Fairmont 48200 User manual

SERVICE MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

48200, 48520, and 48525

Pruners

Serial Codes FNY, FPK, FPL, FRJ, FRK, and FRL

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Table of Contents

Safety .............................................................................2

Purpose of this Manual ..................................................2

Other Publications..........................................................2

Important Safety Information......................................3–4

Service .......................................................................5–7

Troubleshooting .......................................................7–10

Disassembly...........................................................11–12

Inspection.....................................................................12

Assembly................................................................13–15

Illustrations and Parts Lists ....................................16–25

Model 48200 (Serial Code FRJ) .........................16–17

Model 48520 (Serial Code FRK) and

Model 48525 (Serial Code FRL).........................18–19

Model 48200 (Serial Code FNY) ........................20–21

Model 48520 (Serial Code FPK).........................22–23

Model 48525 (Serial Code FPL) .........................24–25

KEEPTHIS MANUAL

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.

Super Sleeve is a trademark of Greenlee Textron.

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 of this Manual

This manual is intended to familiarize all personnel with

the safe service procedures for the following Fairmont

tools:

48200 Open/Closed-Center Hydraulic Pruner

Serial Codes FRJ and FNY

48520 Open-Center Hydraulic Pruner

Serial Codes FRK and FPK

48525 Closed-Center Hydraulic Pruner

Serial Codes FRL and FPL

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge.

Other Publications

Operation Manual: Publication 999 3033.1

Specifications and Parts:

48200 (Serial Code FRJ): Publication 999 3034.0

48520 (Serial Code FRK): Publication 999 3035.8

48525 (Serial Code FRL): Publication 999 3035.8

SAE Standard J1273 (Hose and Hose Assemblies):

Publication 999 3032.3

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

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

preventing 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. Refer also to the

following manuals, which are listed

under “Other Publications”:

• Operation Manual

• Specifications and Parts

Failure to observe this warning can

result in severe injury or death.

Electrical shock hazard:

•

When using this tool near energized

electrical lines, use only certified

nonconductive hoses and proper

personal protective equipment.

• Keep fiberglass extension clean

and dry when working around

energized electrical lines.

Accumulated grease and dirt

reduce insulating properties of tool.

Failure to observe these warnings

can result in severe injury or death.

Skin injection hazard:

Oil under pressure easily punctures

skin, causing serious injury,

gangrene, 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.

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.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replace

when necessary.

• Keep all parts of the body away from the cutter

head when the tool is connected to a power

source.

• Do not dress the blade or inspect, adjust, or clean

tool when it is connected to a power source.

Accidental start-up can result in serious injury.

• Inspect the blade every operating day. Remove

and destroy the blade if cracks, chips, or gouges

are evident. A damaged blade can break and

strike nearby personnel.

• Maintain a firm grip on tool, using both hands at

all times. Serious injury can result if an operator

does not control the tool.

• Do not lock the trigger in the Power-ON position.

Operator cannot stop tool when trigger is locked.

• Wear protective gloves when handling,

sharpening, or adjusting the blade. The blade can

cut even when stationary.

Failure to observe these warnings can result in

severe injury or death.

Do not exceed the maximum hydraulic flow,

pressure relief, or back pressure listed in the

Specifications and Parts manual.

Failure to observe this warning can result in severe

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.

Do not reverse hydraulic flow. Operation with

hydraulic flow reversed can cause tool malfunction.

Connect the pressure (supply) hose and tank

(return) hose to the proper ports.

Failure to observe this warning can result in severe

injury or death.

• Inspect 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.

• Make sure all bystanders are clear of the work

area when operating the tool. Nearby personnel

can be injured by falling debris.

Failure to observe these precautions can result in

injury.

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.

Procedure for connecting or disconnecting hydraulic

hoses, fittings, or components:

1. Move the flow lever on the hydraulic power

source to the off position.

2. Stop the hydraulic power source.

3. Follow the sequence under “Hose Connections”

in the Operation Manual to prevent pressure

buildup. In case some pressure has built up,

loosen hoses, fittings, or components slowly.

Emergency stop/power failure procedure:

1. Release the trigger.

2. Shut off the hydraulic power source.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Service

The service life of the tool will be maximized by proper

care and maintenance. The maintenance schedule that

follows is recommended.

