Greenlee F09, F13, Fairmont F09 / 49617, Fairmont F13 / 49618 Instruction Manual

INSTRUCTION MANUAL
F09 / 49617 F13 / 49618
PORTABLE HYDRAULIC
POWER UNITS
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
999 3166.4 REV 1 © 1999 Greenlee Textron 12/99
F09 and F13 P ortable Hydraulic Power Units
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
Purpose
This instruction manual is intended to familiarize all personnel with the safe operation and maintenance procedures for the Fairmont F09/49617 (Serial Code GBR) and F13/49618 (Serial Code GBT) Portable Hydraulic Power Units.
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: _____________________________
The Fairmont Portable Hydraulic Power Units are lightweight power sources intended for use with open­center hydraulic tools. The F09 provides a variable flow of 18.9 to 37.9 liters per minute (5 to 10 gallons per minute) and a maximum pressure of 124 Bar (1800 psi). The F13 provides a variable flow of 30 to 33 liters per minute (8 to 9 gallons per minute) and a maximum pressure of 140 Bar (2000 psi).
Their 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.
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
Greenlee Textron / Subsidiary of Textron Inc.
KEEP THIS MANUAL
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F09 and F13 P ortable Hydraulic Power Units
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.
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F09 and F13 P ortable Hydraulic Power Units
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 manufacturers 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.
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Identification
F09 and F13 P ortable Hydraulic Power Units
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3
2
1
10
9
8
11 12
7
6
13 10
5
Parts of the F09 and F13 Portable Hydraulic Power Units
1. Gasoline-Powered Engine
2. Serial Number
3. Hour Meter
4. Lifting Hook
5. Battery
6. Hydraulic Reservoir Cap
7. Hydraulic Oil Sight Gauge
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8. Hydraulic Fluid Filter
9. Handle
10. Handle Release Levers
11. Hydraulic Pressure Coupler
12. Hydraulic Tank Coupler
13. Flow Control Knob
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Specifications
F09 and F13 P ortable Hydraulic Power Units
Overall Physical Dimensions
Mass/Weight (Dry) ...................................64 kg (143 lbs)
Length ..................................................... 673 mm (26.5")
Width....................................................... 508 mm (20.0")
Height......................................................699 mm (27.5")
Battery
Output .................................................................12 Volts
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) for F09
Flow........................... 18.9 to 37.9 l/min (5 to 10 gpm)
Pressure ......................................104.5 Bar (1800 psi)
Output (Maximum) for F13
Flow................................... 30 to 33 l/min (8 to 9 gpm)
Pressure ......................................... 140 Bar (2000 psi)
Hydraulic Fluid Capacity ................ 18.9 liters (5 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 owners manual.
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F09 and F13 P ortable Hydraulic Power Units
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 left port (labeled PRESSURE). The tank port is the right 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.
Greenlee Textron / Subsidiary of Textron Inc.
TOOL
TankPressure
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Operation
F09 and F13 P ortable Hydraulic Power Units
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.
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F09 and F13 P ortable Hydraulic Power Units
Operation (contd)
Transportation
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.
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 owners 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 owners manual for tool operating instructions.
Tips for cold weather operation:
See the engine manufacturers 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.
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Maintenance
F09 and F13 P ortable Hydraulic Power Units
MAINTENANCE SCHEDULE
Use this schedule to maximize the power units 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 owners manual and the engine
owners 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 owners 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 organizations regulations, have the tool inspected by an authorized Fairmont service center.
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Troubleshooting
F09 and F13 P ortable Hydraulic Power Units
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 owners manual.
Tool doesnt 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.
tools 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.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Exploded View
F09 and F13 P ortable Hydraulic Power Units
4
9
17
44
11
14
61
29
19
64
58
33
4
9
68
55
41
1
66
28
2
51
28
67
4
59
55
50
39
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12
38
8
6
52
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5
63
F09 and F13 P ortable Hydraulic Power Units
58
19
21
4
58
19
9
56
60
31
7
9
69
13
15
16
2
24
3
27
41
25
37
54
42
29
30
15
21
46
70
43
10
47
26
18
48
6
8
57
23
20
32
4
9
65
45
7
9
4
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71
2
4
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Parts List
F09 and F13 P ortable Hydraulic Power Units
KEY UPC NO. PART NO. DESCRIPTION QTY.
