAVE THESE INSTRUCTIONS Additional copies of this manual are available upon request at no charge. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Do not disconnect tool, hoses, or fittings while the power unit is running or if the hydraulic fluid is hot.
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Page 5: Specifications
Maximum Recommended Back Pressure ... 200 psi (14 bar) 200 psi is the agreed standard for the Hydraulic Tool Manufacturer’s Association (HTMA). Greenlee Fairmont tools operate efficiently at this standard. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Use appropriate lifting equipment. -
Page 6: Hoses And Fittings
Supply hoses and quick couplers are not furnished with the unit. See bulletin 901B for Greenlee Fairmont No-drip quick couplers and hoses. It is recom- mended that 1/2" I.D. hoses be used for the return line, and 3/8" hoses for the pressure line. -
Page 7: Hose/Tool Connections
Hydraulic oil should appear in the lower 1/4 of the sight gauge. PUMP ENGINE Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Disconnecting Hoses 1. Stop the power unit. 2. Disconnect the pressure (supply) hose from the power unit pressure port to the tool pressure port (P). -
Page 8: Operation
Do not use fingers or hands to check for leaks. Depressurize hydraulic system before servicing. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Do not disconnect tool, hoses, or fittings while the power unit is running or if the hydraulic fluid is hot. -
Page 9: Starting And Stopping Procedures
7. To direct oil to the tool, push the red bypass valve on the reservoir DOWN. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Stopping Procedure 1. Pull red bypass valve on the reservoir UP to stop the flow of oil to the tool. -
Page 10: Control Locations
HG3505A / 42303 Portable Power Unit Control Locations IGNITION SWITCH CHOKE LEVER THROTTLE LEVER STARTER CABLE BYPASS VALVE FILLER/BREATHER PLUG SIGHT GAUGE PRESSURE RETURN PORT PORT Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070... -
Page 11: Maintenance
Damaged hoses or couplings can fail, resulting in injury or property damage. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Every Operating Day Inspect hoses and fittings for signs of leaks, cracks, wear, or damage and replace if necessary. -
Page 12: Hydraulic System - Oil & Filter
Perform this procedure in a clean environment. Cleanliness is vital to maintain the service life of the unit. Refer to Exploded View, HG3505A Power Unit. 1. Engine must be shut off, and red bypass valve on reservoir pulled up. Disconnect hoses and tool from the unit. -
Page 13: Troubleshooting
Engine stalls when red bypass valve is pushed in. Oil leaks from breather/filler plug. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit PROBABLE CAUSE Engine out of fuel. Incorrect starting procedure. -
Page 14: Disassembly
8. Lift out; driven gear (11), drive gear (12), and wear plate (5). Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Note: During disassembly, take special note of the position of the wear plate (5) and pressure loading seals (6 &... -
Page 15: Assembly
(9). 11. Replace and fill the reservoir. See Maintenance, Hydraulic System - Oil and Filter. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit Break-In After the pump has been overhauled, it should be broken-in by the following procedure. -
Page 16: Hg3505A Power Unit - Exploded View
HG3505A / 42303 Portable Power Unit HG3505A Power Unit Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070... -
Page 17: Parts List
42120 42956 40858 41978 41323 41348 41979 40891 44752 Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit PART NO. DESCRIPTION F022608 Engine, Kawasaki ... 1 F022609 Rubber Mount ... 4 F001213 Cap Screw, Hex Head 1/4-20 x 1-1/4 Zinc-Plated ... -
Page 18: Pump
48552 48553 48554 48555 48556 48557 *Identifies items included in Seal Kit 43293. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit PART NO. DESCRIPTION F022612 PUMP ... 1 Cap Screw, Hex Head ... 4 Flat Washer ... 4 Pipe Plug ... -
Page 19: Optional Accessories
41256 41431 48562 48563 40875 41994 40892 49321 Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit PART NO. DESCRIPTION 135586 OPTIONAL WHEELS AND HANDLE ... 1 Axle ... 1 Washer ... 4 Wheel ... 2 F003141 Pin, Cutter 1/8 x 1-1/2 ... -
Page 20: Appendix A - Sae J1273 May 1986
Additional caution must be observed in hose selection for gaseous applications. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit 2.5 Size - Transmission of power by means of pressur- ized fluid varies with pressure and rate of flow. - Page 21 Note: Avoid potential hazardous area while testing. Greenlee Textron / Subsidiary of Textron Inc. HG3505A / 42303 Portable Power Unit 4. MAINTENANCE Even with proper selection and installation, hose life may be significantly reduced without a continuing maintenance program.
- Page 22 Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Drive, Rockford, IL 61109-2988 USA Customer Service (International): 815/397-7070 • Fax: 815/397-1391 Customer Service (North America): 800/435-0786 • Fax: 800/451-2632, 815/397-1865 Canada Fax: 800/524-2853 Printed in the U.S.A.