Greenlee Fairmont HG3505A User manual

999 1316.0 REV 3 © 1998 Greenlee Textron 2/98
INSTRUCTION MANUAL
PORTABLE HYDRAULIC
POWER UNIT
HG3505A / 42303
Read and understand this material before operating
or servicing this equipment. Failure to understand
how to safely operate this tool could result in an
accident causing serious injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Table of Contents
Description ............................................................................................................2
Safety Information............................................................................................. 3-5
Specifications........................................................................................................5
Hoses and Fittings ................................................................................................6
Recommended Hydraulic Fluids...........................................................................6
Hose/Tool Connections ........................................................................................7
Operation ........................................................................................................ 8-10
Starting and Stopping Procedures .................................................................9
Control Locations .........................................................................................10
Maintenance ................................................................................................. 11-15
Hydraulic System - Oil & Filter .....................................................................12
Troubleshooting............................................................................................13
Disassembly .................................................................................................14
Assembly ......................................................................................................15
HG3505A Power Unit - Exploded View .............................................................16
- Parts List ......................................................................17
Pump...................................................................................................................18
Optional Accessories ..........................................................................................19
Appendix A - SAE J1273 May 1986 ............................................................. 20-21
Description
The HG3505A Portable Hydraulic Power Unit is compact, efficient and quiet.
Because it is completely portable and self-contained, it can be used at almost
any job site.
Additional or replacement manuals may be obtained from your Greenlee
Fairmont distributor. When tool is received, complete the following record:
SERIAL NUMBER: ____________________________
DATE OF PURCHASE:_________________________
WHERE PURCHASED: ________________________

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
IMPORTANT SAFETY INSTRUCTIONS
SAVETHESE INSTRUCTIONS
Additional copies of this manual and decals are available upon request at no charge.
Safety is a critical factor in the design of Greenlee 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.
The symbol above is used to call your attention
to instructions concerning your personal safety.
Watch for this symbol. It points out important safety
precautions. It means “ATTENTION! Become alert!
Your personal safety is involved!” Read the
message that follows and be alert to the possibility
of personal injury or death.
Immediate hazards which, if not avoided, WILL result in
severe personal injury or death.
SAFETY
ALERT
SYMBOL
Hazards or unsafe practices which, if not avoided, COULD
result in minor personal injury or property damage.
Hazards or unsafe practices which, if not avoided, COULD
result in severe personal injury or death.
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 could
result in injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
IMPORTANT SAFETY 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.
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.
• 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 these warnings could result in
severe injury or death.
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 smok-
ing. 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.
SAVETHESE INSTRUCTIONS
Additional copies of this manual are available upon request at no charge.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 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.
Use appropriate lifting equipment. Make sure all
components used to lift this power unit are rated
for 100 lbs (46 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.
IMPORTANT SAFETY INSTRUCTIONS
Specifications
Height ............................................................................... 18.25 in. (46.4 cm)
Length.................................................................................... 23 in. (58.4 cm)
Width .................................................................................. 16.5 in. (41.9 cm)
Dry Weight.............................................................................55 lbs. (24.9 kg)
Engine
Type of Fuel ...................................................................................... Gasoline
Fuel Tank Capacity .................................................................. 0.7 gal. (2.7 l)
Rated Output ....................................................................4.0 HP @ 3600 rpm
Maximum Output ..............................................................5.2 HP @ 4000 rpm
Hydraulic System Specifications
Type of Hydraulic System ...........................................................Open-Center
Hydraulic Flow at 3600 rpm .............................................. 4.75 gpm (18 lpm)
Hydraulic Pressure - maximum ........................................... 1400 psi (97 bar)
Hydraulic Reservoir Capacity................................................... 0.9 gal. (3.4 l)
Maximum Recommended Back Pressure............................. 200 psi (14 bar)
200 psi is the agreed standard for the Hydraulic Tool Manufacturer’s
Association (HTMA). Greenlee Fairmont tools operate efficiently at this standard.

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Hoses and Fittings
Hoses and fittings must comply with the SAE Standard J1273, SAE Recom-
mended 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.
Supply hoses and quick couplers are not furnished with the unit. See bulletin
901B for Greenlee Fairmont No-drip quick couplers and hoses. It is recom-
mended that 1/2" I.D. hoses be used for the return line, and 3/8" hoses for the
pressure line. Using hoses over 25' in length will cause a decrease in power to
the tool.
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.
Recommended Hydraulic Fluids
Any non-detergent petroleum base 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
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.