Maintenance Schedule

Daily

1. Wipe all tool surfaces clean, especially the fiberglass

extension, of grease, dirt and foreign material. If the

fiberglass extension cannot be wiped clean, use any

approved fiberglass cleaning products.

Do not use solvents or gasoline to clean the

fiberglass extension.

2. Inspect the cutter unit. Check for wear at the pivoting

and sliding surfaces. Repair blades with nicks or

gouges with a very fine file and a pocket whetstone.

Remove and destroy any cutter blade with

severe cracks, chips, or gouges.

3. Lubricate the pivoting and sliding surfaces several

times every operating day with 20W or 30W oil.

Apply a heavy coating to these surfaces before

storing.

4. Several times a day the blade and hook must be

dressed with a pocket whetstone. This keeps the

cutting edge from rolling and chipping.

5. Make sure the extension tube connector nut and

the cutter mounting bracket bolts are tightened

securely.

6. Inspect hydraulic system hoses and fittings for signs

of leaks, cracks, wear, or damage.

7. To prevent contamination, always install dust caps

over couplers when tool is disconnected.

Monthly

Perform a thorough inspection of the hydraulic hoses

and fittings as described in publication 999 3032.3,

SAE J1273 (Hose and Hose Assemblies).

Lubrication

Lubricate the indicated pivoting and sliding surfaces

several times every operating day with 20W or 30W oil.

Apply a heavy coating to these surfaces before storing.

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 dress the blade or inspect, adjust, or clean

tool when it is connected to a power source.

Accidental start-up can result in serious injury.

• Inspect the blade every operating day. Remove

and destroy the blade if cracks, chips, or gouges

are evident. A damaged blade can break and

strike nearby personnel.

Failure to observe these warnings can result in

severe injury or death.

Inspect hydraulic hoses and couplings every

operating day. Repair or replace if leakage, crack-

ing, wear or damage is evident. Damaged hoses or

couplings can fail resulting in injury or property

damage.

Failure to observe this precaution can result in

injury.

oil

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Service (cont’d)

Blade and Hook Maintenance Tension Adjustment

The tension adjustment should be checked after about

one hour of use on a new cutter. A wearing-in process

takes place during this time and the cutter pivot nut may

need tightening.

The cutter hook and cutter blade must fit together

snugly. If they are too tight, the cutter will not perform

properly. If the fit is too loose, the tool will not cut

cleanly, and damage to the tool may occur.

1. Disconnect the tool from the power source.

2. Remove hex nuts (1), shoulder bolts (2), and guide

roller (3).

3. Remove the #10 cap screw and lock washer (4, 5).

4. Remove the cutter bolt lock (6).

5. Tighten shoulder bolt (7) to a very heavy drag when

the blade is opened or closed. This drag can be

tested manually without hydraulic power. When

heavy drag has been set, loosen shoulder bolt (7)

one-quarter (1/4) turn.

6. Using one wrench on the shoulder bolt (7) and a

second wrench on the nut, tighten the nut. The

tension is correct when a moderate drag is felt when

moving the cutter blade by hand.

Dressing the Cutter Blade and Hook

A buildup of metal, referred to as a wire edge, will form

on the edge of a new blade as it seats across the face of

the hook. This wire edge must be removed several

times, until the blade seats itself to the hook.

Rough and dull edges may form on the cutter blade and

the cutter hook from normal usage. Both components

must be dressed with a pocket whetstone several times

each operating day. This keeps the cutting edges sharp

and prevents them from rolling and chipping.

1. Stop the power source.

2. Use the provided pocket whetstone (L046108) to

remove the wire edge by rubbing the whetstone

back and forth on the blade and hook until the

surface irregularities are smooth and the blade

edge is sharp.

Sharpening the Cutter Blade

When a blade has acquired deep nicks and gouges or

has become too dull to be sharpened with a whetstone,

remove the cutter blade and sharpen it with a fine metal-

cutting file.

1. Disconnect the tool from the power source.

2. Remove the cutter blade from the tool. Refer to

“Cutter Head” in the “Disassembly” section of this

manual.

3. Sharpen the blade with a fine metal-cutting file.

Note: When sharpening with a file, it is important to

maintain the original shape and contour of the blade.

An equal amount of material must be removed from

all parts of the blade. Do not sharpen the blade to a

thin, razor edge. This reduces the strength and

shortens the service life of the blade. Do not overuse

the file. It is not advisable to remove large amounts

of metal from the blade.

