Greenlee F05, Fairmont F05 / 49616 Instruction Manual

Page 1

INSTRUCTION MANUAL

PORTABLE HYDRAULIC

F05 / 49616

POWER UNIT

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

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F05 Portable Hydraulic Power Unit

Table of Contents

Description .....................................................................2

Safety.............................................................................2

Purpose..........................................................................2

Purchase Record ........................................................... 2

Important Safety Information .....................................3–4

Identification...................................................................5

Specifications.................................................................6

Hoses and Fittings .........................................................7

Hose Connections .........................................................7

Operation ...................................................................8–9

Maintenance ................................................................ 10

Troubleshooting ........................................................... 11

Exploded View .......................................................12–13

Parts List ................................................................14–15

Description

The Fairmont F05 Portable Hydraulic Power Unit is a lightweight power source intended for use with open-

center hydraulic tools. The F05 provides a maximum flow of 17 liters per minute (4.5 gallons per minute) and a maximum pressure of 104.5 Bar (1500 psi).

Its compact size and light weight allow use at remote worksites that might not be accessible by a larger power unit or hydraulic truck. The ability to get close to the work area allows the use of shorter hydraulic hoses, increasing tool efficiency.

The simple design of the hydraulic circuit and reliable Honda gasoline-powered engine ensure years of trouble-free operation, when serviced according to the maintenance schedule.

Safety

Safety is essential in the use and maintenance of Fairmont tools and equipment. This instruction manual and any markings on the tool provide information for avoiding hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided.

Purpose

This instruction manual is intended to familiarize all personnel with the safe operation and maintenance procedures for the Fairmont F05/49616 (Serial Code GBP) Portable Hydraulic Power Unit.

Keep this manual available to all personnel. Replacement manuals are available upon request at no

charge.

Purchase Record

When the tool is received, complete the following record:

Model Number: _______________________________ Serial Number: _______________________________ Date of Purchase: _____________________________ Name of Fairmont Dealer: ______________________ A date code follows the serial number. The date code

consists of two alpha characters which identify year and month of manufacture as follows:

Year Code Month Code

1999 R Jan A 2000 S Feb B 2001 T March C 2002 V April D 2003 W May E 2004 X June F 2005 Y July G 2006 Z Aug H

Sept J

Oct K Nov L Dec M

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KEEP THIS MANUAL

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F05 P ortable Hydraulic Power Unit

IMPORTANT SAFETY INFORMATION

SAFETY ALERT SYMBOL

This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result in severe injury or death.

Hazards which, if not avoided, COULD result in severe injury or death.

Do not run power unit engine in a confined area.

Engine exhaust fumes are toxic. If inhaled, exhaust fumes can cause injury or death.

Skin injection hazard: Oil under pressure easily punctures

skin causing serious injury, gangrene or death. If you are injured by escaping oil, seek medical attention immediately.

• Do not use fingers or hands to check for leaks.

• Do not hold hose or couplers while the hydraulic system is pressurized.

• Depressurize the hydraulic system before servicing or disconnecting hoses.

Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

Failure to observe this warning will result in severe injury or death.

Fuel is flammable and explosive.

• Stop engine before filling fuel tank.

• Do not fill fuel tank when engine is hot.

• Do not fill fuel tank near an open flame, sparks, or when smoking.

Failure to observe this warning will result in severe injury or death.

Wear eye protection when operating or servicing this tool.

Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.

Wear hearing protection when using this tool.

Failure to observe this warning can result in serious injury.

Do not disconnect tool, hoses or fittings while the power source is running or if the hydraulic fluid is hot. Hot hydraulic fluid can cause serious burns.

Greenlee Textron / Subsidiary of Textron Inc.

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F05 Portable Hydraulic Power Unit

IMPORTANT SAFETY INFORMATION

• Do not operate power unit without safety guards in place.

• Keep all parts of the body and loose clothing away from the engine fan.

Engine, exhaust system, and other components will be hot during and after operation. Use care when working around the power unit. Hot surfaces can cause serious burns.

Do not let power unit engine run unattended. Monitor the engine so that it can be shut down immediately in case of a malfunction.

Failure to observe this warning can result in severe injury or death.

• Inspect the hydraulic hoses and couplings every operating day. Repair or replace if leakage, cracking, wear, or damage is evident. Damaged hoses or couplings can fail, resulting in injury or property damage.