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HG3505A / 42303 Portable Power Unit
Connecting Hoses
1. Pull up red bypass valve on reservoir.
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).
Note: A flow meter may be installed in the return line
to test the rate of flow in the system.
Hose/Tool Connections
Disconnecting Hoses
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.
IMPORTANT
When new hoses are used, it is necessary to
prefill the hoses to keep the reservoir oil level
from dropping excessively. After connecting new
hoses to the unit, run the unit for a few minutes,
filling the hoses with oil. Stop the unit and check
the oil level of the reservoir. Refill as necessary.
Hydraulic oil should appear in the lower 1/4 of the
sight gauge.
TYPICAL
TOOL
PRESSURE
PORT (P)
RETURN
PORT (T)
RETURN
PORT (T)
PRESSURE
PORT (P)
FLOW
METER
RELIEF
VALVE
1400 PSI
BYPASS
VALVE
OIL
COOLER
ENGINE
FILTER
PUMP
POWER
UNIT

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Operation
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 smok-
ing. Fuel is flammable and explosive
and, if ignited, will result in severe
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.
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 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 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 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 these warnings could result in
severe injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Operation (cont’d)
IMPORTANT
Position the power unit on firm level ground.
Pre-Start
1. Check the engine oil level. Refer to the engine
Operating and Maintenance Instructions for the
correct oil type and checking instructions.
2. Check the fuel level. Operating and Maintenance
Instructions for the fuel recommendation.
3. Check the hydraulic reservoir oil level. The hydraulic
oil should appear in the lower 1/4 of the sight
gauge.
4. Verify that all current maintenance has been per-
formed on the power unit. See Maintenance.
Connect the tool hoses and tool to the power unit.
See Hose Connections.
Starting the Power Unit
1. Pull the red bypass valve on the reservoir UP.
2. Set ignition switch to the ON position, and throttle
lever to the START position.
3. Before pulling starter cable, set choke lever to the
CLOSED position if engine is cold, or to HALF
OPEN position if engine is warm.
4. Pull starter cable slowly until some resistance is felt.
Return to starting position, then pull starter cable
out quickly.
Note: If the engine does not start after three attempts,
set choke lever to the OPEN position, to avoid
flooding the engine. Be sure the ignition switch is
in the ON position, and throttle lever is in START
position.
5. After the engine has started, return the choke lever
to the OPEN position, and allow the engine to warm
up for 3-5 minutes without moving the throttle lever.
The efficiency of any hydraulic unit will be reduced
in cold weather if the unit is operated with cold oil.
It is recommended that the power unit be allowed to
warm up before operating any tool.
6. After the engine is warmed up, engine speed can be
controlled by the throttle lever. Move the throttle
lever up, running the engine at full speed.
7. To direct oil to the tool, push the red bypass valve
on the reservoir DOWN.
Stopping Procedure
1. Pull red bypass valve on the reservoir UP to stop
the flow of oil to the tool.
2. Move the throttle lever DOWN to idling speed. Allow
the engine to idle for a moment. Turn ignition switch
to the OFF position.
Note: Do not store unit with fuel in the tank for long
periods of time. Refer to storage procedure in
Kawasaki Engine Service Manual.
Emergency Stopping
In case of an emergency, such as a fire, stop the engine
immediately by turning the ignition switch to the OFF
position.
Lifting the Power Unit
Use appropriate lifting equipment. Make sure all
components used to lift this power unit are rated for
100 lbs (46 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.

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Control Locations
STARTER CABLE
IGNITION SWITCH
CHOKE LEVER
THROTTLE LEVER
SIGHT GAUGE
PRESSURE
PORT
RETURN
PORT
BYPASS VALVE
FILLER/BREATHER
PLUG

Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Maintenance
The service life of the unit will be increased by proper
care and maintenance. The preventative maintenance
steps below are recommended.
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.
Every Operating Day
Inspect hoses and fittings for signs of leaks, cracks,
wear, or damage and replace if necessary. Check
engine oil level. Check reservoir oil level.
Every Month
Perform a detailed inspection of hoses and fittings and
replace if necessary.
Every Year
Drain and clean out hydraulic system. Refill with new oil,
and clean the hydraulic filter. This procedure should be
done more often if unit is operated under severe condi-
tions (i.e., continuous operation, dusty or damp environ-
ment, etc.).
Keeping fluid in the system clean will extend the service
life of the unit. If oil becomes dark or milky-looking, drain
and clean hydraulic system as soon as possible. See
procedure below.
Engine service and maintenance should be performed
according to the engine manufacturer’s recommenda-
tion. See Kawasaki Engine Service Manual.
Always install dust case over hydraulic ports when unit
is disconnected, to prevent contamination of oil.
Disassembly procedures should be done only when
required to repair improperly operating or damaged unit.
If unit does not operate properly, check Troubleshooting
chart before attempting an overhaul.
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.
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 run the power unit engine in a confined
area. Engine exhaust fumes are toxic. If inhaled,
exhaust fumes can cause injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 12 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Hydraulic System - Oil and Filter
Maintenance (cont’d)
Perform this procedure in a clean environment.
Cleanliness is vital to maintain the service life of the
unit. Refer to Exploded View, HG3505A Power Unit.
1. Engine must be shut off, and red bypass valve on
reservoir pulled up. Disconnect hoses and tool from
the unit.
2. Place a pan under pipe plug (41) to catch oil as it
drains. The capacity of the hydraulic reservoir is 0.9
gallons (3.4 liters). Remove pipe plug, and allow the
system to drain.
Note: The hydraulic filter should be cleaned when
the system is drained. In order to clean the filter,
the reservoir must be removed. Cleanliness is
especially important when this procedure is
done.
3. Remove cap nuts (40) and washers (39). Pull
reservoir (38) off of unit. Spacers (37) may fall free.
4. Clean out any dirt which has accumulated in the
bottom of the reservoir.
5. Remove filter (20), screwing it out of pump inlet
port. Inspect O-ring (21) for signs of cracks, wear
or damage. Clean filter with solvent, and dry with
compressed air. If filter is damaged, replace it.
6. Reinstall filter. Check O-ring (34) for cracks, wear,
or damage. Install spacers (37) and reservoir,
secure with cap nuts (40) and washers (39).
Replace pipe plug (41).
7. Remove breather/filler plug (22), clean filter in
breather/filler plug with solvent, and dry with com-
pressed air. Fill reservoir with new, clean oil. See
Specifications. Do not use oil which was drained
from reservoir or recycled oil. Replace breather/filler
plug.
Note: New hoses must be prefilled with hydraulic oil.
See Hose/Tool 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.

Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Troubleshooting
PROBLEM PROBABLE CAUSE PROBABLE REMEDY
Engine will not start. Engine out of fuel. Fill fuel tank.
Incorrect starting procedure. See starting procedure.
Red bypass valve on reservoir is Pull bypass valve up to start engine.
pushed down.
Engine air filter or spark plug need See engine manufacturer’s manual.
service.
Oil in the engine air filter. Replace air filter.
No pressure, or insufficient Red bypass valve on reservoir is Push bypass valve down to operate
hydraulic pressure to tool. pulled up. tool.
Hoses used with unit are too long or See Hoses and Fittings for recom-
too small internal diameter. mended hose length and diameter.
Hydraulic reservoir level low. Fill reservoir. Step 7, Periodic
Maintenance. Check for leakage.
Pump damaged or worn. Repair or replace pump.
Internal leakage. Remove reservoir, inspect pump
outlet fitting and hose connections
for tightness, inspect O-ring seal on
outlet fitting, repair or replace com-
ponents as necessary.
External leakage. Locate leakage point. Tighten, replace
or repair components as necessary.
Engine output insufficient. Adjust throttle, tune up engine, or
Throttle set too low, engine needs return engine to authorized Kawasaki
tune-up or requires service. service center.
Hydraulic filter requires cleaning. Drain hydraulic system. Clean filter.
Engine stalls when red bypass Hydraulic hoses not connected, or Relieve pressure, make sure proper
valve is pushed in. not connected correctly. hydraulic hose connections are made.
Closed-Center tool is being used. Power unit is Open-Center. Make sure
Open-Center tools are used.
Oil leaks from breather/filler Prefilled hoses overfilling the system. Drain oil from reservoir until oil appears
plug. only in lower 1/4 of sight gauge.

