Greenlee Fairmont H4645 Guide

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 1724.6 REV 2 © 1996 Greenlee Textron Inc.
H4645/48600
RAIL CUT-OFF SAW
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. This device should only be
operated by qualified personnel.
10/96

Greenlee Textron Inc. / Subsidiary of Textron Inc. 2
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
OPERATION - H4645 Rail Cut-Off Saw
Safety Information................................................................................... 3-4
Description ..................................................................................................5
Identification ................................................................................................5
Specifications - Tool....................................................................................6
Specifications - Hydraulic Power Source................................................ 6-7
Recommended Hydraulic Fluids .................................................................7
Hoses and Fittings ......................................................................................8
Tool / Hose Connections.............................................................................8
Setup Instructions ................................................................................. 9-11
Operation Instructions...............................................................................12
SERVICE
Maintenance Schedule .............................................................................12
Troubleshooting .................................................................................. 13-16
Disassembly Procedure ...................................................................... 17-18
Inspection..................................................................................................18
Assembly Procedure ........................................................................... 18-19
PARTS
Exploded View ..........................................................................................20
H4645 Rail Cut-Off Saw Parts List ..................................................... 21-22
APPENDICES
Appendix A - SAE J1273 May 1986 ................................................... 23-24
Additional or replacement manuals may be obtained from your Greenlee Fairmont dealer. When tool is received,
complete the following record:
SERIAL NUMBER: ____________________________
DATE OF PURCHASE:_________________________
WHERE PURCHASED: ________________________
Always mention the tool’s serial number when ordering or writing about parts.
For convenience in ordering, parts are listed by part number, description and quantity. If in doubt as to part needed,
send a full description, sketch, or the part itself with the order. Assemblies are in CAPITAL letters, and include all
component parts listed directly below them and indented to the right. When assemblies can be used, order them
to save time assembling individual parts. Prior arrangements must be made before returning a tool for warranty
service.
To insure correct and prompt shipment of parts, always provide the following information when ordering:
1. Quantity of each part wanted 4. Serial Number of tool
2. Part number of item 5. Preferred method of shipment: by mail, UPS, or air freight
3. Description of part
Table of Contents

Greenlee Textron Inc. / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
SAVETHESE INSTRUCTIONS
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.
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.
Immediate hazards which, if not avoided, WILL result in
severe personal injury or death.
SAFETY
ALERT
SYMBOL
Safety is a critical factor in the design of Greenlee Fairmont equipment. The best program starts with a
safety-conscious operator. The information highlighted in this bulletin describes operating practices for the
benefit of the workers who will use our equipment in their daily jobs. Comments from users are appreciated.
A person who has not read and does not understand all
operating instructions is not qualified to operate this tool.
Failure to read and understand safety instructions may
result in injury or death.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 4
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
• The owner of this tool must be certain that all
users of this tool are adequately trained to safely
use this tool in compliance with appropriate
industrial codes or standards.
• Use all appropriate and applicable personal safety
equipment as required, such as: Safety shoes,
hard hat, safety glasses, face shield, aprons and
gloves, etc.
• Protect surroundings from sparks, swarf, and
flying particles. Sparks could ignite clothing,
grass, etc.
• Disconnect tool from power source before
changing or examining blade.
• Disconnect tool from power source before
disassembly, performing maintenance, and
makingadjustments.
• Do not disconnect tool, hydraulic components, lines
or fitting while hydraulic power source is running
and/or if hydraulic fluid is hot. Exposure to hot
hydraulic fluid can cause serious personal burns.
Failure to observe these warnings could result in
severe injury or death.
Always wear safety glasses when
operating this tool.
Failure to observe this warning may
result severe injury.
Skin Injection Hazard:
High pressure oil easily punctures
s kin 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
beforeservicing.
• Use this tool for the manufacturer’s intended
purpose only.
• Inspect hydraulic hoses and couplings every
operating day. Repair or replace if leakage,
cracking, wear, or damage is evident.
• Observe and follow all safety rules and regulations
for the job.
