OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
DUAL CIRCUIT, PORTABLE
HYDRAULIC POWER UNIT
HG3555A / 42306
999 1605.3 © 2000 Greenlee Textron Inc. REV 5 3/00
Read and understand this material before operating or
servicing this power unit. Failure to understand how to
safely operate this power unit could result in an
accident causing serious injury or death.
HG3555A/42306 Portable Power Unit
Table Of Contents
OPERATION
Safety Information ...........................................................................................................................................3-4
Description .........................................................................................................................................................4
Identification ....................................................................................................................................................... 5
Specifications – HG3555A/42306 Portable Power Unit .....................................................................................6
Specifications – Gasoline Engine.......................................................................................................................6
Recommended Hydraulic Fluids ........................................................................................................................6
Hoses and Fittings ............................................................................................................................................. 6
Hose Connections..............................................................................................................................................7
Operation ......................................................................................................................................................8-10
MAINTENANCE
Depressurizing Hydraulic System ....................................................................................................................10
Maintenance Schedule.....................................................................................................................................12
Battery..............................................................................................................................................................13
Pneumatic Tires ...............................................................................................................................................13
Troubleshooting ..........................................................................................................................................13-15
PARTS
Power Unit...................................................................................................................................................16-17
Hydraulic Components and Piping..............................................................................................................18-19
Battery and Wiring............................................................................................................................................ 20
APPENDICES
Appendix A – SAE J1273 May 1986 ...........................................................................................................21-22
A person who has not read and does not understand all operating instructions is
not qualified to operate this tool.
Failure to read and understand safety instructions may result in injury or death.
Additional or replacement manuals may be obtained from your Fairmont distributor. When tool is received, complete
the following record:
SERIAL NUMBER: ____________________________
DATE OF PURCHASE:_________________________
WHERE PURCHASED: ________________________
Always mention the tool’s serial number when ordering or writing about parts.
For convenience in ordering, parts are listed by part number, description and quantity. If in doubt as to part needed,
send a full description, sketch, or the part itself with the order. Assemblies are in CAPITAL letters, and include all
component parts listed directly below them and indented to the right. When assemblies can be used, order them to
save time assembling individual parts. Prior arrangements must be made before returning a tool for warranty service.
To insure correct and prompt shipment of parts, always provide the following information when ordering:
1. Quantity of each part wanted 4. Serial Number of tool
2. Part number of item 5. Preferred method of shipment: UPS or air freight
3. Description of part
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3555A/42306 Portable Power Unit
THIS SYMBOL MEANS:
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.
Safety is a critical factor in the design of Fairmont equipment. The best program starts with a safetyconscious 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. Comments from users are appreciated.
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. Fuel is
flammable and explosive and, if ignited,
will result in severe injury or death.
Do not run the power unit engine in a confined
area. Engine exhaust fumes are toxic. If inhaled,
exhaust fumes can cause injury or death.
Electrical Shock Hazard:
When using this unit near energized
electrical lines, use only certified
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning could
result in severe injury or death.
Do not disconnect tool, hoses, or fittings while
the power unit is running or if the hydraulic fluid is
hot. Exposure to hot hydraulic fluid can cause
serious burns.
Wear eye protection when operating
this tool.
Failure to wear eye protection can
result in serious eye injury from flying
debris or hydraulic oil.
• Do not operate power unit without
safety guards in place.
• Keep all parts of the body and
loose clothing away from the
engine fan.
Skin Injection Hazard:
High pressure oil easily punctures skin
causing serious injury, gangrene or
death. If injured seek medical help
immediately to remove oil.
Do not use fingers or hands to
check for leaks.
Depressurize hydraulic system
before servicing.
SAVE THESE INSTRUCTIONS
Greenlee Textron / Subsidiary of Textron Inc.
• Engine, exhaust system, pump, etc. may be hot.
Use caution when working around power unit.
Hot surfaces can cause serious burns.
• Do not let the power unit engine run unattended.
The engine must be monitored so that it can be
shut down immediately in case of a malfunction.
Failure to observe this warning could result in
severe injury or death.
3
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HG3555A/42306 Portable Power Unit
• 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 tool for manufacturer’s intended
purpose only. Use other than that which is
described in this manual could result in injury
or property damage.
• Make sure all bystanders are clear of the work
area when handling, starting, and operating
the tool. Nearby personnel can be injured by
flying or falling debris or by flying parts in the
event of a tool malfunction.
Description
The HG3555A Portable Power Unit is a compact,
2000 psi (137.9 bar) power source for Open-Center
system hydraulic tools. The HG3555A provides two
5 gpm (19 lpm) circuits or one 10 gpm (37 lpm) circuit.
HTMA couplers are provided for tool connection.
The unit is powered by a 20 hp Kohler air-cooled
gasoline engine with electric start.
Other features include a large capacity oil cooler, inline
flow meter, engine hour meter and pneumatic tires.
Use the lifting eye and appropriate lifting equipment.
Make sure all components used to lift this power
unit are rated for 350 lbs (159 kg) and are securely
attached between the power unit and lifting equipment. Inadequate components may fail and cause
the power unit to fall, resulting in injury or property
damage.
Note: Keep all decals clean and legible. Replace decals
when necessary with new decals listed in the
Parts section of this manual.
