Assembly - Greenlee Fairmont HG3505A Instruction Manual

Assembly

Note: It is recommended that new seals contained
in the seal kit be installed when the pump is
overhauled.
1. See Exploded View, Pump. Remove pressure
loading seals (6 & 14) from wear plate and discard
if new parts are available. Install new seals into
groove with smooth, flat surface out. The seals
should extend a minimum of 0.005 inch (.127 mm)
above surface of wear plate. Do not push seals
below wear plate surface at any point. The entire
seal must be started into the groove, and no part of
the seal should extend beyond the groove.
2. Place body (13) on flat plate with shaft seal bore up.
Install new shaft seal (8). Press seal until it is 3/16
inch below from surface. Pack the area between the
double lip of the seal with Lubriplate or equivalent.
3. Invert body so that gear bores are up. Install wear
plate (5) in bottom of bore, making sure that pres-
sure unloading seals (6 & 14) are positioned cor-
rectly in seal grooves and installed against bottom
of bore surface. See detail A of illustration for
correct assembly.
4. Lubricate bushings in the body, and surface of wear
plate, with SAE 10 oil.
5. Apply Lubriplate or equivalent to outer surface of
drive shaft sleeve. Insert sleeve into shaft seal
from front of pump until sleeve contacts drive gear
bushing. Install drive gear (12). Install driven gear
(11) with long journal toward front of pump. Lubri-
cate rear gear faces and journals with SAE 10 oil.
6. Apply a small amount of grease to seal ring groove
and install new seal ring (4) into groove.
7. Install dowel pins (7) into body (13). Lubricate
bushings in cover with SAE 10 oil and install cover
(10), matching scribe marks on cover and body.
8. Insert cap screws (1) and washers (2). Torque to
7-8 foot-pounds. Install Woodruff key (9). Turn drive
shaft with adjustable wrench to ensure that no
mechanical binding occurs.
9. See Exploded View, HG3505 Power Unit. Install
pump shaft into coupler (15). Be sure screen (36) is
in position around coupler and engages pilot
diameter on pump, aligning keyway in coupler with
Woodruff key in pump shaft. Install spacers (18)
between manifold (10) and pump flanges. Install
hex head cap screws (19) with washers through
pump flanges, spacers, and manifold, tightening cap
screws into body of engine. Tighten set screw (16).
Connect swivel nut of hose assembly (32) to elbow
(33). If filter (20) has been removed and cleaned,
replace it.
10. Replace baffle (30) on studs (29). Return tube (27)
to its original position, and tighten nut of male
connector (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. Check for leak-
age, and listen for any abnormal noises as each step is
performed.
1. Connect hoses as described in Hose/Tool Connec-
tion. Start the unit but let it idle for about two min-
utes at about 1/4 of the maximum engine speed.
Do not push red bypass valve down.
2. Increase engine speed by 1/4 increments, letting
the unit run for two minutes at each setting.
3. After full engine speed is reached, push red bypass
valve down. Allow unit to run for two minutes before
applying load.
4. Actuate and hold the tool, building pressure to the
relief valve setting several times. If no leakage has
occurred, and unit is operating correctly, break-in is
complete.
15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070