1 49684 504 9684.0 Filter ..................................................................1
2 49626 504 9626.3 Nut, Jam ..........................................................20
3 49685 504 9685.9 Bolt, 3/8" ............................................................4
4 49627 504 9627.1 Bolt, 1/4" ..........................................................29
5 49686 504 9686.7 Plug, Magneto ...................................................1
6 49687 504 9687.5 Nut, 3/8".............................................................6
7 49628 504 9628.0 Nut, 1/4".............................................................6
8 49630 504 9630.1 Washer, 3/8" Lock .............................................6
9 49631 504 9631.0 Washer, 1/4" Lock ...........................................31
10 49688 504 9688.3 Fitting.................................................................2
11 49689 504 9689.1 Bolt, 3/8"............................................................4
12 49690 504 9690.5 Pin, 1/8" Cotter ..................................................2
13 49632 504 9632.8 Clamp ................................................................2
14 49691 504 9691.3 Washer, 3/8"......................................................4
15 49692 504 9692.1 Fitting.................................................................2
16 49693 504 9693.0 Valve, Relief ......................................................1
17 49694 504 9694.8 Gauge, Hour Meter............................................1
18 49695 504 9695.6 Bolt, 1/4"............................................................2
19 49644 504 9644.1 Clamp, Hose......................................................4
20 49696 504 9696.4 Strap..................................................................1
21 49645 504 9645.0 Fitting.................................................................3
22 49697 504 9697.2 Tie, 8" ................................................................6
23 49698 504 9698.0 Fitting.................................................................1
24 49699 504 9699.9 Nut, 3/8".............................................................4
25 49651 504 9651.4 Gauge, Sight .....................................................1
26 49700 504 9700.6 Bolt, 3/8"............................................................2
27 49701 504 9701.4 Latch, Handle ....................................................2
28 49702 504 9702.2 Clamp, Hose......................................................2
29 49703 504 9703.0 Cable, Positive (Red) ........................................1
30 49704 504 9704.9 Cable, Negative (Blk) ........................................1
31 49653 504 9653.0 Valve .................................................................1
32 49672 504 9672.7 Spacer, Handle..................................................2
33 49705 504 9705.7 Fitting.................................................................1
37 49709 504 9709.0 Cap....................................................................1
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F09 and F13 P ortable Hydraulic Power Units
Parts List (contd)
KEY UPC NO. PART NO. DESCRIPTION QTY.
38 49710 504 9710.3 Axle ...................................................................1
39 49711 504 9711.1 Wheel ................................................................2
40 49712 504 9712.0 Container ...........................................................1
41 49713 504 9713.8 Hose, Pressure..................................................1
42 49714 504 9714.6 Fitting.................................................................1
43 49715 504 9715.4 Fitting.................................................................1
44 49716 504 9716.2 Trim, 1/16" .........................................................1
45 49717 504 9717.0 Bumper, Hood ...................................................1
46 49718 504 9718.9 Coupler, Hydraulic .............................................1
47 49719 504 9719.7 Coupler, Hydraulic .............................................1
48 49720 504 9720.0 Handle ...............................................................1
49 49721 504 9721.9 Graphic Set .......................................................1
50 49722 504 9722.7 Coupler, Pump Drive .........................................1
51 49723 504 9723.5 Hose, Suction ....................................................1
52 49724 504 9724.3 Tank, Hydraulic .................................................1
53 49725 504 9725.1 Spacer, Axle ......................................................2
54 49726 504 9726.0 Grill ....................................................................1
55 49727 504 9727.8 Guard, Fan ........................................................1
56 49728 504 9728.6 Cooler, Hydraulic ...............................................1
57 49729 504 9729.4 Pump, for F09 only ............................................1
57 49706 504 9706.5 Pump, for F13 only ............................................1
58 49730 504 9730.8 Hose, Hydraulic Return .....................................2
59 49731 504 9731.6 Fan ....................................................................1
60 49732 504 9732.4 Manifold, Hydraulic ............................................1
61 49733 504 9733.2 Engine, Honda 9 H.P., for F09 only...................1
61 49614 504 9614.0 Engine, Honda 13 H.P., for F13 only.................1
62 49734 504 9734.0 Hood ..................................................................1
63 49735 504 9735.9 Foot, Rear .........................................................1
64 49736 504 9736.7 Fitting Bushing...................................................1
65 49737 504 9737.5 Battery ...............................................................1
66 49738 504 9738.3 Element, Hydraulic Filter ...................................1
67 49739 504 9739.1 Key, Engine/Fan ................................................1
68 49740 504 9740.5 Wire, Hour Meter ...............................................1
69 49741 504 9741.3 Spacer ...............................................................2
70 49749 504 9749.9 Decal, Top Panel ...............................................1
71 49747 504 9747.2 Decal, Side Panel, for F09 only .........................2
71 49748 504 9748.0 Decal, Side Panel, for F13 only .........................2
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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.
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