4. After the contoured side of the blade has been

sharpened, turn it over so that the flat side is facing

up. Dress the blade with a whetstone just enough to

smooth away any nicks and irregular sharp edges

that may have formed during sharpening of the

contoured side of the blade.

5. Remove any nicks or rough edges on the hook with

a pocket whetstone. The inner curve of the hook

should have a beveled cutting edge. This can be

achieved with the whetstone also. Failure to do this

can ruin a new or sharpened blade.

Do not dress the blade or inspect, adjust or clean

tool when it is connected to a power source.

Accidental start-up can result in serious injury.

1, 2 7

4, 5

1, 2, 3

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Service (cont’d)

Closure Adjustment

Proper closure adjustment of the cutter is set at the

factory and should not be readjusted until repeated

sharpening of the blade or installation of a new blade

requires it. When open, the flat edge of cutter blade

should be flush with an imaginary line between the two

protrusions on the connector link as shown below.

Flat Edge of

Cutter Blade

Imaginary Line

When closed, the blade should cover 5 mm (3/16") on

the face of the cutter hook.

If the blade is improperly adjusted, blade closure

must be readjusted while the blade is in the fully

open position.

1. Stop the power source and disconnect the tool from

the power source.

2. Loosen jam nut on lower end of outer extension

tube.

• If blade overlaps less than 5 mm (3/16"), or if

blade opening is too great, thread the outer

extension tube further onto the actuator end.

• If blade overlaps more than 5 mm (3/16"), or if

blade is not opening far enough, unscrew the

outer extension tube from the actuator end.

3.Tighten the nut.

Connect the tool to power source and actuate

several times. Blade action should be smooth and

uniform from fully-open position to fully-closed

position [5 mm (3/16") beyond the hook edge]. There

should be no sloppiness in the cutter unit linkage.

Repeat the above procedure until blade closure

is correct.

Troubleshooting

Before You Begin

1. Tool must be connected to the correct power source

system. Refer to the Specifications and Parts

manual for the type of hydraulic system required.

Verify the power source hydraulic system.

2. Verify that the pressure and return hoses are

connected properly to the tool and power source

ports.

3. Power source reservoir must be filled to FULL mark

with hydraulic fluid.

4. Start the power source. All power source shut-off

devices must be engaged or opened (clutch-

engaged, separate ON/OFF valves open, etc.).

5. After verifying all of the above, check the tool to see

if it operates.

If the tool does not operate, it will be necessary

to pinpoint the tool, hose, or power source as the

problem area. The following steps will help to

determine the problem area.

Determine the Problem Area

1. Check the power source and pressure if the proper

gauges and tools are available. If these items are

not available, proceed to the next step.

2. Stop the power source.

3. Disconnect the tool from the hoses and power

source.

4. Connect a known working tool to the hoses and

power source. Refer to the tool’s operator’s manual

for correct hookup procedure. Start the power

source.

• If the known working tool operates, the problem is

in the disconnected tool. Refer to the Trouble-

shooting charts in this manual.

• If the known working tool does not operate, the

problem is likely to be in the hoses or the power

source. Proceed to next step.

5. Stop the power source.

6. Disconnect the existing hoses from the known

working tool and power source.

7. Connect a different set of hoses to the known

operating tool and power source. Start the power

source.

• If the known working tool operates with the

different set of hoses, the problem is in the

disconnected hoses.

• If the known working tool does not operate, the

problem is in the power source. Refer to your

power source operator’s manual for

troubleshooting.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Troubleshooting (cont’d)

Probable Cause

Problem Probable Remedy

Tool inoperative. Tool connected to improper power Verify that the power source meets

source hydraulic system. the specifications. Refer to the

Specifications and Parts manual.

No hydraulic fluid in system or fluid Check fluid level. Fill to FULL mark.

level low. Check system for leaks.

Incorrect fluid viscosity. Use fluid viscosity recommended.

Refer to the Specifications and

Parts manual.

Tool components loose. Tighten component hardware.

Dirt, contaminants, etc., in tool Disassemble tool and clean

components. components.

Tool components worn or damaged. Disassemble tool. Replace worn or

damaged components.