SAVE THESE INSTRUCTIONS
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Identification
HG3555A/42306 Portable Power Unit
Figure 1
15 8 2 6
12
3
7
10
11
Parts of the HG3555A Portable Power Unit
1. Serial Number 7. Oil Cooler
2. Gasoline Engine 8. Control Panel
3. Retractable Handles 9. Flow Selector Handles
4. Hydraulic Oil Filter 10. Tool Connection – Pressure
5. Fuel Fill Cap 11. Tool Connection – Return
6. Hydraulic Reservoir Cap 12. Lifting Eye
4
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HG3555A/42306 Portable Power Unit
Specifications
HG3555A Power Unit
Weight (Dry) .............................................................................................314 lbs. (142.4 kg)
Weight (Wet) ............................................................................................384 lbs. (174.2 kg)
Length ...........................................................................................................33.5 in. (85 cm)
Width .............................................................................................................32.5 in. (83 cm)
Height............................................................................................................30.0 in. (76 cm)
Fuel Capacity .................................................................................................4.0 gal. (15.0 l)
Hydraulic Oil Capacity....................................................................................2.8 gal. (10.5 l)
Rated Flow:
2 Circuits ..............................................................................................2-5 gpm (8-19 lpm)
1 Circuit .............................................................................................. 1-10 gpm (4-37 lpm)
Pressure Relief Setting ......................................................................... 2000 psi (137.9 bar)
Type of Hydraulic System ................................................................................. Open-Center
Pressure Port (1/2 M NPT (both circuits).............................................. HTMA Male Coupler
Return Port (1/2 M NPT) (both circuits .............................................HTMA Female Coupler
Filtration ................................................................................................ 10 Micron (Nominal)
Battery – Utility Type (lead acid battery)
12 volts, cranking amps @ 0˚F = 235 amps,
Overall Dimensions (inches): Length–7.75", Width–5.18", Height–7.31"
Kohler Magnum Air Cooled Gasoline Engine
Horsepower – Maximum ..........................................................................20 hp @ 3600 rpm
Torque (ft. lbs.) – Maximum ............................................................ 32.8 ft. lbs. @ 2600 rpm
Recommended Hydraulic Fluids
Electrical Shock Hazard:
When utilizing this tool near energized electrical lines, select and maintain the hydraulic fluid to
meet the minimum dielectric standards required by your safety department. Failure to observe
this warning could result in severe injury or death.
Any non-detergent hydraulic fluid which meets the following specifications or HTMA specifications may be used.
S.U.S. @ 100°F (38°C) ...........................................................................................140 to 225
@ 210°F (99°C) ........................................................................................40 minimum
Flash Point......................................................................................... 340°F (170°C) minimum
Pour Point........................................................................................... -30°F (-34°C) minimum
Hoses and Fittings
Hoses and fittings must comply with the SAE Standard J1273, SAE Recommended Practice for Selection,
Installation, and Maintenance of Hose and Hose Assemblies. See Appendix A.
Failure to observe this warning could result in severe injury or death.
Hose assemblies and quick-connect couplers are available from Fairmont as accessories. SEE BULLETIN ON
FAIRMONT NO-DRIP COUPLERS AND HOSES. CONTACT AUTHORIZED FAIRMONT DISTRIBUTOR.
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HG3555A/42306 Portable Power Unit
Hose Connections
Do not disconnect tool, hoses, or fittings while the power unit is running or if the hydraulic fluid is hot.
Exposure to hot hydraulic fluid can cause serious burns.
Figure 3 shows the power unit being used with a typical
tool.
Connecting Hoses (See Figures 1 and 3)
1. Stop the power unit.
2. Connect the return (tank) hose from the power unit
port to the tool return port (T).
Note: Return (tank) hose connection should always
be connected before pressure (supply) hose
connection to prevent pressure build-up inside
the tool.
3. Connect the pressure (supply) hose from the power
unit pressure port to the tool pressure port (P).
Disconnecting Hoses (See Figures 1 and 3)
1. Stop the power unit.
2. Disconnect the pressure (supply) hose from the
power unit pressure port to the tool pressure
port (P).
Note: Pressure (supply) hose connection should always
be disconnected before return (tank) hose
connection to prevent pressure build-up inside
the tool.
RETURN
PORT
FLOW
METER
CONTROL
VALVE
RELIEF
VALVE
2000 PSI
PRESSURE
PORT (5 GPM)
R
P
RETURN
PORT
PRESSURE
PORT
PRESSURE
PORT (10 GPM)
PRESSURE
PORT (5 GPM)
C2 C2
C1 C1 R P
TYPICAL
TOOL
CONTROL
VALVE
RELIEF
VALVE
2000 PSI
RETURN
PORT
3. Disconnect the return (tank) hose from the power
unit return port to the tool return port (T).
4. To prevent contamination, always install dust caps
over the hydraulic ports of the tool, hoses, and
power unit when disconnected.
Greenlee Textron / Subsidiary of Textron Inc.
ENGINE
POWER
PUMP
OIL
COOLER
FILTER
(10 NICRON)
UNIT
Figure 3
Hydraulic Schematic
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Operation
HG3555A/42306 Portable Power Unit
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. Fuel is
flammable and explosive and, if ignited,
will result in severe injury or death.
Do not run the power unit engine in a confined
area. Engine exhaust fumes are toxic. If inhaled,
exhaust fumes can cause injury or death.