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HG3505A / 42303 Portable Power Unit
Note: During disassembly, take special note of the
position of the wear plate (5) and pressure
loading seals (6 & 14). The open side of the
seals should be toward the inlet side of pump.
The gear contact pattern in the bore is additional
identification of the inlet side.
9. Invert pump body with shaft seal (8) up. Remove
shaft seal by prying it out with a large screwdriver.
Damaging the shaft seal bore will result in seal
leakage.
10. Wash all parts and dry thoroughly.
11. Inspect wear plate (5) and replace if scoring or
uneven wear is observed. A somewhat heavier
wear pattern is normal on the inlet side of the wear
plate, but there should be no heavy scoring in this
area.
12. Inspect bushings in body and cover. Replace cover
or body if bushings are heavily scored or burned.
13. Inspect gear journals and faces. Replace if faces or
journals are scored or worn, or if shaft journal wear
exceeds 0.001 inch (.025 mm).
Disassembly
Pump disassembly should be done only if trouble-
shooting indicates that the pump is not operating
properly. Overhaul pump only in a clean, dust-free
location, using clean tools and equipment. Dirt or grit
will damage the highly machined surfaces and will result
in leakage or premature failure of the pump.
Before beginning disassembly, scribe a mark on inlet
side of the body and the cover to insure that the pump
will be reassembled in the same manner as it was
shipped from the factory. If the body or the cover is
replaced during overhaul, scribe a mark on the new part
in the same location as the mark on the part it replaces.
Reference numbers refer to items illustrations listed.
1. See Exploded View, HG3505 Power Unit. Drain
the hydraulic system and remove reservoir. Filter
should be removed and cleaned whenever reservoir
is removed. Loosen nut of male connector (9) and
turn tube (27) aside. Remove baffle (30).
Note: Do not adjust the hex nuts and washers located
on studs (29).
2. Remove swivel nut of hose assembly (32) from
elbow (33), leaving elbow in place. Remove hex
head cap screws (19) and washers from pump
flanges. Spacers (18) may fall free. Loosen set
screw (16) which secures the pump shaft to the
coupler (15). It is not necessary to loosen the two
set screws (16) which secure the engine output
shaft to the coupler. Remove pump from power unit.
3. See Exploded View, Pump. Clean outside of pump
with a good grade solvent and dry thoroughly.
4. Remove Woodruff key (9) from drive shaft. Using a
file or stone, remove any burrs from shaft end or
keyway. Grease keyway before sliding drive shaft
through shaft seal.
5. Secure pump in vise with shaft end down, using
light clamping pressure. Remove cap screws (1)
and washers (2). Remove pump from vise.
6. When separating the body from the cover, use one
hand to support cover from underneath, since cover
and internal parts will drop suddenly when dowel
pins are disengaged. Separate cover (10) from
body (13) by supporting pump, shaft end up, on the
mounting flanges and pressing on end of drive shaft
with an arbor press. OR use two large screwdrivers
to pry in the indented areas between body and
cover, OR tap drive shaft lightly with a plastic mallet.
Note: Do not insert screwdrivers further into the pump
than the depth of the indentations. Any burrs or
scratches must be removed from the body and/or
cover after this procedure to assure a good seal
between body and cover.
7. Holding pump with shaft end down, remove cover
(10). Dowel pins (7) and seal ring (4) may remain
either in the body or cover.
8. Lift out; driven gear (11), drive gear (12), and wear
plate (5).
JOURNAL WEAR IN
BEARING AREA
14. Inspect body for wear and scoring. If gear contact
wear on the inlet side exceeds 0.005 inch (.127
mm), replace body. If the body is usable, remove
any burrs with suitable burring tool.
A
A
IN
OUT
.005
SECTION A-A

Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Assembly
Note: It is recommended that new seals contained
in the seal kit be installed when the pump is
overhauled.
1. See Exploded View, Pump. Remove pressure
loading seals (6 & 14) from wear plate and discard
if new parts are available. Install new seals into
groove with smooth, flat surface out. The seals
should extend a minimum of 0.005 inch (.127 mm)
above surface of wear plate. Do not push seals
below wear plate surface at any point. The entire
seal must be started into the groove, and no part of
the seal should extend beyond the groove.
2. Place body (13) on flat plate with shaft seal bore up.
Install new shaft seal (8). Press seal until it is 3/16
inch below from surface. Pack the area between the
double lip of the seal with Lubriplate or equivalent.
3. Invert body so that gear bores are up. Install wear
plate (5) in bottom of bore, making sure that pres-
sure unloading seals (6 & 14) are positioned cor-
rectly in seal grooves and installed against bottom
of bore surface. See detail A of illustration for
correct assembly.
4. Lubricate bushings in the body, and surface of wear
plate, with SAE 10 oil.
5. Apply Lubriplate or equivalent to outer surface of
drive shaft sleeve. Insert sleeve into shaft seal
from front of pump until sleeve contacts drive gear
bushing. Install drive gear (12). Install driven gear
(11) with long journal toward front of pump. Lubri-
cate rear gear faces and journals with SAE 10 oil.
6. Apply a small amount of grease to seal ring groove
and install new seal ring (4) into groove.
7. Install dowel pins (7) into body (13). Lubricate
bushings in cover with SAE 10 oil and install cover
(10), matching scribe marks on cover and body.
8. Insert cap screws (1) and washers (2). Torque to
7-8 foot-pounds. Install Woodruff key (9). Turn drive
shaft with adjustable wrench to ensure that no
mechanical binding occurs.
9. See Exploded View, HG3505 Power Unit. Install
pump shaft into coupler (15). Be sure screen (36) is
in position around coupler and engages pilot
diameter on pump, aligning keyway in coupler with
Woodruff key in pump shaft. Install spacers (18)
between manifold (10) and pump flanges. Install
hex head cap screws (19) with washers through
pump flanges, spacers, and manifold, tightening cap
screws into body of engine. Tighten set screw (16).
Connect swivel nut of hose assembly (32) to elbow
(33). If filter (20) has been removed and cleaned,
replace it.
10. Replace baffle (30) on studs (29). Return tube (27)
to its original position, and tighten nut of male
connector (9).
11. Replace and fill the reservoir. See Maintenance,
Hydraulic System - Oil and Filter.
Break-In
After the pump has been overhauled, it should be
broken-in by the following procedure. Check for leak-
age, and listen for any abnormal noises as each step is
performed.
1. Connect hoses as described in Hose/Tool Connec-
tion. Start the unit but let it idle for about two min-
utes at about 1/4 of the maximum engine speed.
Do not push red bypass valve down.
2. Increase engine speed by 1/4 increments, letting
the unit run for two minutes at each setting.
3. After full engine speed is reached, push red bypass
valve down. Allow unit to run for two minutes before
applying load.
4. Actuate and hold the tool, building pressure to the
relief valve setting several times. If no leakage has
occurred, and unit is operating correctly, break-in is
complete.

Greenlee Textron / Subsidiary of Textron Inc. 16 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
HG3505A Power Unit
24 23
22 10
13 26 9
15 36
31
12
11
14
27 529
19
8
76
1
9
3037 34
38
42
39 40
24
28 32 33 17 21 20
916
18
41
25
3
4
5

Greenlee Textron / Subsidiary of Textron Inc. 17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Parts List
UPC NO.
KEY 78-3310- PART NO. DESCRIPTION QTY
1 44111 F022608 Engine, Kawasaki......................................1
3 41969 F022609 Rubber Mount ...........................................4
4 41256 F001213 Cap Screw, Hex Head 1/4-20 x 1-1/4
Zinc-Plated...........................................4
5 41291 F007022 Hex Nut, 1/4-20 Zinc-Plated.....................10
6 41174 140328 Oil Cooler with tubing (includes #7) ..........1
7 42130 42130 Trim (included in #6) .................................1
8 42081 F023752 Cap Screw, Hex Head 1/4-20 x 2
Zinc-Plated...........................................2
9 41319 F010175 Male Connector with Nut...........................4
10 40855 134327 Manifold.....................................................1
11 43244 F001875 O-Ring, 3/8 x 9/16 x 3/32-70.....................4
12 41971 F002611 O-Ring, 1-15/16 x 2-1/8 x 3/32-70 ............1
13 41456 F014099 Cap Screw, Socket Head 5/16-24 x 3/4....2
14 44108 44108 Key ............................................................1
15 44112 134328 Coupler......................................................1
16 41362 F011592 Set Screw, #10-24 NC-3 x 1-1/4...............3
17 41972 F022612 Pump (see Exploded View, Pump) ...........1
18 44113 134329 Spacer .......................................................2
19 44114 F022613 Cap Screw, Hex Head 5/16-24 x 5
Zinc-Plated...........................................2
20 41973 F022614 FILTER ......................................................1
21 41397 F012813 O-Ring, .644 x .818 x .087-90 .............1
22 41974 F022615 Breather/Filler Plug ...................................1
23 41975 F022616 Bypass Valve ............................................1
43318 43318 Replacement Seal Kit ..........................1
24 44115 F022617 Elbow, 90°3/8 MNPT x 3/8 FNPT ............2
25 41692 F018353 Level Seal Plug, 1/4 NPTF........................1
26 41976 F022618 Relief Valve - 1400 PSI.............................1
27 44116 134331 Tube ..........................................................1
28 44117 134333 Tube ..........................................................1
29 40856 134334 Stud ...........................................................2
30 44118 134335 Baffle .........................................................1
31 41380 F012056 Adapter, 9/16-18 JIC x 3/8 MNPTF...........1
32 40857 134336 Hose Assembly - 19.5" - 9/16-18
JIC union each end..............................1
33 41414 F013327 Elbow - 90°9/16-18 JIC x 9/16-18
M. Str. Thd ...........................................1
41353 F011302 Replacement O-Ring
.468 x .624 x .078-90 ...........................1
34 41977 F022621 O-Ring, 6-1/2 x 6-11/16 x 3/32-70 ............1
36 42120 42120 Screen .......................................................1
37 42956 134338 Spacer .......................................................2
38 40858 134339K Reservoir ...................................................1
39 41978 F022625 Washer, Self-Sealing ................................2
40 41323 F010506 Cap Nut, 1/4-20 UNC-28...........................2
41 41348 F011169 Pipe Plug, 3/8 NPTF .................................1
42 41979 F022626 Sight Check Gauge ...................................1
40891 135326 Decal - DANGER (STOP ENGINE) ..........1
44752 44752 Decal - I.D. ................................................1

