Greenlee Fairmont HG3555A Guide

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 1605.3 © 2000 Greenlee Textron Inc. REV 5 3/00
DUAL CIRCUIT, PORTABLE
HYDRAULIC POWER UNIT
HG3555A / 42306
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
Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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
PARTSPower Unit...................................................................................................................................................16-17
Hydraulic Components and Piping..............................................................................................................18-19
Battery and Wiring............................................................................................................................................20
APPENDICES
Appendix A – SAE J1273 May 1986 ...........................................................................................................21-22
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
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.

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
THIS SYMBOL MEANS:
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.
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.
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.
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 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 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, 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.
Safety is a critical factor in the design of Fairmont equipment. The best program starts with a safety-
conscious 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.
SAVETHESE INSTRUCTIONS
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.

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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.
• 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.
SAVETHESE INSTRUCTIONS
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 equip-
ment. 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.

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Identification
Figure 1
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
3
15 8 2 6
7
4
11
10
12

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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
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
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.
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.
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.

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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.
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.
Figure 3
Hydraulic Schematic
PRESSURE
PORT
RETURN
PORT
TYPICAL
TOOL
PRESSURE
PORT (10 GPM)
PRESSURE
PORT (5 GPM)
PRESSURE
PORT (5 GPM)
RETURN
PORT
RETURN
PORT
FLOW
METER
CONTROL
VALVE
CONTROL
VALVE
RELIEF
VALVE
2000 PSI
RELIEF
VALVE
2000 PSI
PUMP
ENGINE
OIL
COOLER
FILTER
(10 NICRON)
POWER
UNIT
C2 C2
C1 C1
R
P
R
P

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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.
•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.
Operation
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.

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Figure 4
Power Unit Controls
51
OFF RUN
START SLOW FAST
CHOKE
4 2 3
1. Flow Levers
2. Choke Knob
3. Engine Throttle Lever
4. Key Switch
5. Retaining Pins
Position the power unit on firm level ground.
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.
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
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.
Operation (cont’d)

HG3555A/42306 Portable Power Unit
Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
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.
Operation (cont’d)
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.