Tool operates erratically. Hydraulic fluid cold. Viscosity of oil may be too high at start

of tool operation. Allow oil to warm to

operating temperature. Actuating tool

intermittently will reduce time required

to warm oil to an efficient operating

temperature.

Air in hydraulic system. Check pump suction line for damage

or loose clamps. Tighten clamps or

replace components if necessary.

Fill reservoir.

Tool components sticking or binding. Check for dirt or gummy deposits.

Clean components. Check for worn or

damaged components. Replace

components.

Dirt, contaminants, etc., in tool Disassemble tool. Clean components.

components.

Tool operates slowly. Power source components not Refer to power source operator’s

adjusted correctly. manual for recommended speed, flow,

and pressure settings.

Hydraulic fluid cold. Viscosity of oil may be too high at start

of tool operation. Allow oil to warm to

operating temperature. Actuating tool

intermittently will reduce time required

to warm oil to an efficient operating

temperature.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Troubleshooting (cont’d)

Tool operates slowly. (cont’d) Hydraulic fluid level low. Check fluid level. Fill to FULL mark.

Check system for leaks.

Hydraulic fluid viscosity too heavy. Use fluid viscosity recommended.

Refer to the Specifications and

Parts manual.

Tool components loose. Tighten component hardware.

Dirt, contaminants, etc., in tool Disassemble tool. Clean components.

components.

Tool components worn or damaged. Disassemble tool. Replace worn or

damaged components.

Tool leaks hydraulic fluid. Tool components loose. Tighten component hardware.

Tool components worn or damaged. Disassemble tool. Replace worn or

damaged components.

Tool feels hot. Hydraulic fluid level low. Check fluid level. Fill to FULL mark.

Check system for leaks.

Hydraulic fluid viscosity exceeds Use fluid viscosity recommended.

specifications. Refer to the Specifications and

Parts manual.

Hydraulic fluid dirty. Drain reservoir, flush and fill with clean

fluid. Change filter.

Tool control valve stuck in partial Free spool so it returns to neutral

power-ON position. position.

Power source components not adjusted Refer to power source operator’s

correctly. manual for recommended speed,

flow, and pressure settings.

Dirt, contaminants, etc., in tool Disassemble tool. Clean components.

components.

Worn or damaged O-rings or gaskets. Replace worn or damaged O-rings

or gaskets.

Tool components worn or damaged. Disassemble tool. Replace worn or

damaged components.

Probable Cause

Problem Probable Remedy

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Troubleshooting (cont’d)

Tool control valve sticks or Check for dirt or gummy deposits. Clean components.

works hard.

Misalignment or binding of control Correct alignment. Lubricate linkage

linkage. joints. Replace damaged components.

Valve components worn or damaged. Disassemble valve and replace worn

or damaged components.

Tool operates backwards. Hydraulic flow reversed to tool. Reverse flow to tool. Check for

valve in system that has reversed flow.

Check hoses for proper flow.

Hydraulic pressure and return lines Disconnect hoses. Reverse couplers.

connected to opposite tool ports. Reconnect hoses to proper tool ports.

Tool components assembled incorrectly.

Disassemble tool. Reassemble

correctly.

Tool operates, but blade does Cutter blade loose. Tighten cutter blade nut and bolt

not cut. securely. Refer to “Tension Adjustment”

in the “Service” section of this manual.

Cutter blade not closing properly. Readjust blade closure. Refer to

“Closure Adjustment” in the “Service”

section of this manual.

Cutter blade dull. Remove blade and sharpen, or install

a sharp, new blade.

Extension assembly loose. Loose extension connector nut. Tighten extension connector nut.

Probable Cause

Problem Probable Remedy

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Disassembly

Complete disassembly of the tool is not recommended.

If a complete overhaul is necessary, return the tool to

your nearest authorized Fairmont distributor or to

Fairmont.

The disassembly procedure is divided into sections of

the tool. Disassemble only the section(s) necessary to

complete the repair.

Disassemble the tool on a flat, clean surface. Take care

not to lose or damage any parts that may fall free during

disassembly.

Inspect all parts as they are disassembled and mating

parts in tool that are not removed for signs of damage,

wear, cracks, etc. Replace any parts which appear to be

damaged.

When removing O-rings which must slide over sharp

surfaces, be careful not to damage the O-rings. Use a

rolling motion, and apply hydraulic fluid to ease removal

of O-rings if necessary.