• Do not transport or store rail saw with the blade
mounted.
• Do not grind on the side of a cutting wheel.
• Follow the wheel manufacturer’s instructions for
storage of abrasive cutting wheels.
Failure to observe these precautions could result in
injury or property damage.
Note: Keep all decals clean and legible. Replace
decals when necessary with new decals
listed in Parts section of this manual.
• Do not use power head without rail clamp
assembly. Read and understand the proper
setup procedure for the rail clamp assembly.
• Use the rail cut-off saw for cutting rail only.
• Do not use the rail saw without the wheel guard.
• Use only 1/8"–5/32" thick, high-strength,
reinforced, abrasive cut-off wheels rated for at
least 3800 rpm meeting ANSI B7.1-1978 Class 10.
• Do not use an abrasive cutting wheel which has
cracks, chips, gouges, or evidence of damage
from handling or storage.
• Do not contact the cutting wheel when it is
rotating.
• Keep all parts of the body clear of moving parts of
the tool when connected to a power source or in
operation.
• Do not stand in the path of the cutting wheel.
• Do not place any part of the body over the rotating
cutting wheel.
• Make sure all bystanders are clear of the work
area when handling, starting and operating tool.
• Maintain a firm grip on tool, using both hands at
all times.
Failure to observe these warnings could result in
severe injury or death.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
The Greenlee Fairmont H4645 Rail Cut-Off Saw is used for cutting rail to facilitate track repair. The single lever
on the base clamp is provided to give quick, simple and accurate rail saw set up when clamping to the rail.
The directional spool and pivot arm permit cutting on both sides of the rail with a single setup. The outer and inner
blade flanges are keyed to allow the change in blade direction. The Greenlee Fairmont H4645 Rail Cut-Off Saw will
fit 85 lb. to 155 lb. rail.
Figure 1
Parts of the H4645 Rail Cut-Off Saw
Identification
1. Base 6. Hydraulic Motor
2. Supply (pressure) 7. Handle
3. Return 8. Clamp Screw
4. Trigger 9. Wing Nut
5. Reversing Spool 10. Arms
Description
8
4
7
6
5
7
3
2
1
9
10

Greenlee Textron Inc. / Subsidiary of Textron Inc. 6
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Height.......................................................................................................15-3/4 in.
Length (Maximum measurement of tool extended)........................................39 in.
Length(Powerhead).......................................................................................30 in.
Length (Extended Arm and Clamp Assembly) ............................................... 24 in.
Width ..............................................................................................................24 in.
Weight (Total)............................................................................................... 58 lbs.
Weight (Arm and Clamp Assembly) ............................................................. 31 lbs.
Weight(Powerhead) .................................................................................... 27 lbs.
Abrasive Cutting Wheel (Diameter)................................................................16 in.
Center Hole of Cutting Wheel
(Nominal) ...................................................................................................1 in.
Use only 1/8" – 5/32" thick, high-strength, reinforced, abrasive cut-off wheels
rated for at least 3800 rpm meeting ANSI B7.1-1978 class 10.
Specifications—Tool
Any hydraulic power source used with this tool must meet the following requirements:
Type of Hydraulic System .................................................................. Open-Center
Flow - Minimum............................................................................8 gpm (30.3 lpm)
Recommended ..................................................................9 gpm (34.1 lpm)
Maximum .........................................................................10 gpm (37.9 lpm)
OperatingPressure
Minimum ......................................................................................... 1000 psi
Maximum ........................................................................................ 2000 psi
Filtration ................................................................................. 10 Micron (Nominal)
Pressure ReliefSetting ...........................................................2000 psi (137.9 bar)
Back Pressure - *Maximum.........................................................200 psi (13.8 bar)
* 200 psi (13.8 bar) is the maximum agreed standard back pressure for the Hydraulic Tool Manufacturers Associa-
tion (HTMA). Greenlee Fairmont tools will operate satisfactorily at this standard.
1. Maximum hydraulic fluid temperature must not exceed 140°F (60°C) at the maximum expected ambient tempera-
ture. A sufficient oil cooling capacity is needed to limit the hydraulic fluid temperature.
