Greenlee Fairmont F07 User manual

INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 4450.2 REV 4 © 2002 Greenlee Textron 6/02
F07
Portable Power Unit
Serial Code GFN

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
KEEPTHIS MANUAL
Table of Contents
Description .....................................................................2
Purpose of this Manual ..................................................2
Other Publications..........................................................2
Important Safety Information.......................................3-4
Identification ...................................................................5
Specifications .................................................................6
Hose Connections..........................................................7
Operation ....................................................................8-9
Maintenance............................................................10-11
Troubleshooting ......................................................12-13
Service .........................................................................14
Illustrations and Parts List .......................................15-17
Safety
Safety is essential in the use and maintenance of
Fairmont tools and equipment. This 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.
Purpose
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
Fairmont F07 Portable Power Unit (504 5894.9).
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Other Publications
Tool Owners/Users
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 999 3032.3
Description
The F07 Portable Power Unit is a compact unit providing
a flow of 18.9 lpm (5 gpm) and a maximum pressure of
117 bar (1700 psi). It is a lightweight power source
intended for use with open-center system hydraulic
tools. HTMA couplers are provided for tool connection.
Its compact size and light weight allow use at remote
work sites that might not be accessible by a larger power
unit or hydraulic truck. The ability to get close to the work
area allows the use of shorter hydraulic hoses, increas-
ing tool efficiency.
The simple design of the hydraulic circuit and reliable
Honda gasoline-powered engine ensure years of
trouble-free operation, when serviced according to the
recommended maintenance schedule. Other features
include a large capacity oil cooler, sight level gauges,
pneumatic tires, and handles for ease of transport.
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron shall not be liable for damages
resulting from misapplication or misuse of its products.

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
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 prevent-
ing 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 will
result in severe injury or death.
Fuel is flammable and explosive.
• Stop engine before filling fuel tank.
• Do not fill fuel tank when engine
is hot.
• Do not fill fuel tank near an open
flame, sparks, or when smoking.
Failure to observe this warning will
result in severe injury or death.
Do not run power unit engine in a
confined area.
Engine exhaust fumes are toxic.
If inhaled, exhaust fumes can cause
injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Do not disconnect tool, hoses or fittings while the
power source is running or if the hydraulic fluid is
hot. Hot hydraulic fluid can cause serious burns.
Skin injection hazard:
Oil under pressure easily punctures
skin, causing serious injury, gan-
grene, or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Depressurize the hydraulic system
before servicing or disconnecting
hoses.
Wear hearing protection when using
this tool.
Long-term exposure to high noise
levels can result in hearing loss.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
IMPORTANT SAFETY INFORMATION
Note: Keep all decals clean and legible, and replace
when necessary.
Do not let power unit engine run unattended.
Monitor the engine so that it can be shut down
immediately in case of a malfunction.
Failure to observe this warning can result in
severe injury or death.
• Inspect the hydraulic hoses and couplings every
operating day. Repair or replace if leakage, crack-
ing, wear, or damage is evident. Damaged hoses
or couplers can fail, resulting in injury or property
damage.
• Use this power source for manufacturer’s intended
purpose only. Use other than that which is
described in this manual can result in injury or
property damage.
• Make sure that all bystanders are clear of the work
area when handling, starting, and operating the
power unit. Nearby personnel can be injured by
flying parts in the event of a tool malfunction.
Hydraulic oil can cause skin irritation.
• Handle the tool and hoses with care to prevent
skin contact with hydraulic oil.
• In case of accidental skin contact with hydraulic
oil, wash the affected area immediately to remove
the oil.
Failure to observe these precautions can result in
injury.
Engine, exhaust system, and other
components will be hot during and
after operation. Use care when
working around the power unit. Hot
surfaces can cause serious burns.
• Do not operate power unit without
safety guards in place.
• Keep all parts of the body and
loose clothing away from the
engine fan.
Emergency stop procedure: Switch the engine OFF.
Procedure for connecting or disconnecting hydraulic
hoses, fittings or components:
1. Rotate the flow control knob to the OFF
position.
2. Switch the engine OFF.
3. Follow the sequence under “Hose Connections”
to prevent pressure buildup. In case some
pressure has built up, loosen hoses, fittings or
components slowly.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Identification
F07 Portable Power Unit
1. Gasoline Engine, 6.5 hp 7. Hydraulic Reservoir
2. Hydraulic Pump 8. Oil Cooler
3. Handle 9. Flow ON/OFF Valve
4. Bumper 10. Tool Connection—Pressure
5. Hydraulic Oil Filter 11. Tool Connection—Return
6. Fuel Tank 12. Oil Fluid Level Gauge
6912
73
10
11
1
4
2
5
8
10
11

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Specifications
F07 Portable Power Unit
Weight (dry)............................................. 48 kg (105 lb)
(wet) ............................................ 57 kg (125 lb)
Length ....................................................... 76 cm (30 in)
Width ......................................................... 43 cm (17 in)
Height........................................................ 64 cm (25 in)
Fuel Capacity .......................................... 3.6 l (0.95 gal)
Engine Oil Capacity................................... 0.6 l (0.63 qt)
Hydraulic Oil Capacity............................. 6.9 l (1.83 gal)
Rated Flow ........................................... 19 l/min (5 gpm)
Operating Pressure (max.)................ 117 bar (1700 psi)
Type of Hydraulic System ........................... Open-center
Pressure Port (3/8" NPT) .................HTMA male coupler
Return Port (3/8" NPT)..................HTMA female coupler
Filtration ..........................................10 micron (nominal)
Honda Air-cooled Gasoline Engine Model GX200
Horsepower (maximum)....................6.5 hp @ 3600 rpm
Torque (maximum).......13.2 Nm (9.76 ft-lb) @ 2500 rpm
Hydraulic Schematic
Recommended Hydraulic Fluids
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
TYPICAL
TOOL
PRESSURE
PORT (P)
RETURN
PORT (T)
RETURN
PORT (T)
PRESSURE
PORT (P)
CONTROL
VALVE
RELIEF
VALVE
138 bar
(2000 psi)
OIL
COOLER
FILTER
(10 micron)
ENGINE
PUMP
POWER
UNIT