Cutter Head

1. Remove hex nut (51), shoulder bolt (49), and guide

roller (50).

2. Remove hex nut (51) and shoulder bolt (63).

Remove connector link (48).

3. Remove socket head cap screw (60) and lock

washer (59). Remove bolt lock (56).

4. Remove elastic stop nut (58), hex head cap screw

(57), and shim (54). Remove shear blade (53).

5. Remove hex head cap screws (62), lock washers

(61), cutter hook (52), and cutter brace (55).

6. Loosen connector nut and unscrew cutter mount

(47) from extension tube (45). Remove O-ring (46).

Outer Extension Tube and Inner Pull Rod

1. Loosen jam nut (68) and remove outer extension

tube (45) from upper end actuator (27).

2. Remove retainer sleeve (44) and pin (43) from lower

extension rod end to disconnect the inner pull rod

(42).

Skin injection hazard:

Oil under pressure easily punctures

skin, causing serious injury,

gangrene, 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.

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.

Procedure for connecting or disconnecting hydraulic

hoses, fittings, or components:

1. Move the flow lever on the hydraulic power

source to the off position.

2. Stop the hydraulic power source.

3. Follow the sequence under “Hose Connections”

in the Operation Manual to prevent pressure

buildup. In case some pressure has built up,

loosen hoses, fittings, or components slowly.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Ram and Piston Actuator

1. Remove jam nut (68) from upper end actuator (27).

2. Use a strap wrench to unscrew cylinder (19) from

upper end (27). The piston and rod assembly (20)

will remain in cylinder (19) when unscrewing and

removing from upper end (27).

3. Remove internal retaining ring (32), seal retainer

(31), rod seal (30), rod seal support (29), felt

breather filter (28), and O-ring (15) from upper end

(27).

4. Remove piston and rod assembly (20) with seal

(21, 22), etc., from cylinder (19).

5. Remove the seal (21, 22) from piston and rod

assembly (20).

6. Remove the internal retaining ring (18) from inside of

piston and rod assembly (20). Remove seal body

(26) from piston and rod assembly and O-rings

(24, 25) from seal body (26).

7. Remove O-ring (15) from handle (1). Remove

internal retaining ring (18) which secures return tube

assembly (17) into the handle (1). Remove return

tube assembly. Remove O-ring (16) from return tube

assembly.

8. Remove the round slotted head machine screws

(14) and internal tooth lock washers (13). Remove

trigger guard (12).

9. Remove the external retaining rings (11) and slide

trigger pivot pin (10) out of handle (1). Remove

trigger (9).

10. Remove retaining ring (6) from valve handle (1)

opposite trigger side. Also remove washer (8) and

spring (7). Remove retaining ring (6) from trigger

side, washer (5). Remove spool (3).

SUPER SLEEVE™ (on 48200 Model Only)

1. Remove retaining rings (33) from cylinder (19).

2. Remove SUPER SLEEVE (35) from cylinder (19).

3. Remove ball (37), spring (38), pin (39), and plug (40)

from sleeve (35). Remove O-ring (36) from sleeve

(35).

Inspection

1. Cutter Blade (53): Cutting surface must be smooth

and free of grooves, nicks, or gouges. If blade has

minor grooves, nicks, or gouges, remove them and

sharpen blade with a file or the pocket whetstone

provided with tool. If blade has severe damage,

replace the blade. Both holes in blade are pivot

holes. If either hole is out-of-round, replace blade.

2. Cutter Hook (52): The surface of the cutter hook

which mates with the cutter blade (53) must be

smooth and free of nicks or gouges. If hook has

minor blemishes, remove them with a file. The inner

radius of hook’s cutting surface must be beveled

slightly with a pocket whetstone provided with tool.

3. Valve Spool (3): All surfaces must be smooth and

free of grooves, nicks, or scratches. If it has grooves,

nicks, or scratches, replace the spool.

4. Piston and Rod Assembly (20): All surfaces must

be smooth and free of grooves, nicks, or scratches.

If either component has grooves, nicks, or scratches,

replace the component.

5. Cylinder (19): All inner surfaces must be smooth

and free of grooves, nicks, or scratches. If either

component has severe grooves, nicks, or scratches,

replace the component.