2. Maximum hydraulic flow must not exceed 10 gpm (23 lpm). Install a flow meter in the return line to test the rate of
hydraulic flow in the system before working the tool.
3. Pressure relief valve must not exceed 2000 psi (137.9 bar) @10 gpm (23 lpm). The pressure relief valve must be
located in the supply circuit between the pump and tool to limit excessive hydraulic pressure to the tool.
Figure 2 shows a typical hydraulic power source being used with the tool.
Specifications—Hydraulic Power Source
• Power source flow must not exceed 10 gpm (37.9 lpm).
• Limit relief pressure to 2000 psi (137.9 bar).
Failure to observe these warnings could result in excessive cut-off speed
and over-pressurizing the hydraulic system causing severe injury to
operator or bystanders.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
Figure2
HydraulicSchematic
Specifications—Hydraulic Power Source (cont’d)
Recommended Hydraulic Fluids
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
Any non-detergent hydraulic fluid which meets the following specifications or HTMA specifications may be used.
FILTER
(10 MICRON)
COOLER
RELIEF
VALVE
2000 PSI
CONTROL
VALVE FLOW METER
T
PTOOL
RESERVOIR
PUMP
POWER SOURCE

Greenlee Textron Inc. / Subsidiary of Textron Inc. 8
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hoses and Fittings
Tool/Hose Connections
Connecting Hoses (See Figures 1 and 3)
Note: Return (tank) hose connection should always be
connected before supply (pressure) hose
connection to prevent pressure build-up inside
the tool.
1. Stop the power source.
2. Connect the return (tank) hose from the power
source (port T) to the tool (T port).
3. Connect the supply (pressure) hose from the power
source (port P) to the tool (P port).
Disconnecting Hoses (See Figures 1 and 3)
Note: Supply (pressure) hose connection should always
be disconnected before return (tank) hose
connection to prevent pressure build-up inside
the tool.
1. Stop the power source.
2. Disconnect the supply (pressure) hose from the
power source (port P) to the tool (P port).
3. Disconnect the return (tank) hose from the power
source (port T) to the tool (T port).
4. To prevent contamination, always install dust caps
over the hydraulic ports of the tool when discon-
nected.
Hose assemblies and quick connect couplers are available from Greenlee Fairmont as accessories.
SEE BULLETIN ON GREENLEE FAIRMONT NO-DRIP COUPLERS AND HOSES. CONTACT AUTHORIZED
GREENLEE FAIRMONT DISTRIBUTOR.
Hoses and fittings used with this tool must comply with SAE Standard J1273
(See Appendix A) recommended practice for selection, installation and
maintenance of hose and hose assemblies.
Failure to observe these warnings could result in over-pressurizing the
system causing severe injury to operator or bystanders.
Always stop power source before connecting or disconnecting tool.
Read and understand the procedures for connecting and disconnecting hoses.
Failure to observe these warnings could result in over-pressurizing the
system causing severe injury to operator or bystanders.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
Setup Instructions
Figure 3
POWERHEAD
CLAMP/ARM
ASSEMBLY
WING
NUT
CLAMP SCREW
Connect Powerhead to Clamp and Arm Assembly
1. Remove wing nut from pivot bolt on powerhead.
2. Extend upper arm of clamp and arm assembly.
3. Slide pivot bolt through hole in upper arm.
4. Screw the wing nut onto pivot bolt (see Figure 4).
Figure 4
Attach Clamp and Arm Assembly to Rail
The clamp and arm assembly must be attached
to the rail before using the tool.
1. Place the clamp assembly on top of the rail.
The cleats inside of the clamp should rest snugly
under the rail head (see figure 3).
2. Tighten clamp screw until it grips the side of the
rail head.