Greenlee Textron / Subsidiary of Textron Inc. 18 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Pump
UPC NO.
KEY 78-3310- PART NO. DESCRIPTION QTY
41972 F022612 PUMP ........................................................1
1 48544 Cap Screw, Hex Head ........................4
2 48545 Flat Washer ........................................4
3 48546 Pipe Plug ............................................1
4* 48547 Seal Ring ............................................1
5 48548 Wear Plate ..........................................1
6* 48549 Pressure-Loading Seal .......................1
7 48550 Dowel Pin............................................2
8* 48551 Shaft Seal ...........................................1
9 48552 Woodruff Key ......................................1
10 48553 Cover ..................................................1
11 48554 Driven Gear ........................................1
12 48555 Drive Gear ..........................................1
13 48556 Body Assembly ...................................1
14* 48557 Pressure-Loading Seal (Nylatron) ......1
*Identifies items included in Seal Kit 43293.
1210
4
12 9
7
14
6
5
3
(LARGE PORT)
IN
DETAIL A 5, 6, 8, 14
ASSEMBLED
13
8
11

Greenlee Textron / Subsidiary of Textron Inc. 19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 Portable Power Unit
Optional Accessories
5
7
6
13
9
8
4
2
1
3
12
11
10
UPC NO.
KEY 78-3310- PART NO. DESCRIPTION QTY
40899 135586 OPTIONAL WHEELS AND HANDLE .......1
1 48558 Axle.....................................................1
2 48559 Washer ...............................................4
3 48560 Wheel..................................................2
4 F003141 Pin, Cutter 1/8 x 1-1/2.........................2
5 48561 48561 Foot.....................................................2
6 41256 F001213 Cap Screw, Hex Head 1/4-20 x 1-1/4
Zinc-Plated ......................................2
7 41431 F013588 Stop Nut, 1/4-20 Helas .......................2
8 48562 Handle ................................................1
9 48563 Grip .....................................................1
10 40875 134719 Chain...................................................1
11 41994 F022696 Pin, 5/16" Quick-Disconnect...............1
12 40892 135328 Decal - CAUTION (DO NOT TOUCH).. 1
13 49321 49321 Power Unit Frame ............................... 1

Greenlee Textron / Subsidiary of Textron Inc. 20 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
HG3505A / 42303 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, installa-
tion 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.
2.5 Size - Transmission of power by means of pressur-
ized 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 reason-
able 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 recom-
mendations substantiated by testing to industry stan-
dards such as SAE J517d (November, 1976).
2.11 Length - When establishing proper hose length,
motion absorption, hose length changes due to pres-
sure, as well as hose and machine tolerances must be
considered.
2.12 Specifications and Standards - When selecting
hose, government, industry, and manufacturer’s specifi-
cations 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 cleanli-
ness 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.
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 consid-
ered 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 nega-
tive pressure of the system.
2.3 Temperature - Care must be taken to insure that
fluid and ambient temperatures, both static and tran-
sient, 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.