• Use this power source for manufacturer’s intended purpose only. Use other than that which is described in this manual can result in injury or property damage.

• Make sure all bystanders are clear of the work area when handling, starting, and operating the power source. Nearby personnel can be injured by flying parts in the event of a tool malfunction.

Use appropriate lifting equipment. Make sure all components used to lift this power unit are rated for 90 kg (200 lbs) and are securely attached to the frame of the power unit. Inadequate components may fail and cause the power unit to fall, resulting in injury or property damage.

Hydraulic oil can cause skin irritation.

• Handle the tool and hoses with care to prevent skin contact with hydraulic oil.

• In case of accidental skin contact with hydraulic oil, wash the affected area immediately to remove the oil.

Failure to observe these precautions can result in injury.

Procedure for connecting or disconnecting hydraulic hoses, fittings or components:

1. Rotate the flow control knob to the OFF

position.

2. Switch the engine OFF.

3. Follow the sequence under Hose Connections

to prevent pressure buildup. In case some pressure has built up, loosen hoses, fittings or components slowly.

Emergency stop procedure: Switch the engine OFF.

Note: Keep decals clean and legible. Replace decals

when necessary.

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

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Identification

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F05 P ortable Hydraulic Power Unit

Parts of the F05 Portable Hydraulic Power Unit

1. Gasoline-Powered Engine 5. Flow Control Knob

2. Serial Number 6. Hydraulic Reservoir Cap

3. Hydraulic Tank Coupler 7. Hydraulic Oil Sight Gauge

4. Hydraulic Pressure Coupler 8. Hydraulic Fluid Filter

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Specifications

F05 Portable Hydraulic Power Unit

Overall Physical Dimensions

Mass/Weight (Dry) ..................................38.1 kg (84 lbs)

Length ..................................................... 596 mm (23.5")

Width....................................................... 431 mm (17.0")

Height......................................................419 mm (16.5")

Hydraulic Characteristics

Type of Hydraulic System...........................Open-Center

Pressure Port ........... 3/8" Male HTMA Quick Disconnect

Tank Port ............. 3/8" Female HTMA Quick Disconnect

Output (Maximum)

Flow............................. 17 to 20 l/min (4.5 to 5.3 gpm)

Pressure ......................................104.5 Bar (1500 psi)

Hydraulic Fluid Capacity ............. 6.6 liters (1.74 gallons)

Filtration .......................................... 10 Micron (Nominal)

Recommended Hydraulic Fluids

Use any non-detergent, petroleum-based hydraulic fluid which meets these specifications:

Metric

Viscosity (Measured in Centistokes)

38° C..................................................... 30 to 48 cSt

99° C.............................................. 4.2 cSt Minimum

Flash Point .............. Equal to or Greater Than 170° C

Pour Point......................Equal to or Less Than -34° C

SAE

Viscosity (Measured in Saybolt Universal Seconds)

100° F ............................................. 140 to 225 SUS

210° F ...........................................40 SUS Minimum

Flash Point ............... Equal to or Greater Than 340° F

Pour Point...................... Equal to or Less Than -30° F

Some hydraulic fluids which meet these criteria include, but are not limited to, the following:

Manufacturer Catalog Number

American Oil Co. (Amoco) Rykon 32

Rykon 46 Conoco Super Hydraulic Oil 5W-20 Phillips Petroleum Co. Magnus A 150

Magnus A 215 Sun Oil Co. (Sunoco) Sun Hydraulic Oil 2105 Texaco Rando B

Rando HDAZ

Rando HD32

Rando HD46 Union Oil Co. Unax AW 150

Unax AW 215

Engine Characteristics

See engine owner’s manual.

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

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F05 P ortable Hydraulic Power Unit

Hoses and Fittings

Installation and Maintenance

See publication 999 3032.3, SAE J1273 (Hose and Hose Assemblies).

Replacement

Refer to a Fairmont catalog or publication 999 1032.2, Low Pressure Quick Couplers, Adapters and Hoses.

Hose Connections

Power Source Port Identification

The pressure port on the power unit is the upper port (labeled PRESSURE). The tank port is the lower port (labeled RETURN).