For ease of handling, the rail saw is shipped as two
component pieces. It is more convenient to move
the two as separate pieces between different locations
on the job site and for storage. The rail clamp/arm
assembly and the powerhead must be assembled
before cutting rail.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 10
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
4
5
°
4
5
°
4
5
°
4
5
°
C
L
"TAP"
HERE
Figure 5
Note: An abrasive cutting wheel is not sold as part of
the Greenlee Fairmont Rail Cut-Off Saw, but must
be purchased separately by the user of the tool.
Before mounting an abrasive cutting wheel, inspect it for
damage. Do not use a wheel which as cracks, chips
gouges or evidence of damage from handling or storage.
After visually inspecting the wheel, apply the “ring” test
per ANSI-B7.1:
1. Suspend the cutting wheel from the center hole on a
small pin or your finger.
2. Tap the wheel gently with a nonmetallic implement
such as a wooden screwdriver handle. Tap the
cutting wheel about 45˚ each side of a vertical center
line (four places) and about 1 to 2 inches from the
periphery (see figure 5).
A sound and undamaged wheel will give a clear
tone. If the wheel is cracked, there will be a dead
sound (not a clear “ring”) and the wheel should not
be used.
3. Rotate the wheel 45˚ and repeat test.
If a wheel passes the visual inspection and the “ring”
tests it may be mounted to the arbor (see figure 6).
Setup Instructions (cont’d)
Do not use an abrasive cutting wheel which has
cracks, chips, gouges, or evidence of damage from
handling or storage.
Failure to observe this warning could result in
severe injury or death.
New or remounted wheels should run at operating
speed for one full minute before use.
Failure to observe this warning could result in
severe injury or death.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
Figure 6
Mounting a new cutting wheel: (See Figure 6)
1. Remove shaft clamping nut and outer flange.
2. Remove old cutting wheel.
3. Discard old wheel and blotters.
4. Clean the clamping surfaces of inner and outer
flanges thoroughly.
Note: Blotters must always be used between flanges
and abrasive cutting wheel surfaces to ensure
uniform distribution of flange pressure.
5. Place new blotters, flanges and cutting wheel
together inside wheel guard.
6. Line up pin in outer flange with groove on the
inner flange.
7. Attach items to arbor with clamping nut.
8. Tighten nut so that cutting wheel is gripped firmly
between flanges. Tighten nut to 20 ft. lb. Torque.
9. Every time a new wheel is mounted, or a used wheel
is remounted, it should be run at operating speed
with safety guard attached at least one minute
before applying work.
OUTER
FLANGE
NUT
CUTTING
WHEEL
Setup Instructions (cont’d)
Do not place any part of the body over the rotating
cutting wheel.
Failure to observe this warning could result in
severe injury or death.
New or remounted wheels should run at operating
speed for one full minute before use.
Failure to observe this warning could result in
severe injury or death.
BLOTTER

Greenlee Textron Inc. / Subsidiary of Textron Inc. 12
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
1. See “Setup Instructions” on page 10 to properly
attach Rail Cut-Off Saw to rail.
2. Remove enough ballast from beneath rail to provide
cutting wheel clearance.
3. Connect hoses to proper ports.
(See “Tool/Hose Connections”.)
4. Start the power source.
5. Push spool down to its stop. This changes the
direction in which the cutting wheel rotates.
Note: The cutting wheel should rotate forward,
away from the operator, so that sparks are
sent downward into the ballast.
6. Squeeze the trigger to start tool.
Note: Do not rest the cutting wheel on the rail when
starting the tool.
7. Allow wheel to spin up to speed before cutting.
8. Cut using a rocking motion. This prevents localized
overheating of the rail and reduces wear on cutting
wheel.
PUSHSPOOL
DOWN
FORWARD
ROTATION
Operating Instructions
Pivot Function
Cutting from opposite side of rail:
1. Stop the tool.
2. Use handle to lift and pivot tool so that cutting wheel
edge faces desired direction.
3. Push spool down to its stop. This changes the
direction in which the cutting wheel rotates.
Note: The cutting wheel should rotate forward,
away from the operator, so that sparks are
sent downward into the ballast.
4. Squeeze the trigger to start tool.
Note: Do not rest the cutting wheel on the rail when
starting the tool.