Electrical Shock Hazard:
When using this unit near energized
electrical lines, use only certified
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning could
result in severe injury or death.
Do not disconnect tool, hoses, or fittings while
the power unit is running or if the hydraulic fluid is
hot. Exposure to hot hydraulic fluid can cause
serious burns.
Wear eye protection when operating
this tool.
Failure to wear eye protection can
result in serious eye injury from flying
debris or hydraulic oil.
• Do not operate power unit without
safety guards in place.
• Keep all parts of the body and
loose clothing away from the
engine fan.
Skin Injection Hazard:
High pressure oil easily punctures skin
causing serious injury, gangrene or
death. If injured seek medical help
immediately to remove oil.
Do not use fingers or hands to
check for leaks.
Depressurize hydraulic system
before servicing.
• Engine, exhaust system, pump, etc. may be hot.
Use caution when working around power unit.
Hot surfaces can cause serious burns.
• Do not let the power unit engine run unattended.
The engine must be monitored so that it can be
shut down immediately in case of a malfunction.
Failure to observe this warning could result in
severe injury or death.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3555A/42306 Portable Power Unit
Operation (cont’d)
Figure 4
Power Unit Controls
5
Position the power unit on firm level ground.
1
Pre-Start
1. Check engine oil level. Refer to engine Operating
and Maintenance Instructions for correct oil type and
checking instructions.
2. Check fuel level. Refer to engine Operating and
Maintenance instructions for fuel recommendations.
3. Check hydraulic reservoir oil level. Fill to FULL mark
on dipstick. See Maintenance. See Recommended
Hydraulic Fluids for correct hydraulic fluid.
4. Verify that all current maintenance has been
performed on the power unit. See Maintenance.
5. Connect the tool hoses and tool to the power unit.
See Hose Connections.
OFF
RUN
START
C
H
O
K
E
4 2 3
SLOW
1. Flow Levers
2. Choke Knob
3. Engine Throttle Lever
4. Key Switch
5. Retaining Pins
Starting the Power Unit (See Figure 4)
1. Move the two flow levers (1) to the NEUTRAL
position.
2. Pull out the choke knob (2).
Note: A warm engine requires less choking than a cold
engine.
3. Move throttle lever (3) out to the fully open position.
4. Move the key switch (4) to the ON position.
5. Turn key to start position to start engine.
Note: The best starter life is provided by using short
FAST
starting cycles of several seconds. Prolonged
cranking, more than 15 seconds per minute, can
damage the starter motor.
6. After the engine has started, reduce the rpm.
Slowly open choke.
7. Position the two flow levers (1) to the desired
setting—5 or 10 gpm.
Note: Both levers must be set at 10 gpm position for
operation with 10 gpm output.
8. It is recommended that the power unit be allowed to
run (idle) for a few minutes to warm the hydraulic
reservoir fluid. Actuating the tool intermittently will
reduce the time required to warm the fluid to an
efficient operating temperature.
9. Using the engine throttle lever (3), adjust the engine
rpm to obtain the rated hydraulic oil flow. DO NOT
EXCEED THE MAXIMUM ALLOWABLE FLOW
RATE FOR THE TOOL BEING USED WITH THE
POWER UNIT. See your tool operator’s manual for
proper flow rate.
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HG3555A/42306 Portable Power Unit
Operation (cont’d)
Stopping the Power Unit (See Figure 4)
1. Move the two flow levers (1) to the NEUTRAL
position. Idle the power unit engine for a few
moments. Move the key switch (4) to the OFF
position.
2. Disconnect the tool hoses from the power unit.
See Hose Connections.
Retractable Handles
The handles on the power unit can be extended when
transporting the power unit or retracted for convenience
when connecting/disconnecting tool hoses, starting
power unit, etc. To use the handles in the extended
position for transport: Pull out the retaining pins (5), Pull
the handles fully out. Replace retaining pins (5) through
the handles into the holes in the cover of the power unit.
Lifting the Power Unit
Use the lifting eye and appropriate lifting equipment.
Make sure all components used to lift this power
unit are rated for 350 lbs (159 kg) and are securely
attached between the power unit and lifting
equipment. Inadequate components may fail
and cause the power unit to fall, resulting in injury
or property damage.
Stop the power unit engine before lifting. Take care
when attaching the lifting device (chain, strap, etc.) to
the lifting eye so as not to damage the power unit.
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Maintenance
HG3555A/42306 Portable Power Unit
Skin Injection Hazard:
High pressure oil easily punctures skin
causing serious injury, gangrene or
death. If injured seek medical help
immediately to remove oil.
Do not use fingers or hands to
check for leaks.
Depressurize hydraulic system
before servicing.
Depressurizing Hydraulic System
Hydraulic system must be depressurized when performing maintenance or repair on the power unit hydraulic
system. Depressurizing the hydraulic system will also
make tool hose connections/disconnections easier.
1. Stop power unit engine.
2. Move the two flow levers to the 5 GPM position.
System will be depressurized.
3. Before re-starting power unit engine, move the two
flow levers to the NEUTRAL position.
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. Fuel is
flammable and explosive and, if ignited,
will result in severe injury or death.
Do not run the power unit engine in a confined
area. Engine exhaust fumes are toxic. If inhaled,
exhaust fumes can cause injury or death.