Connecting Hoses

1. Rotate the flow control knob completely counterclockwise (OFF).

2. Switch the engine OFF.

3. Connect the tank hose to the tank port on the power source, and then to the tank port on the tool.

4. Connect the pressure hose to the pressure port on the tool, and then to the pressure port on the power source.

Disconnecting Hoses

1. Rotate the flow control knob completely counterclockwise (OFF).

2. Switch the engine OFF.

3. Disconnect the pressure hose from the power source, and then from the tool.

4. Disconnect the tank hose from the tool, and then from the power source.

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TOOL

TankPressure

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Page 8

Operation

F05 Portable Hydraulic Power Unit

Fuel is flammable and explosive.

• Stop engine before filling fuel tank.

• Do not fill fuel tank when engine

is hot.

• Do not fill fuel tank near an open flame, sparks, or when smoking.

Failure to observe this warning will result in severe injury or death.

Do not run power unit engine in a confined area.

Engine exhaust fumes are toxic. If inhaled, exhaust fumes can cause injury or death.

Skin injection hazard: Oil under pressure easily punctures

skin causing serious injury, gangrene or death. If you are injured by escaping oil, seek medical attention immediately.

• Do not use fingers or hands to check for leaks.

• Do not hold hose or couplers while the hydraulic system is pressurized.

• Depressurize the hydraulic system before servicing.

Do not disconnect tool, hoses or fittings while the power source is running or if the hydraulic fluid is hot. Hot hydraulic fluid can cause serious burns.

• Do not operate power unit without safety guards in place.

• Keep all parts of the body and loose clothing away from the engine fan.

Engine, exhaust system, and other components will be hot during and after operation. Use care when working around the power unit. Hot surfaces can cause serious burns.

Procedure for connecting or disconnecting hydraulic hoses, fittings or components:

1. Rotate the flow control knob to the OFF position.

2. Switch the engine OFF.

3. Follow the sequence under Hose Connections to prevent pressure buildup. In case some pressure has built up, loosen hoses, fittings or

components slowly.

Wear eye protection when operating or servicing this tool.

Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.

Greenlee Textron / Subsidiary of Textron Inc.

Emergency stop procedure: Switch the engine OFF.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

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F05 P ortable Hydraulic Power Unit

Operation (cont’d)

Transportation

1. Stop the power unit. See Stopping the Power Unit under Operation.

2. Allow the power unit to cool.

3. Attach lifting equipment securely to the frame of the unit.

Pre-Start

1. Position the power source on firm level ground.

2. Refer to the engine owner’s manual to:

• Check the engine oil level. Add oil if necessary.

• Check the fuel level. Add fuel if necessary.

• Verify that any other maintenance has been

performed according to the schedule.

3. Connect the hoses and tool to the power unit. See Hose Connections in this manual.

Stopping the Power Unit

Set the flow control knob to the OFF position before shutting the engine off. Shutting the engine off with the control knob in the ON position will allow gasoline into the exhaust system.

Failure to observe this precaution can result in property damage.

1. Rotate the flow control knob completely counterclockwise (OFF).

2. Move the engine control lever to the slowest setting. Allow the engine to idle for a few moments.

3. Switch the engine OFF.

Starting the Power Unit

1. Rotate the flow control knob completely counterclockwise (OFF).

2. Refer to the engine owner’s manual to start the engine. Allow the engine to idle for a few minutes to warm the hydraulic fluid.

3. Move the control lever to the proper setting.

4. Rotate the flow control knob clockwise (ON) to supply hydraulic power to the tool.

5. Refer to the tool owner’s manual for tool operating instructions.

Tips for cold weather operation:

• See the engine manufacturer’s cold start instructions.

• Allow the engine a longer idle time to warm the

hydraulic fluid (with the hydraulic control knob in the OFF position). Warm hydraulic fluid puts less internal pressure on the hoses than cold hydraulic fluid.

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 10

Maintenance

F05 Portable Hydraulic Power Unit

MAINTENANCE SCHEDULE

Use this schedule to maximize the power unit’s service

Skin injection hazard: Oil under pressure easily punctures

skin causing serious injury, gangrene or death. If you are injured by escaping oil, seek medical attention immediately.

• Do not use fingers or hands to check for leaks.

• Do not hold hose or couplers while the hydraulic system is pressurized.

• Depressurize the hydraulic system before servicing.

Wear eye protection when operating or servicing this tool.

Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.

life. See the tool owner’s manual and the engine owner’s manual for the maintenance of those items.

Note: Keep decals clean and legible. Replace decals

when necessary.