6. Inner Extension Assembly (42): All components

must be straight and free of damage. Replace if bent

or damaged.

7. O-Rings and Seals: Always replace O-rings and

seals in components that have been disassembled

with new O-rings and seals during assembly. A

packing kit is available that includes all O-rings and

seals.

8. Felt Breather Filter (28): Always replace the felt

breather filter with a new breather filter during

assembly.

Disassembly (cont’d)

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Assembly

When assembling parts, refer to the Illustrations and

Parts Lists for correct orientation and placement of parts.

Clean all parts with solvent and then dry thoroughly. Do

not expose O-rings or other packing components to

solvent for long periods of time.

Inspect all parts as they are assembled for signs of

damage, wear, cracks, etc. Do not install any parts

which appear to be damaged.

Apply hydraulic fluid or O-ring lubricant to all O-rings and

all metal surfaces which O-rings must slide over. When

installing an O-ring over a sharp edge, use a rolling

action to avoid damage to the O-ring.

Wherever assembled parts cause metal-to-metal

contact, coat the surfaces with hydraulic fluid or O-ring

lubricant.

Handle and Valve

1. Install O-ring (2), spool (3), spring (7), washer (8),

and retaining ring (6) to upper end of insulated valve

body handle (1).

2. Install O-ring (4), washer (5), and retaining ring (6)

on lower end of valve body handle (1).

3. Position trigger (9) on valve handle (1), aligning

holes in each component. Install trigger pivot pin

(10) and secure in place with two external retaining

rings (11).

4. Position trigger guard (12) on handle (1) and secure

with round slotted head cap screws (14) and internal

tooth lock washers (13). On later model pruners, use

two button-head screws to secure one end guard to

the handle.

5. Install O-ring (15) onto handle (1).

6. Install O-ring (16) on return tube assembly (17).

Install return tube assembly in the handle and

secure in place with internal retaining ring (18).

7. Install felt breather filter (28), rod seal support (29),

rod seal (30), and seal retainer (31) into upper end

(27). Secure components in place with internal

retaining ring (32). Install O-ring (15) on upper end

(28).

8. Install ball (37), spring (38), pin (39), plug (40), and

O-ring (36) in sleeve (35). Install O-rings (34) on

cylinder (19) on 48200 Model only.

9. Install sleeve (35) and retaining rings (33) on

cylinder (19) on 48200 Model only.

10. Clamp upper end (27) in a vise and thread cylinder

(19) onto upper end (27). Tighten with a strap

wrench.

11. Use steps 12 through 22 to install piston seal

(21, 22) on piston and rod assembly (20).

12. Place O-ring on piston (21).

13. Place the piston seal (22) in the groove as shown.

14. Bend the seal over as shown. This will help hold the

seal in the groove when installing.

15. Remove the seal from the groove.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Assembly (cont’d)

Handle and Valve (cont’d)

16. Place the bent section of the seal in the groove on

the piston as shown.

17. Install seal by using a blunt tool with no sharp

corners or edges, such as the shank portion of an

O-ring installation tool.

18. Stretch the seal over the outside diameter of the

piston until it is in the groove.

Note: Overstretching will break the seal.

19. The piston seal will be stretched out of shape when

installed in the groove. Place the piston with the seal

installed on a clean, flat surface and roll it back and

forth to reshape the seal.

20. Use a sizing tube fixture to compress and form the

seal back to the original shape. The dimensions for

this fixture are as shown. The tapered surface must

be smooth—approximately a 16 micro finish.

1.81 DIA

1.00

1.690 REF

21. Lubricate the tapered fixture end with oil or grease.

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Outer Extension Tube and Inner Pull Rod

1. Install pull rod (42) to piston assembly (20) with pin

(43) and secure with sleeve (44).

2. Slide outer tube assembly (45) over inner pull rod

(42) and screw onto upper actuator end (27). Thread

the jam nut (68) onto the outer tube (45). Refer to

“Closure Adjustment” in the “Service” section of this

manual.

Cutter Head

1. Screw cutter mount (47) in end of outer extension

tube (45).

2. Fasten cutter hook (52) and cutter brace (55) to

opposing sides of cutter mount (47) with hex head

cap screws (62) and lock washers (61).

3. Position cutter blade (53) and washer (54) between

cutter hook (52) and cutter brace (55). Secure cutter

blade (53) with hex head shoulder bolt (57) and hex

nut (58).