Do not disconnect tool, hoses, or fittings while
the power unit is running or if the hydraulic fluid is
hot. Exposure to hot hydraulic fluid can cause
serious burns.
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.
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HG3555A/42306 Portable Power Unit
Maintenance (cont’d)
The service life of the power unit will be maximized by
proper care and maintenance. The maintenance schedule below is recommended.
Note: Change engine oil after the first 5 hours of
operation. Thereafter, change engine oil
according to the Maintenance Schedule.
Every 5 Hours
1. Check engine crankcase oil level. Fill if necessary.
See Oil Recommendations – Engine Manual.
2. Check fuel tank level. Fill if necessary. See Fuel
Recommendation – Engine Manual.
3. See Figure 5. Check hydraulic reservoir oil level. Fill
to FULL mark on dipstick. Do not overfill reservoir.
See Recommended Hydraulic Fluids.
Every 10 Hours
1. Wipe all power unit surfaces clean of grease, dirt
and foreign material.
2. Inspect the hydraulic system hoses and fittings for
signs of leaks, cracks, wear, or damage. Replace if
necessary.
Every 25 Hours
1. Service engine air cleaner pre-cleaner. See Engine
Manual.
Every 50 Hours
1. Change engine crankcase oil and oil filter. See
Engine Manual.
Every 100 Hours or Once Yearly
1. Drain hydraulic reservoir oil. Clean and flush reservoir. Change hydraulic oil filter. Fill reservoir with
new, clean hydraulic oil. See Recommended Hydraulic Fluids. Operate power unit to circulate oil
through the hydraulic system. Stop power unit.
Recheck hydraulic oil level. Fill reservoir to the
FULL mark on the dipstick. Do not overfill reservoir.
See Figure 5.
2. Service engine air cleaner cartridge. See Engine
Manual.
3. Perform a detailed inspection of the system hoses
and fittings as stated in Appendix A – S.A.E Standard J1273, May 1986. Replace the hoses and/or
fittings if necessary.
Figure 5
Hydraulic Reservoir Dipstick
F
OPERATING AREA
E
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HG3555A/42306 Portable Power Unit
Maintenance (cont’d)
Battery
Stop engine when checking battery
electrolyte level. Do not check or fill
battery electrolyte level near an open
flame, sparks, or when smoking.
Battery fumes are flammable and
explosive, and if ignited will result in
severe injury or death.
When working on or around the battery:
• Remove jewelry, wristwatches and any other
conductive items. The current produced by the
battery can cause severe burns.
• Wear eye protection and gloves and handle the
battery carefully. Contact with battery acid can
cause severe burns or blindness.
Failure to observe these warnings could result in
severe injury or death.
Battery Maintenance and Replacement
Check battery electrolyte level at least once a month.
Stop power unit engine when checking battery electrolyte level. If electrolyte level is low, fill to required level
using distilled water only. Clean battery terminals and
cable clamps when required. After cleaning, coat battery
terminals and cable clamps with grease or other suitable
product to reduce corrosion. When battery replacement
becomes necessary it is recommended that replacement
battery should meet or exceed original battery specifications; amps, cranking power, etc.
Pneumatic Tires
Inflate power unit tires to the recommended pressure
printed on the sidewalls of the tires. Do not exceed tire
manufacturer’s recommended maximum pressure
printed on the sidewalls of the tires or rim
manufacturer’s recommended maximum pressure
stamped on the rim, whichever is lower.
Troubleshooting
Before You Begin
1. Any tool used with this power unit must be an
Open-Center system type tool.
2. Verify that the pressure and return hoses are connected properly to the power unit and tool ports.
3. Power unit reservoir must be filled to FULL level with
hydraulic fluid.
4. Start the power unit hydraulic oil flow. All separate
shut-off devices must be opened (on/off valves, etc.)
5. After verifying all of the above, check the tool to see
if it operates.
If the tool does not operate, it will be necessary to
pinpoint the power unit, tool, or hoses as the problem area. The following steps will help to determine
the problem area.
Determine the Problem Area
1. Stop the power unit hydraulic oil flow. Disconnect the
existing tool from the hoses and power unit.
2. Connect a known working tool to the hoses and
power unit. See the tool’s operators manual for
correct hook-up procedure. Start the power unit
hydraulic oil flow.
If the known working tool operates, the problem is in
the disconnected tool. See the tool operator’s
manual for troubleshooting.
If the known working tool does not operate, the
problem is likely to be in the hoses or the power unit.
Proceed to Step 3.
3. Stop the power unit hydraulic oil flow. Disconnect the
existing hoses from the known working tool and
power unit.
4. Connect a different set of hoses to the known
working tool and power unit. Start the power unit
hydraulic oil flow.
If the known working tool operates with the different
set of hoses, the problem is in the disconnected
hoses.
If the known working tool does not operate,
the problem is in the power unit. See the Troubleshooting charts in this operator’s manual.
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HG3555A/42306 Portable Power Unit
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Engine does not turn over. Battery weak or dead. Recharge or replace battery.
Battery cables corroded. Clean battery cable terminals or
replace cables.
Electrical short, broken wire or loose Check wires and connections.
connection. Repair or replace.
Engine starter inoperative. Repair or replace starter. See
engine operator’s manual.
Engine turns over, but does not No fuel in tank. Fill fuel tank.
start.
A flow handle is in the 5 or 10 gpm Move handle to the NEUTRAL position.
position.