Every 5 Hours

1. Check the engine crankcase oil level. See the engine owner’s manual.

2. Check the hydraulic reservoir oil level. Add oil until the sight tube indicates FULL. See Recommended Hydraulic Fluids under Specifications.

Every 10 Hours

1. Wipe all surfaces clean.

2. Inspect the hydraulic hoses and fittings for signs of leaks, cracks, wear or damage. Replace if necessary.

Every Month

Perform a thorough inspection of the hydraulic hoses and fittings as described in publication 999 3032.3, SAE J1273 (Hose and Hose Assemblies).

Do not disconnect tool, hoses or fittings while the power source is running or if the hydraulic fluid is hot. Hot hydraulic fluid can cause serious burns.

Do not overfill the engine crankcase or the hydraulic reservoir. Overfilling either of these will cause severe internal damage and void the warranty.

Failure to observe this precaution will result in damage to the power unit.

Procedure for connecting or disconnecting hydraulic hoses, fittings or components:

1. Rotate the flow control knob to the OFF position.

2. Switch the engine OFF.

3. Follow the sequence under Hose Connections to prevent pressure buildup. In case some pressure has built up, loosen hoses, fittings or components slowly.

Every 100 Hours or Annually

Note: Perform this procedure more often if the power

source is used in cold, moist or dusty conditions.

1. Drain the hydraulic fluid reservoir.

2. Clean and flush the reservoir. Change the hydraulic filter. Fill the reservoir with new, clean hydraulic fluid. Add oil until the sight tube indicates FULL.

3. Operate the power unit to circulate the oil through the hydraulic system. Stop the power unit and check the hydraulic fluid level. Add oil until the sight tube indicates FULL.

4. Dispose of used oil and filter in accordance with federal, state and local laws.

Annual Inspection

If required by your organization’s regulations, have the tool inspected by an authorized Fairmont service center.

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 11

Troubleshooting

F05 Portable Hydraulic Power Unit

Before troubleshooting, determine whether the problem is in the tool, the hoses, or the power source. Substitute a tool, hoses, or power source known to be in good working order to eliminate the item that is not operating.

PROBABLE CAUSEPROBLEM PROBABLE REMEDY

Engine trouble. See engine owner’s manual.

Tool doesn’t operate. Improper power source. Verify that the power source meets the

Hydraulic fluid level low. Check the fluid level. Check system for leaks. Incorrect hydraulic fluid viscosity. Use hydraulic fluid with the correct viscosity.

Power source output is low. Measure the flow, pressure and back pressure of

Tool operates slowly or Hydraulic fluid cold. Allow fluid to warm to the operating temperature. erratically. Actuate the tool intermittently to reduce the

If the problem is in the tool, see the troubleshooting section of the tool instruction manual. If the problem is in the power source, see the troubleshooting table below.

tool’s specifications.

See Recommended Hydraulic Fluids.

the power source. If output is low, send the power source to an authorized Fairmont service center for repair.

warming time. Hydraulic fluid level low. Check the fluid level. Check system for leaks. Incorrect hydraulic fluid viscosity. Use hydraulic fluid with the correct viscosity.

See Recommended Hydraulic Fluids. Power source output is low. Measure the flow, pressure and back pressure of

the power source. If output is low, send the power

source to an authorized Fairmont service

center for repair.

Tool feels hot. Hydraulic fluid level low. Check the fluid level. Check system for leaks.

Incorrect hydraulic fluid viscosity. Use hydraulic fluid with the correct viscosity.

See Recommended Hydraulic Fluids. Hydraulic fluid dirty. Replace the hydraulic oil and filter. Power source output is low. Measure the flow, pressure and back pressure of

the power source. If output is low, send the power

source to an authorized Fairmont service

center for repair.

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 12

Exploded View

F05 Portable Hydraulic Power Unit

7 4

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 13

F05 Portable Hydraulic Power Unit

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 14

Parts List

F05 Portable Hydraulic Power Unit

KEY UPC NO. PART NO. DESCRIPTION QTY.