Note: The cutter hook (52) and cutter blade (53)

must fit together snugly. If they are too tight, the

cutter will not perform properly. If the fit is too loose,

the tool will not cut cleanly and damage to the tool

may occur. Wood may jam in between the hook and

cutter blade, springing them apart and permanently

bending either one.

4. Install bolt lock (56) on cutter brace (55) and secure

with socket head cap screw (60) and lock washer

(59).

Note: If slot in bolt lock (56) does not align with hole

in cutter brace (55), turn bolt lock over. This will

allow bolt lock to be positioned so that slot will line

up with matching hole in the cutter brace, allowing

socket head cap screw (60) to secure it in place.

Handle and Valve (cont’d)

22. Place the piston with the seal in the tapered end of

the fixture and push it down and completely through.

23. Install O-rings (24, 25) on seal body (26). Install seal

body and O-rings (24, 25, 26) in bottom end

of piston and rod assembly (20) and secure into

place with internal retaining ring (18).

24. Slide piston and rod assembly (20) in cylinder and

upper end assembly.

25. Screw handle assembly (1) onto cylinder (19). Seal

retainer (41) into end of the upper end (27). Thread

nut (68) onto upper end (27) approximately 25 mm

(1").

Assembly (cont’d)

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Illustration—Model 48200 (Serial Code FRJ)

12 69

27 66

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Parts List—Model 48200 (Serial Code FRJ)