Electric short, broken wire or loose Check wires and connection.
connection. Repair or replace.
Engine lacks power, runs rough,
backfires, etc.
Tool used with power unit Both flow valves are in NEUTRAL Move flow valve to proper gpm
inoperative. position. position.
Tool is a Closed-Center system type. Use only Open-Center system tools.
No hydraulic fluid in system or fluid Check fluid level. Fill to FULL mark.
level low. Check system for leaks.
Incorrect hydraulic fluid viscosity. Use fluid viscosity recommended.
Hydraulic filter needs service. Replace hydraulic filter.
Power unit components (pump, valve, Repair or replace components.
etc.) worn or damaged.
Engine output insufficient. Engine See engine operator’s manual.
needs adjustment, tune-up, etc.
See engine operator’s manual.
See recommended Hydraulic Fluids.
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HG3555A/42306 Portable Power Unit
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Tool used with power unit Hydraulic fluid cold. Viscosity of oil may be too high at
operates erratically. start of tool operation. Allow oil to
warm to operating temperature.
Actuating tool intermittently will
reduce time required to warm oil to
an efficient operating temperature.
Hydraulic fluid level low. Check fluid level. Fill to FULL mark.
Check system for leaks.
Incorrect hydraulic fluid viscosity. Use fluid viscosity recommended.
See recommended Hydraulic Fluids.
Air in system. Check pump suction line for damage
or loose clamps. Tighten clamps or
replace components if necessary.
Fill reservoir.
Hydraulic oil flow (gpm) incorrect for Adjust engine rpm to achieve
tool being used. correct flow (gpm) for tool being used.
Hydraulic filter needs service. Replace hydraulic filter.
Power unit components (pump, valve, Repair or replace components.
etc.) worn or damaged.
Engine output insufficient. Engine See engine operator’s manual.
needs adjustment, tune-up, etc.
Tool used with power unit Hydraulic fluid level low. Check fluid level. Fill to FULL mark.
feels hot. Check system for leaks.
Hydraulic fluid viscosity too light. Use fluid viscosity recommended.
See Recommended Hydraulic Fluids.
Hydraulic fluid dirty. Drain reservoir, flush and fill with
clean fluid. Change filter.
Hydraulic oil flow (gpm) incorrect Adjust engine rpm to achieve
for tool being used. correct flow (gpm) for tool being
used.
Tool used with power unit Hydraulic flow reversed to tool. Reverse flow to tool. Check for
operates backwards. valve in system that has reversed
Greenlee Textron / Subsidiary of Textron Inc.
flow. Check hoses for proper flow.
Hydraulic pressure and return lines Disconnect hoses. Reverse
connected to incorrect power unit or couplers. Reconnect hoses to
tool ports. proper power unit and tool ports.
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HG3555A/42306 Portable Power Unit
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HG3555A/42306 Power Unit and Parts List
Figure 6
8
60
4
TORQUE TO 25FT/LB
APPLY LOCTITE (F015744)
TO SET SCREWS
TORQUE TO 100 IN/LB
5
6
7
3
2
12
9
20
17
13
14
15
16
23
22
21
19
18
59
37
36
54
43
42
26
53
28
52
76
77
75
35
58
APPLY LOCTITE (F015744)
TO THREADS
55
3132
25
48
69
EXISTING AXLE
26
28
40
41
39
38
47
25
71
72
33
30
74
73
34
70 26
45
29
44
26
DETAIL “A”
28
46
28
26
25
2625
68
62
1
26
25
28
51
50
34
61
65
26
67
66
49
AXLE ASSEMBLY
SEE DETAIL "A"
26
26
57
24
64
63
56
27
53
28
HG3555A/42306 Portable Power Unit
KEY 78-3310- PART NO. DESCRIPTION QTY.