1 49625 504 9625.5 Fitting, 3/8" x 2.5 Nipple ....................................2

2 49626 504 9626.3 Nut, Jam ..........................................................11

3 49627 504 9627.1 Bolt, 1/4" NC x 3/4 ...........................................14

4 49628 504 9628.0 Nut, 1/4".............................................................7

5 49629 504 9629.8 Nut, 1/4" Nylon Insert ........................................2

6 49630 504 9630.1 Washer, 3/8" Lock .............................................3

7 49631 504 9631.0 Washer, 1/4" Lock ...........................................18

8 49632 504 9632.8 Clamp ................................................................2

9 49633 504 9633.6 Nut, 5/16"...........................................................4

10 49634 504 9634.4 Washer, 1/4" Flat, Plated.................................11

13 49635 504 9635.2 Valve, Relief ......................................................1

14 49636 504 9636.0 Pump .................................................................1

15 49637 504 9637.9 Washer, 5/16" Lock, Plated ...............................8

16 49638 504 9638.7 Washer, 5/16" Flat.............................................6

17 49639 504 9639.5 Screw ................................................................2

18 49640 504 9640.9 Bolt, 1/4" x 1/2 ...................................................4

19 49641 504 9641.7 Bolt, 3/8" x 1 ......................................................3

20 49642 504 9642.5 Bolt, 5/16" x 1 ....................................................4

21 49643 504 9643.3 Fitting.................................................................1

22 49644 504 9644.1 Clamp, Hose......................................................6

23 49645 504 9645.0 Fitting.................................................................2

24 49646 504 9646.8 Fitting.................................................................1

25 49647 504 9647.6 Fitting.................................................................1

26 49648 504 9648.4 Filter ..................................................................1

27 49649 504 9649.2 Manifold .............................................................1

28 49650 504 9650.6 Cap, Hydraulic Fill .............................................1

29 49651 504 9651.4 Gauge, Sight .....................................................1

30 49652 504 9652.2 Bolt, 5/16" x 1-1/4 ..............................................4

31 49653 504 9653.0 Valve .................................................................1

32 49654 504 9654.9 Fitting.................................................................1

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 15

F05 Portable Hydraulic Power Unit

Parts List (cont’d)

KEY UPC NO. PART NO. DESCRIPTION QTY.

33 49655 504 9655.7 Bolt, 1/4" x 1-1/2 ................................................2

34 49656 504 9656.5 Filter, Manifold, Hydraulic ..................................1

35 49657 504 9657.3 Screw ................................................................3

36 49658 504 9658.1 Bolt, 1/4" x 1 ......................................................4

37 49659 504 9659.0 Foot ...................................................................3

38 49660 504 9660.3 Bolt, 1/4" x 1 ......................................................6

39 49661 504 9661.1 Fitting.................................................................1

40 49662 504 9662.0 Coupler, Hydraulic .............................................1

41 49663 504 9663.8 Coupler, Hydraulic .............................................1

42 49664 504 9664.6 Fitting.................................................................1

43 49665 504 9665.4 Engine, Honda 5.5 H.P......................................1

44 49666 504 9666.2 Fan, Guard at Engine ........................................1

45 49667 504 9667.0 Bolt, 1/4" x 1/2 Socket Head..............................3

46 49668 504 9668.9 Pump, Coupler to Engine ..................................1

47 49669 504 9669.7 Fan ....................................................................1

48 49670 504 9670.0 Pump, Mount .....................................................1

49 49671 504 9671.9 Frame ................................................................1

50 49672 504 9672.7 Spacer, Foot ......................................................3

51 49673 504 9673.5 Trim, 1/8" ...........................................................2

52 49674 504 9674.3 Tank, Hydraulic .................................................1

53 49675 504 9675.1 O-ring ................................................................1

56 49676 504 9676.0 Cooler ................................................................1

57 49677 504 9677.8 Hose, Pressure..................................................1

58 49678 504 9678.6 Hose, 1/2" x 4 ....................................................1

59 49679 504 9679.4 Hose, 1/2" x 12 ..................................................1

61 49680 504 9680.8 Hose, 1/2" x 19 ..................................................1

62 49681 504 9681.6 Panel, Side ........................................................1

63 49682 504 9682.4 Panel, Filler .......................................................1

64 49683 504 9683.2 Dampener, Vibration .........................................2

65 49749 504 9749.9 Decal, Top Panel ...............................................1

66 49746 504 9746.4 Decal, Side Panel ..............................................2

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

Page 16

Greenlee Textron / Subsidiary of Textron Inc.

4455 Boeing Drive, Rockford, IL 61109-2988 USA

Customer Service (International): 815/397-7070 • Fax: 815/397-9247

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.