5. Allow wheel to spin up to speed before cutting.
6. Cut using a rocking motion. This prevents localized
overheating of the rail and reduces wear on cutting
wheel.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
The life of your Greenlee Fairmont hydraulic tool will
be extended with proper care and handling. The preven-
tative maintenance checks listed below are suggested
on a regular basis and whenever needed.
Daily:
• The operator should wipe all exposed surfaces clean
of dirt and foreign material. Inspect hydraulic hoses
and couplings every operating day. Repair or replace
if cracking, wear or damage is evident.
Monthly
• Make a detailed inspection of hoses and connections.
Before You Begin
1. Verify that the pressure and return hoses are con-
nected properly to the tool and power source ports.
2. Power source reservoir must be filled to FULL level
with hydraulic fluid.
3. Start the power source. All power source shut-off
devices must be engaged or opened (clutch en-
gaged, separate on/off valves open, etc.).
4. 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, hoses or power source as the
problem area. The following steps will help to
determine the problem area.
Determining the Problem Area
1. Check power source flow 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. Disconnect the existing tool
from the hoses and power source.
3. Connect a known working tool to the hoses and
power source. See the tool’s operator’s manual for
correct hook-up procedure. Start the power source.
If the known working tool operates, the problem is in
the disconnected tool. See the Troubleshooting
charts in this operator’s manual.
If the known working tool does not operate, the
problem is likely to be in the hoses or the power
source. Proceed to the next step.
4. Stop the power source. Disconnect the existing
hoses from the known working tool and power
source.
5. Connect a different set of hoses to the known
working 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. See your power
source operator’s manual for troubleshooting.
Maintenance Troubleshooting

Greenlee Textron Inc. / Subsidiary of Textron Inc. 14
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
PROBABLE CAUSE
PROBLEM POSSIBLE REMEDY
Troubleshooting (cont’d)
Tool inoperative. Tool connected to improper power See Tool Specifications for type of
source hydraulic system (Open-Center hydraulic system required. Verify
or Closed-Center). power source hydraulic system.
No hydraulic fluid in system or fluid Check fluid level. Fill to FULL mark.
level low. Check system for leaks.
Incorrect hydraulic fluid viscosity. Use fluid viscosity recommended.
See Recommended Hydraulic Fluids.
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 fluid may be too high at
start of tool operation. Allow fluid to
warm up to operating temperature.
Actuating tool intermittently will reduce
time required to warm up fluid to an
efficient operating temperature.
Air in system. Check pump suction line for damage
or loose clamps. Tighten clamps or
replace components if necessary.
Replace components.
Tool components sticking or binding. Check for gummy deposits. Clean
components. Check for worn or
damaged components. Replace
components.
Dirt, contaminants, etc., in components. Disassemble tool. Clean components.
Tool operates slowly. Power source components not adjusted Refer to power source manual for
correctly. recommended power source speed.
Hydraulic fluid cold. Viscosity of fluid may be too high at
start of tool operation. Allow fluid to
warm to operating temperature.
Actuating tool intermittently will reduce
time required to warm fluid to an
efficient operating temperature.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
POSSIBLE REMEDY
PROBABLE CAUSE
PROBLEM
Troubleshooting (cont’d)
Tool operates slowly. (cont.) Hydraulic fluid level low. Check fluid level. Fill to FULL mark.
Check system for leaks.
Hydraulic fluid viscosity too heavy. Use fluid viscosity recommended.
See Recommended Hydraulic Fluids.
Tool components loose. Tighten component hardware.
Dirt, contaminants, etc., in components. Disassemble tool. Clean components.
Tool components worn or damaged. Disassemble tool. Replace worn or
damaged components.
Tool operates too fast. Power source speed excessive. Refer to power source manual for
recommended power source speed.
Power source components not adjusted Refer to power source operator’s
correctly. manual for proper adjustment of
components.
Tool feels hot. Hydraulic fluid level low. Check fluid level. Fill to FULL mark.
check system for leaks.