1 48813 48813 Handle ................................................. 1

2* 41488 F015255 O-ring, .562 x .750 x .093–68 .............. 1

3 48852 48852 Spool ................................................... 1

4* 41489 F015257 O-ring, .437 x .562 x .062–68 .............. 1

5 43401 170236 Washer ................................................ 1

6 41712 F018511 Retaining ring, .750 ............................. 2

7 40087 094826 Spring, compression,

.325 x .427 x 1.27 ................................ 1

8 41095 138312 Cap ...................................................... 1

9 42576 L060106 Trigger ................................................. 1

10 42547 L060058 Trigger pivot ........................................ 1

11 42827 L085019 Retaining ring ...................................... 2

12 48817 48817 Trigger guard ....................................... 1

13 42812 L084015 Washer, lock, #10, internal tooth ......... 1

14 41677 F018077 Screw, machine, #10–32 x .375,

round head .......................................... 1

15* 42744 L080035 O-ring, 1.625 x 1.75 x .062 .................. 2

16* 43355 F021753 O-ring, .375 x .500 x .062–70 .............. 1

17 42537 L060043 Tube assembly, return......................... 1

18 41648 F017595 Retaining ring, .750 ............................. 2

19 48203 48203 Cylinder ............................................... 1

20 48199 48199 Piston assembly .................................. 1

21* 48204 48204 O-ring, 1.171 x 1.449 x .139–70 .......... 1

22* 48205 48205 Seal, piston.......................................... 1

24* 41402 F012946 O-ring, .562 x .687 x .062–70 .............. 1

25* 54563 905 4563.0 O-ring, .362 x .568 x .103–70 .............. 1

26 42542 L060052 Body, seal............................................ 1

27 43402 170252 Actuator upper end.............................. 1

28* 42866 L089020 Breather filter ....................................... 1

29* 42686 L060607 Support, rod seal ................................. 1

30* 42760 L081004 Seal, rod .............................................. 1

31* 42708 L060729 Retainer, seal ...................................... 1

32 42841 L085061 Retaining ring ...................................... 1

33 48202 48202 Retaining ring, 1.963 x 2.279 x .031.... 2

34* 43170 F016713 O-ring, 1.875 x 2.062 x .093–90 .......... 2

35 48201 48201 Super Sleeve ....................................... 1

36* 41618 F016876 O-ring, 2.062 x 2.25 x .093–70 ............ 1

37 41295 F008541 Ball, .250, stainless steel ..................... 2

38 48228 48228 Spring .................................................. 2

39 48229 48229 Pin, dowel, .187 x .375 ........................ 2

40 F018357 Pipe plug, 1/8" NPTF........................... 2

41 42506 L060007 Bushing ............................................... 1

42 48183 48183 Extension rod assembly ...................... 1

43 42405 L055153 Pin, .218 x .562 ................................... 1

44 42442 L055279 Retainer sleeve ................................... 1

45 48167 48167 Tube .................................................... 1

46* 41335 F010894 O-ring, .562 x .750 x .093–70 .............. 1

47 48172 48172 Mount assembly .................................. 1

48 42406 L055154 Connecting link .................................... 1

49 41149 139577 Bolt, 5/16–24 x 1.125 .......................... 1

50 42401 L055060 Roller ................................................... 1

51 41367 F011686 Nut, hex, 5/16–24, lock........................ 2

52 48197 48197 Hook .................................................... 1

53 42508 L060009 Blade ................................................... 1

54 40001 062593 Washer, flat, .484 x 1.50 x .010,

brass.................................................... 1

55 42510 L060011 Brace ................................................... 1

56 42502 L060003 Cutter bolt lock .................................... 1

57 40078 093149K1 Bolt, hex, 7/16–20 x 1.09..................... 1

58 41555 F015618 Nut, hex, 7/16–20, lock........................ 1

59 42807 L084001 Washer, #10, lock................................ 1

60 42785 L083028 Screw, cap, #10–32 x .250,

socket head ......................................... 1

61 42808 L084005 Washer, lock, .250............................... 2

62 42781 L083013 Screw, cap, 1/4–28 x .750,

hex head, grade 8 ............................... 2

63 40080 093150K1 Bolt, hex, 5/16–24 x .940..................... 1

64 48243 48243 Decal ................................................... 1

65 48244 48244 Decal ................................................... 1

66 40580 128066 Decal ................................................... 1

67 41114 138663 Decal ................................................... 1

68 42551 L060062 Nut, jam ............................................... 1

69 43701 F021676 Screw, cap, #10–32 x .375,

socket button head .............................. 2

70 42952 F017347 Adapter, 3/8 NPTF to 9/16-18,

1.21 LG................................................ 1

71 41638 F017348 Adapter, 3/8 NPTF to 3/4-16,

1.28 LG................................................ 1

Repair Kit

* 48208 48208 Packing kit (includes items

marked with an asterisk) ..................... 1

UPC No.

Key 78-3310- Part No. Description Qty UPC No.

Key 78-3310- Part No. Description Qty

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Illustration—Model 48520 (Serial Code FRK) and Model 48525 (Serial Code FRL)

27 66

26a

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 19 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Parts List—Model 48520 (Serial Code FRK) and Model 48525 (Serial Code FRL)

UPC No.

Key 78-3310- Part No. Description Qty

1 48813 48813 Handle ................................................. 1

2* 41488 F015255 O-ring, .562 x .750 x .093–68 .............. 1

3 48852 48852 Spool ................................................... 1

4* 41489 F015257 O-ring, .437 x .562 x .062–68 .............. 1

5 43401 170236 Washer ................................................ 1

6 41712 F018511 Retaining ring, .750 ............................. 2

7 40087 094826 Spring, compression,

.325 x .427 x 1.27 ................................ 1

8 41095 138312 Cap ...................................................... 1

9 42576 L060106 Trigger ................................................. 1

10 42547 L060058 Trigger pivot ........................................ 1

11 42827 L085019 Retaining ring ...................................... 2

12 48817 48817 Trigger guard ....................................... 1

13 42812 L084015 Washer, lock, #10, internal tooth ......... 1

14 41677 F018077 Screw, machine, #10–32 x .375,

round head .......................................... 1

15* 42744 L080035 O-ring, 1.625 x 1.75 x .062 .................. 2

16* 43355 F021753 O-ring, .375 x .500 x .062–70 .............. 1

17 42537 L060043 Tube assembly, return......................... 1

18 41648 F017595 Retaining ring, .750 ............................. 2

19 42538 L060044 Cylinder ............................................... 1

20 48199 48199 Piston assembly .................................. 1

21* 48204 48204 O-ring, 1.171 x 1.449 x .139–70 .......... 1

22* 48205 48205 Seal, piston.......................................... 1

23 42534 L060038 Seal, bypass (Model 48520)................ 1

24* 41402 F012946 O-ring (Model 48525) ......................... 1

25* 54563 905 4563.0 O-ring (Model 48525) ......................... 1

26 42542 L060052 Body, seal (Model 48525) ................... 1

26a 43263 L060039 Body, seal (Model 48520) ................... 1