1 155789 Frame ............................................................................................................................... 1
2 F025078 GASOLINE ENGINE – Kohler 20 hp ............................................................................... 1
3 43154 155825 Adapter, Fan..................................................................................................................... 1
4 F010324 Cap Screw, 3/8 - 16 x 1" Socket Head ............................................................................ 4
5 41358 F011455 Lock Washer, 3/8" ............................................................................................................ 4
6 41986 F022683 Fan ................................................................................................................................... 1
7 43156 079423 Square Key, 3/16 x 1-1/8" ................................................................................................ 1
8 43160 F024642 Oil Cooler ......................................................................................................................... 1
9 49966 Coupling ........................................................................................................................... 1
12 M005187 Square Key, 1/4 x 1-3/4".................................................................................................. 1
13 F003048 HHCS 3/4 -16 x 2-3/4" .................................................................................................... 1
14 F001322 Cap Screw ........................................................................................................................ 3
15 F015922 Hex Stop Nut .................................................................................................................... 3
16 F001115 Washer, 3/8"..................................................................................................................... 4
17 F025079 Pump Adapter .................................................................................................................. 1
18 F003912 Cap Screw, 7/16 x 1-1/4" Hex Head ................................................................................ 4
19 F001291 SAE Lock Washer, 7/16".................................................................................................. 4
20 F025077 PUMP ............................................................................................................................... 1
21 F013308 Cap Screw, 3/8 x 1-1/2" Socket Head ............................................................................. 2
22 F001115 Washer, 3/8"..................................................................................................................... 2
23 F021755 Washer, 3/8"..................................................................................................................... 2
24 41437 F013775 Roll Pin, 1/4 x 1 ................................................................................................................ 2
25 F024672 Cap Screw, 1/4 x 1-1/2" Button Socket Hd...................................................................... 8
26 41431 F013588 Light Hex Stop Nut, 1/4" ................................................................................................. 19
27 155811 Tube Assembly................................................................................................................. 1
28 41245 F001050 Washer, 1/4" ..................................................................................................................... 8
29 158284 Control Panel.................................................................................................................... 1
30 F024678 Fuel Tank Cap .................................................................................................................. 1
31 F030032 Spring Hose Clamp .......................................................................................................... 1
32 43214 F006584 90° Strt Elbow 1/8 NPT .................................................................................................... 1
33 F024679 Oil Reservoir Cap ............................................................................................................. 1
34 41278 F003085 Cap Screw, 1/4 x 1/2" Hex Head ..................................................................................... 4
35 152339 Roll Pin, 1/8 x 1" ............................................................................................................... 2
36 155834 Leg ................................................................................................................................... 2
37 158150 Pad, Leg ........................................................................................................................... 2
38 41311 F009667 Cap Screw, 1/4 x 1-1/2" Hex Head ..................................................................................4
39 155777 Rubber Hose, 1/4" ID Fuel ...............................................................................................1
40 F016087 Connector, 1/8 M NPT ..................................................................................................... 1
41 F009188 45° Elbow, 1/8 M NPT x 1/8 F NPT ................................................................................. 1
42 155826 Handle .............................................................................................................................. 2
43 41359 F011458 Hand Grip ......................................................................................................................... 2
44 155832 Bar ................................................................................................................................... 1
45 41267 F002355 Cap Screw, 1/4 x 3/4" Hex Head ..................................................................................... 2
46 155823 Battery Holder .................................................................................................................. 1
47 42001 F022740 Wheel ............................................................................................................................... 2
48 42980 F001104 Cotter Pin, 1/8 x 1" ........................................................................................................... 4
49 F005185 Clip ................................................................................................................................... 1
50 F021103 Trim .................................................................................................................................. 1
51 155815 Shroud, Fan/Cooler .......................................................................................................... 1
52 158285 Guard................................................................................................................................ 1
53 F024673 Cap Screw, 1/4 x 1-3/4 Button Head ............................................................................... 2
54 43199 155797 Fuel Tank ......................................................................................................................... 1
55 40891 135326 Decal, Danger – Stop Engine .......................................................................................... 1
56 158287 Decal, Flow Control .......................................................................................................... 1
57 43534 156228 Decal , ID.......................................................................................................................... 1
58 43203 156229 Decal ................................................................................................................................ 2
59 F011164 Cap Screw ........................................................................................................................ 2
60 41300 F009288K Snap Ring, External ......................................................................................................... 1
61 F022988 Hose Clamp...................................................................................................................... 3
62 F030034 Screw................................................................................................................................ 6
63 158288 Decal, Gasoline ................................................................................................................ 1
64 158289 Decal, Hydraulic Oil ......................................................................................................... 1
65 158341 Exhaust Pipe .................................................................................................................... 2
66 158286 Bracket ............................................................................................................................. 1
67 41267 F002355 HHCS 1/4 - 20 x 3/4 ......................................................................................................... 1
68 41387 F012367 SHCS 1/4 - 20 x 1-3/4 ...................................................................................................... 4
69 158157 Axle Extension ................................................................................................................. 2
70 43051 F024249 Washer ............................................................................................................................. 2
71 F014073 SHCS 1/4 - 20 x 2 ............................................................................................................ 3
72 F025086 Pin ................................................................................................................................... 2
73 158290 Decal, Coupling ................................................................................................................ 1
74 158153 Lift Eye ............................................................................................................................. 1
75 F025087 Muffler............................................................................................................................... 1
76 F017607 Hose Clamp...................................................................................................................... 3
77 158340 Muffler Fabric ................................................................................................................... 2
78 F011749 Set Screw ......................................................................................................................... 2
UPC NO.
48676 48676 Packing Kit................................................................................................................. 1
Greenlee Textron / Subsidiary of Textron Inc.
17
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3555A/42306 Portable Power Unit
HG3555A/42306 Power Unit
Hydraulic Components and Piping
11
14
10
8 9
7
Figure 7
11
28
HYDRAULIC PUMP
15
29
5
19
27
OIL COOLER
16
26
12
22
20
11
2
1
4
3
17
18
14
13
24
Greenlee Textron / Subsidiary of Textron Inc.
25
18
32
6
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
30
31
HG3555A/42306 Portable Power Unit
HG3555A/42306 Power Unit
Hydraulic Components and Piping Parts List
KEY 78-3310- PART NO. DESCRIPTION QTY.
