Fairmont 42276 User manual

99916096 REV 7 © 2006 Greenlee Textron Inc. 6/06
H6635 / 42276
Portable Alternator
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

H6635 / 42276 Portable Alternator
Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Description ..................................................................... 2
Important Safety Instructions ......................................3-4
Identification ................................................................... 5
Specifications
Alternator ................................................................... 6
Hydraulic Power Source .........................................6-7
Recommended Hydraulic Fluids ................................ 7
Hoses and Fittings ..................................................... 8
Unit / Hose Connections ............................................ 8
Operation ..................................................................9-10
Maintenance............................................................11-12
Troubleshooting ........................................................... 13
Disassembly ................................................................. 14
Inspection ..................................................................... 15
Assembly...................................................................... 15
Illustration and Parts ...............................................16-17
Accessories (Optional) ................................................. 18
Table of Contents
Description
The H6635/42276 Portable Alternator provides instant
electric power for lighting, heaters and other electrical
equipment. It is driven by a hydraulic gear motor and is
able to operate from hydraulic systems with flow rates
from 30-45 l/min (8-12 gpm). The alternator, a 60-cycle,
single-phase unit, is capable of delivering up to 3500
watts of electrical power through its 120 and 240 volt AC
outlets.
The 120 volt duplex receptacle is split so that 15 amps
of current may be drawn from either half of the receptacle.
These outlets may be used along with the 240 volt
receptacle provided the alternator is not overloaded.
A maximum of 14.6 amps may be drawn from the 240
volt receptacle provided it is the only receptacle used.
When using the unit, current must be limited to the
ratings on the nameplates of the equipment being
used. If the 240 volt receptacle is used along with the
120 volt receptacles, the total load drawn must not
exceed the equipment’s nameplate ratings.
Purpose
This instruction manual is intended to familiarize
personnel with the safe operation and maintenance
procedures for the following Fairmont tool:
H6635/42276 Portable Alternator
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
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.
KEEP THIS MANUAL
Outlet 1 120 Volts x Amps Draw = Watts #1
Outlet 2 120 Volts x Amps Draw = Watts #2
Outlet 3 240 Volts x Amps Draw = Watts #3
Outlet 4 240 Volts x Amps Draw = Watts #4
Total of all outlets used
must not exceed 3500 watts.
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Safety
Do not discard this product or throw away!
For recycling information, go to
www.greenlee.com.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H6635 / 42276 Portable Alternator
IMPORTANT SAFETY INFORMATION
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 pre-
venting or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
SAFETY
ALERT
SYMBOL
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning could
result in severe injury or death.
Electrical shock hazard:
• This unit generates up to 240
volts. Contact with live circuits can
result in severe injury or death.
• Do not operate or store the unit in
wet or damp locations.
• Keep the unit clean and dry.
• Do not connect any electrical
device with a damaged cord.
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.

H6635 / 42276 Portable Alternator
Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION
Do not reverse hydraulic flow. Operation with
hydraulic flow reversed can cause tool malfunction.
Always connect supply (pressure) hose and return
(tank) hose to proper tool ports.
Failure to observe this warning could result in
severe injury or death.
Do not inspect, adjust or clean tool when it is
connected to a power source. Accidental startup
can result in serious injury.
Failure to observe these warnings 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.
• Do not exceed the maximum electrical load.
Overloading will damage the unit.
• Keep the ventilation slots clean and free of debris.
Blocked ventilation slots will cause overheating
and damage the unit.
• Use this tool for manufacturer’s intended purpose
only. Use other than that which is described in this
manual can result in injury or property damage.
• Inspect hydraulic hoses and couplings every
operating day. Repair or replace if leakage,
cracking, wear or damage is evident. Damaged
hoses or coupling can fail resulting in injury or
property damage.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H6635 / 42276 Portable Alternator
Identification
H6635/42276 Portable Alternator
1. Carrying Handle 7. Ground Lug
2. Mounting Plate 8. Hydraulic Motor
3. Alternator Unit 9. Pressure Port “P”
4. 120 Volt Receptacles 10. Return Port “T”
5. 240 Volt Receptacle 11. Flow Control Cartridge
6. Circuit Breakers (Do Not Adjust)
3
2
8
10
9
4
7
5
6
11
1