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Hose Connections
Connecting Hoses
1. Stop the power unit hydraulic flow.
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 buildup inside the
tool.
3. Connect the pressure (supply) hose from the power
unit pressure port to the tool pressure port (P).
Disconnecting Hoses
1. Stop the power unit hydraulic flow.
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 buildup 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.
Do not disconnect tool, hoses or fittings while
the power unit is running or if the hydraulic fluid
is hot. Hot hydraulic fluid can cause serious burns.
Failure to observe this warning can result in severe
injury.

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Operation
Fuel is flammable and explosive.
• Stop engine before filling fuel tank.
• Do not fill fuel tank when engine
is hot.
• Do not fill fuel tank near an open
flame, sparks, or when smoking.
Failure to observe this warning will
result in severe injury or death.
Do not run power unit engine in a
confined area.
Engine exhaust fumes are toxic.
If inhaled, exhaust fumes can cause
injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Do not disconnect tool, hoses or fittings while the
power source is running or if the hydraulic fluid is
hot. Hot hydraulic fluid can cause serious burns.
Skin injection hazard:
Oil under pressure easily punctures
skin, causing serious injury, gan-
grene, or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Depressurize the hydraulic system
before servicing or disconnecting
hoses.
Wear hearing protection when using
this tool.
Long-term exposure to high noise
levels can result in hearing loss.
Do not let power unit engine run unattended.
Monitor the engine so that it can be shut down
immediately in case of a malfunction.
Failure to observe this warning can result in
severe injury or death.
Engine, exhaust system, and other
components will be hot during and
after operation. Use care when
working around the power unit. Hot
surfaces can cause serious burns.
• Do not operate power unit without
safety guards in place.
• Keep all parts of the body and
loose clothing away from the
engine fan.

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Pre-Start
1. Check engine oil level. Running the engine with a
low oil level can cause engine damage. The oil alert
system will automatically stop the engine before the
engine oil level falls below safe limits. However, to
avoid the inconvenience of an unexpected shut-
down, always check the engine oil level before
startup.
Refer to the Engine Owner’s Manual for correct oil
type and checking instructions.
2. Check fuel level. Refer to the Engine Owner’s
Manual for fuel recommendations.
3. Check hydraulic reservoir oil level. Fill to full level
as shown on hydraulic fluid level decal. Refer to
“Recommended Hydraulic Fluids” for correct
hydraulic fluid.
4. Check the air filter. A dirty air filter will restrict air flow
to the carburetor, reducing engine performance.
5. Verify that all current maintenance has been per-
formed on the power unit. Refer to the “Maintenance”
section.
Starting the Power Unit
1. Move the flow ON/OFF lever to the OFF position.
2. Move the fuel valve lever to the ON position.
Operation (cont’d)
3. To start a cold engine, move the choke lever to the
CLOSED position.
To restart a warm engine, leave the choke lever in
the OPEN position.
4. Move the throttle lever away from the SLOW posi-
tion, about 1/3 of the way to the FAST position.
5. Turn the engine switch to the ON position.
6. Pull the recoil starter grip lightly until you feel resis-
tance, then pull briskly. Return the starter grip gently.
7. If the choke lever has been moved to the CLOSED
position to start the engine, gradually move it
towards the OPEN position as the engine warms up.
8. Move flow ON/OFF valve to the ON position.
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 hydraulic
reservoir fluid to an efficient operating temperature.
Stopping the Engine
1. Move the flow ON/OFF lever to the OFF position.
Idle the power unit engine for a few moments.
2. Turn the engine switch to the OFF position.
3. Turn the fuel valve lever to the OFF position.
4. Disconnect the tool hoses from the power unit.
Refer to “Hose Connections.”
Position the power unit on firm level ground.
FUELVALVE
LEVER
ON
ON
CHOKE LEVER
OPEN
CLOSE
ON
THROTTLE LEVER
SLOW
ON

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
F07 Portable Power Unit
Maintenance
Depressurizing Hydraulic System
Hydraulic system must be depressurized when perform-
ing maintenance or repair on the power unit hydraulic
system. Depressurizing the hydraulic system also makes
tool hose connections/disconnections easier.
1. Stop power unit engine.
2. Move flow ON/OFF lever to the ON position.
System will be depressurized.
3. Before restarting power unit engine, move flow
ON/OFF lever to the OFF position.
Fuel is flammable and explosive.
• Stop engine before filling fuel tank.
• Do not fill fuel tank when engine
is hot.
• Do not fill fuel tank near an open
flame, sparks, or when smoking.
Failure to observe this warning will
result in severe injury or death.
Skin injection hazard:
Oil under pressure easily punctures
skin, causing serious injury, gan-
grene, or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Depressurize the hydraulic system
before servicing or disconnecting
hoses. Do not run 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 source is running or if the hydraulic fluid is
hot. Hot hydraulic fluid can cause serious burns.
• Inspect the hydraulic hoses and couplings every
operating day. Repair or replace if leakage, crack-
ing, wear, or damage is evident. Damaged hoses
or couplers can fail, resulting in injury or property
damage.
• Use this power source for manufacturer’s intended
purpose only. Use other than that which is
described in this manual can result in injury or
property damage.
• Make sure that all bystanders are clear of the work
area when handling, starting, and operating the
power unit. Nearby personnel can be injured by
flying parts in the event of a tool malfunction.