1 158547 Hydraulic Reservoir ...................................................................................................1
2 F008544 Level Seal Plug, 1/8 M NPT ......................................................................................1
3 F024683 FILTER ......................................................................................................................1
4 41267 F002355 Cap Screw, 1/4 x 3/4" Hex Head ..............................................................................2
5 43811 158283 Manifold .....................................................................................................................1
6 41990 F022688 Rotary Valve ..............................................................................................................2
7 41315 F009825 Cap Screw, 1/4 x 1" Hex Head .................................................................................4
8 41291 F007022 Hex Nut, 1/4" .............................................................................................................4
9 41431 F013588 Light Hex Stop Nut, 1/4"............................................................................................4
10 F015627 Hose Clip ...................................................................................................................4
11 F012147 Hose Clamp...............................................................................................................4
12 F022989 Hose Clamp...............................................................................................................4
13 41989 F022687 Relief Valve ...............................................................................................................2
14 F024695 90° Elbow, 3/4 M NPT x 3/4 ID Hose........................................................................3
15 F024676 90° Elbow, 1/2 F NPT x 7/8 M STR ..........................................................................2
16 F024677 90° Elbow, 1-1/16 M JIC x 1 Hose ............................................................................2
17 F013468 90° Elbow, 1/2 M NPT x 1/2 F NPT Street ...............................................................2
18 F023359 Gasket, Silicon ..........................................................................................................1
19 41351 F011243 Hex Nipple, 1/2 M NPT x 1/2 M NPT ........................................................................5
20 41999 F022736 Adapter, 3/4 M NPT x 1/2 F NPT ..............................................................................1
21 43158 F002197 Pipe Nipple ................................................................................................................1
22 F011003 90° Elbow ..................................................................................................................1
24 41778 F020196K Female Quick Connector ..........................................................................................2
25 41779 F020197K Male Quick Connector...............................................................................................3
26 43352 155778 Hose ..........................................................................................................................2
27 43345 158342 Hose ..........................................................................................................................1
28 43344 158343 Hose ..........................................................................................................................1
29 43343 158344 Hose ..........................................................................................................................2
30 41850 F021495 Level Seal Plug .........................................................................................................1
31 41694 F018355 Level Seal Plug .........................................................................................................1
32 41328 F010577 SHCS, 5/16 - 18 x 1-3/4 ............................................................................................8
UPC NO.
42100 F024680 Replacement Filter Element ...............................................................................1
Greenlee Textron / Subsidiary of Textron Inc.
19
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3555A/42306 Portable Power Unit
HG3555A/42306 Power Unit
Battery and Wiring Parts List
12
CUT GROMMET
INSTALL AS SHOWN
Figure 8
ATTACH TO STARTER TERMINAL
5
1
13
8
GROUND TO
ENGINE BOLT
9
10
11
EXISTING SPARK PLUG
2 3
4
GROUND TO ENGINE
MOUNTING TUBE
UPC NO.
KEY 78-3310- PART NO. DESCRIPTION QTY.
6
7
1 F024696 12 Volt Battery (See page 6 for battery specifications) ............................................1
2 F001684 Carriage Bolt, 1/4 x 1" ...............................................................................................2
3 41291 F007022 Hex Nut, 1/4" .............................................................................................................2
4 156654 Wire Assembly ..........................................................................................................1
5 155785 Wire Assembly ..........................................................................................................1
6 41276 F003067 HHCS, 1/4 - 20 x 5/8 .................................................................................................1
7 41431 F013588 Nut, 1/4 - 20 ...............................................................................................................1
8 F030027 Hour/Tach Meter .......................................................................................................1
9 F016532 #8 Machine Screw .....................................................................................................2
10 F030029 #8 Lock Washer ........................................................................................................2
11 F005273 #8 Hex Nut.................................................................................................................2
12 F030035 Grommet....................................................................................................................1
13 41790 F020627 Battery Hold-Down ....................................................................................................1
Greenlee Textron / Subsidiary of Textron Inc.
20
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3555A/42306 Portable Power Unit
Appendix A
SELECTION, INSTALLATION AND MAINTENANCE OF
HOSE AND HOSE ASSEMBLIES
- SAE J1273 MAY 1986*
SAE RECOMMENDED PRACTICE
The following recommendations on selection, installation
and maintenance of hose and hose assemblies was
established by the S.A.E. in 1979 and reaffirmed May
1986. Please read these general instructions carefully.
1. SCOPE
Hose (also includes hose assemblies) has a finite life and
there are a number of factors which will reduce its life.
This recommended practice is intended as a guide to
assist system designers and/or users in the selection,
installation, and maintenance of hose. The designers and
users must make a systematic review of each application
and then select, install, and maintain the hose to fulfill
the requirements of the application. The following are
general guidelines and are not necessarily a complete
list.
Improper selection, installation or maintenance
may result in premature failures, bodily injury, or
property damage.
2. SELECTION
The following is a list of factors which must be
considered before final hose selection can be made.
2.1 Pressure – After determining the system pressure,
hose selection must be made so that the recommended
maximum operating pressure is equal to or greater than
the system pressure. Surge pressures higher than the
maximum operating pressure will shorten hose life and
must be taken into account by the hydraulic designer.
2.2 Suction – Hoses used for suction applications must
be selected to insure the hose will withstand the negative
pressure of the system.
2.3 Temperature – Care must be taken to insure that
fluid and ambient temperatures, both static and
transient, do not exceed the limitations of the hose.
Special care must be taken when routing near hot
manifolds.
2.4 Fluid Compatibility – Hose selection must assure
compatibility of the hose tube, cover, and fittings with
fluid used. Additional caution must be observed in hose
selection for gaseous applications.
2.5 Size – Transmission of power by means of
pressurized fluid varies with pressure and rate of flow.