H6635 / 42276 Portable Alternator
Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Specifications
Alternator
Mass/Weight .............................................................................. 28.6 kg (63 lb)
Height ................................................................................... 36.8 cm (14.00 in)
Length .................................................................................. 41.9 cm (16.50 in)
Width ....................................................................................... 21.6 cm (8.50 in)
Power ............................................................................................... 3500 Watts
Voltage .......................................................................................... 120/240 VAC
Frequency ................................................................................................. 60 Hz
Current ...................................................................................... 29.2/14.6 Amps
Phase ....................................................................................................... Single
Insulation Class ................................................................................................ F
Ambient Temperature ................................................................ 40°C (104°F)
Pressure Port ......................................................................... 1/2 NPTF Female
Return Port ............................................................................. 1/2 NPTF Female
• Power source flow must be at least 30.3 l/min (8 gpm) and must not
exceed 45.4 l/min (12 gpm).
• Limit relief pressure to 172.4 bar (2500 psi).
Failure to observe these warnings could result in over-pressurizing the
system causing severe injury to operator or bystanders.
Type of Hydraulic System ................................................ Open- or Closed-Center
Filtration ..................................................................................10 micron (nominal)
Flow
Minimum ............................................................................ 30.3 l/min (8 gpm)
Maximum ......................................................................... 45.4 l/min (12 gpm)
Pressure Relief Setting ......................................................... 172.4 bar (2500 psi)
Back Pressure (maximum)* ...................................................... 13.8 bar (200 psi)
* 13.8 bar (200 psi) is the maximum agreed standard back pressure for the
Hydraulic Tool Manufacturers Association (HTMA). Fairmont tools will operate
satisfactorily at this standard.
1. Maximum hydraulic fluid temperature must not exceed 60°C (140°F).
A sufficient oil cooling capacity is needed to limit the hydraulic fluid
temperature.
2. Maximum hydraulic flow must be at least 30.3 l/min (8 gpm) and must not
exceed 45.4 l/min (12 gpm). Install a flow meter in the return line to test the
rate of hydraulic flow before working the tool.
3. Pressure relief valve setting must not exceed 172.4 bar (2500 psi). Locate
the pressure relief valve at your tool’s maximum flow in the supply circuit to
limit excessive hydraulic pressure to the tool.
Hydraulic Power Source

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H6635 / 42276 Portable Alternator
Specifications (cont’d)
FILTER
(10 MICRON)
COOLER
RELIEF
VALVE
2000 PSI
CONTROL
VALVE FLOW METER
T
PALTERNATOR
RESERVOIR
PUMP
POWER SOURCE
Hydraulic Schematic
Use any non-detergent, petroleum-based hydraulic fluid which meets the following
specifications or HTMA specifications may be used.
S.U.S.
@ 38°C (100°F) ........................................................................... 140 to 225
@ 99°C (210°F) .........................................................................40 minimum
Flash Point ................................................................... 170°C (340°F) minimum
Pour Point ...................................................................... -34°C (-30°F) minimum
Recommended Hydraulic Fluids