The size of the components must be adequate to keep
pressure losses to a minimum and avoid damage to the
hose due to heat generation or excessive turbulence.
2.6 Routing – Attention must be given to optimum
routing to minimize inherent problems.
2.7 Environment – Care must be taken to insure that the
hose and fittings are either compatible with or protected
from the environment to which they are exposed.
Environmental conditions such as ultraviolet light, ozone,
salt water, chemicals, and air pollutants can cause
degradation and premature failure and, therefore, must
be considered.
2.8 Mechanical Loads – External forces can significantly
reduce hose life. Mechanical loads which must be
considered include excessive flexing, twist, kinking,
tensile or side loads, bend radius, and vibration. Use of
swivel type fittings or adapters may be required to insure
no twist is put in the hose. Unusual applications may
require special testing prior to hose selection.
2.9 Abrasion – While a hose is designed with a
reasonable level of abrasion resistance, care must be
taken to protect the hose from excessive abrasion which
can result in erosion, snagging and cutting of the hose
cover. Exposure of the reinforcement will significantly
accelerate hose failure.
2.10 Proper End Fitting – Care must be taken to insure
proper compatibility exists between the hose and
coupling selected based on the manufacturer’s
recommendations substantiated by testing to industry
standards such as SAE J517d (November, 1976).
2.11 Length – When establishing proper hose length,
motion absorption, hose length changes due to pressure,
as well as hose and machine tolerances must be
considered.
2.12 Specifications and Standards – When selecting
hose, government, industry, and manufacturer’s
specifications and recommendations must be reviewed
and applicable.
2.13 Hose Cleanliness – Hose components vary in
cleanliness levels. Care must be taken to insure that the
assemblies selected have an adequate level of
cleanliness for the application.
2.14 Electrical Conductivity – Certain applications
require that the hose be non-conductive to prevent
electrical current flow. Other applications require the
hose to be sufficiently conductive to drain off static
electricity. Hose and fittings must be chosen with these
needs in mind.
Greenlee Textron / Subsidiary of Textron Inc.
21
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Appendix A (cont’d)
3. INSTALLATION
After selection of proper hose, the following factors must
be considered by the installer.
3.1 Pre-Installation Inspection – Prior to installation, a
careful examination of the hose must be performed. All
components must be checked for correct style, size, and
length. In addition, the hose must be examined for
cleanliness, I.D. obstructions, blisters, loose cover, or any
other visible defects.
3.2 Follow Manufacturers’ Assembly Instructions.
3.3 Minimum Bend Radius – Installation at less than
minimum bend radius may significantly reduce hose life.
Particular attention must be given to preclude sharp
bending at the hose/fitting juncture.
3.4 Twist Angle and Orientation – Hose installations
must be such that relative motion of machine
components produces bending of the hose rather than
twisting.
3.5 Securement – In many applications, it may be
necessary to restrain, protect, or guide the hose to
protect it from damage by unnecessary flexing, pressure
surges, and contact with other mechanical components.
Care must be taken to insure such restraints do not
produce additional stress or wear points.
3.6 Proper Condition of Ports – Proper physical
installation of the hose requires a correctly installed port
connection while insuring that no twist or torque is put
into the hose.
3.7 Avoid External Damage – Proper installation is not
complete without insuring tensile loads, side loads,
kinking, flattening, potential abrasion, thread damage, or
damage to sealing surfaces are corrected or eliminated.
3.8 System Check Out – After completing the
installation, all air entrapment must be eliminated and the
system pressurized to the maximum system pressure
and checked for proper function and freedom from leaks.
Note: Avoid potential hazardous areas while testing.
4. MAINTENANCE
Even with proper selection and installation, hose life may
be significantly reduced without a continuing
maintenance program. Frequency should be determined
by the severity of the application and risk potential.
A maintenance program should include the following as a
minimum.
4.1 Hose Storage – Hose products in storage can be
affected adversely by temperature, humidity, ozone,
sunlight, oils, solvents, corrosive liquids and fumes,
insects, rodents and radioactive material. Storage areas
should be relatively cool and dark, and free of dust, dirt,
dampness and mildew.
4.2 Visual Inspection – Any of the following conditions
requires replacement of the hose:
(a) Leaks at fitting or in hose. (Leaking fluid is a fire
hazard).
(b) Damaged, cut or abraded cover. (Any reinforcement
exposed).
(c) Kinked, crushed, flattened or twisted hose.
(d) Hard, stiff, heat cracked or charred hose.
(e) Blistered, soft degraded or loose cover.
(f) Cracked, damaged, or badly corroded fittings.
(g) Fitting Slippage on hose.
4.3 Visual Inspection – The following items must be
tightened, repaired, or replaced as required:
(a) Leaking port conditions.
(b) Clamps, guards, shields.
(c) Remove excessive dirt buildup.
(d) System fluid level, fluid type, and any air entrapment.
4.4 Functional Test – Operate the system at maximum
operating pressure and check for possible malfunctions
and freedom from leaks.
Note: Avoid potential hazardous areas while testing.
4.5 Replacement Intervals – Specific replacement
intervals must be considered based on previous service
life, government or industry recommendations, or when
failures could result in unacceptable down time, damage,
or injury risk.
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
*Reprinted with permission© 1991 from the Society of
Automotive Engineers, Inc. Handbook.
Canada Fax: 800/524-2853
Printed in the U.S.A.
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