H6635 / 42276 Portable Alternator
Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Specifications (cont’d)
Hoses and fittings used with this tool must comply
with SAE Standard J1273 (See Appendix A)
recommended practice for selection, installation
and maintenance of hose and hose assemblies.
Failure to observe this warning could result in
severe injury.
Hoses and Fittings
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.
Unit/Hose Connections
• Always stop power source before connecting or
disconnecting tool.
• Do not disconnect hydraulic components, lines
or fittings while hydraulic power source is
running and/or hydraulic fluid is hot. Exposure to
hot hydraulic fluid can cause serious burns.
Failure to observe these warnings could result in
severe injury.
Connecting Hoses (see Figures 1, 2, 3)
Note: Return (tank) hose connection should always
be connected before supply (pressure) hose connection
to prevent pressure buildup inside the unit.
1. Stop the power source.
2. Connect the return (tank) hose from the power
source (port T) to the unit (T port).
3. Connect the supply (pressure) hose from the power
source (port P) to the unit (P port).
Disconnecting Hoses (see Figures 1, 2, 3)
Note: Supply (pressure) hose connection should always
be disconnected before return (tank) hose connection to
prevent pressure buildup inside the tool.
1. Stop the power source.
2. Disconnect the supply (pressure) hose from the
power source (port P) to the unit (P port).
3. Disconnect the return (tank) hose from the power
source (port T) to the unit (T port).
4. To prevent contamination, always install dust
caps over the hydraulic ports of the unit when
disconnected.

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H6635 / 42276 Portable Alternator
Operation
Electrical shock hazard:
• This unit generates up to 240
volts. Contact with live circuits can
result in severe injury or death.
• Do not operate or store the unit in
wet or damp locations.
• Keep the unit clean and dry.
• Do not connect any electrical
device with a damaged cord.
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.
Do not inspect, adjust or clean tool when it is
connected to a power source. Accidental startup
can result in serious injury.
Failure to observe these warnings could result in
severe injury or death.
Do not reverse hydraulic flow. Operation with
hydraulic flow reversed can cause tool malfunction.
Always connect supply (pressure) hose and return
(tank) hose to proper tool ports.
Failure to observe this warning could result in
severe injury or death.
• Do not exceed the maximum electrical load.
Overloading will damage the unit.
• Keep the ventilation slots clean and free of debris.
Blocked ventilation slots will cause overheating
and damage the unit.
• Use this tool for manufacturer’s intended purpose
only. Use other than that which is described in this
manual may result in injury or property damage.
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 could cause serious
burns.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.

H6635 / 42276 Portable Alternator
Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Operation (cont’d)
Setup
1. Stop the power source.
2. Disconnect all electrical loads from the alternator.
3. Place alternator in a clean, dry location.
4. To help prevent accidental shock, make sure that
the alternator is grounded. Connect a grounding
wire from the grounding lug on the alternator to a
suitable ground, such as a water pipe, or a copper
rod driven into the ground.
Note: Do not use a pipe carrying combustible
materials as the ground source.
TO
GROUND
A
Grounding the Alternator
Operation
Plug in electrical cord of appliance into proper
receptacle. 120 volt appliances utilize the top two
receptacles, and 240 volt appliances utilize the
bottom receptacle.
Receptacles
120 Volt Receptacle:
This duplex receptacle is split so that 15 amps
of current may be drawn from either half of the
receptacle. However, total power must be kept
within the ratings on the nameplates of the
equipment. These receptacles may be used
along with the 240 volt receptacle provided
the alternator is not overloaded.
240 Volt Receptacle:
A maximum of 14.6 amps may be drawn from the
240 volt receptacle provided it is the only receptacle
used. However, current must be limited to the
ratings on the nameplates of the equipment. If the
240 volt receptacle is used along with the 120 volt
receptacles, the total load drawn must not exceed
the equipment’s nameplate ratings.
REMEMBER: VOLTS x AMPS = WATTS
Circuit Protection
The receptacles are protected by an AC circuit breaker.
If the alternator is overloaded or an external short circuit
occurs, the circuit breaker will trip. If this occurs, discon-
nect all electrical loads and try to determine the cause
of the problem before attempting to use the alternator
again. Reset the circuit breaker by pushing the button
on the breaker.
5. Connect hydraulic hoses from power source to unit.
Start the power source.