Hydraulic fluid viscosity too light. Use fluid viscosity recommended.
See Recommended Hydraulic Fluids.
Hydraulic fluid dirty. Drain reservoir, flush and fill with
clean fluid.
Tool control valve stuck in partial Free spool so it returns to neutral
power-ON position. position.
Power source speed excessive. Refer to power source operator’s
manual for proper adjustment of
components (flow).
Dirt, contaminants, etc., in components. Disassemble tool. Clean 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.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 16
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
POSSIBLE REMEDY
PROBABLE CAUSE
PROBLEM
Troubleshooting (cont’d)
Tool leaks hydraulic fluid. Tool components loose. Tighten component hardware.
Tool components worn or damaged. Disassemble tool. Replace worn or
damaged components.
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 worn or damaged
components.
Valve components worn or damaged. Disassemble valve and replace worn
or damaged components.
Tool operates continuously. Tool control valve stuck in partial Free spool so it returns to neutral
power-ON position. position.
Tool operates backwards. Directional spool in wrong position. Shift directional spool to opposite
position.
Hydraulic pressure and return lines Disconnect hoses. Reconnect hoses
connected to opposite tool ports. to proper tool ports.
Tool components assembled incorrectly. Disassemble tool. Reassemble
correctly.
Power source operates but Inappropriate hydraulic system. Check type of power source hydraulic
lacks power or cutting wheel system, Open-Center or Closed-Center.
does not rotate. Control spool damaged; leaking fluid Replace damaged components.
internally.
Drive components worn or damaged Replace damaged components.
(bearings, races, gears, shafts, keys,
etc.)

Greenlee Textron Inc. / Subsidiary of Textron Inc. 17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
Disassembly
COMPLETE DISASSEMBLY OF TOOL IS NOT
RECOMMENDED. RETURN TOOL TO YOUR
NEAREST AUTHORIZED GREENLEE DISTRIBUTOR
OR TO THE FACTORY.
Disassembly procedure is divided into sections of the
tool. Complete disassembly of the tool is seldom
necessary. Disassemble only the area(s) necessary to
correct the problem. See Parts illustrations for
identification of parts as they are removed.
Disassembly should be done on a flat, clean surface.
Some of the parts may fall free during disassembly. To
prevent part loss or damage, keep the tool as close to the
working surface as possible.
Inspect all parts as they are disassembled and mating
parts in the 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.
Clamp Base and Pivot Arms
1. Remove Nut (44) from Bolt (25) allow washer
(17 & 27) to be free when removing rotating arm (6)
from Pivot Arm.
2. Remove Nut (44) from Pivot Arm (7).
3. Remove washers (17 & 27), Pivot Arm (7) from
Clamp Base Bolt (72).
4. Remove Clamp Screw (18) from base (8).
5. Remove the nut (56) from bolt (55) then remove
handle (28) from screw (18).
Saw Valve Handle
1. Remove hoses (9 & 10) from valve fittings (22) and
motor fittings (23).
2. Remove fitting (22) from valve handle (11).
3. Remove the four screws (24) that secure the valve
handle (11) to the frame arm (14).
4. Remove the two whip hoses (1) from valve handle
(11).
Trigger Components
1. Remove the connecting link (39), the #10 x 1/4 inch
slotted round head machine screw (38), and the #10
stop nut (40) to remove the trigger (34).
2. Remove the retaining ring (35) and washer (33) from
trigger end of valve spool (29). Remove retaining
ring (35), cap (30), and spring (32) from the opposite
end of the valve spool. Remove the valve spool (29)
from the insulated handle (11). Remove O-ring (37)
from the valve spool. Remove O-ring (36) from the
insulated handle (11) using an O-ring tool.
Directional Spool
1. Remove both of the #10 x 1/2 inch flat socket head
cap screws (41) and buttons (31) from the ends of
the directional spool (28) part way through the bore
to expose one O-ring (37). Slide the directional spool
through the bore in the opposite direction. Remove
O-ring (37) from the other end of the directional
spool. Remove the directional spool (28).
Note: Attempting to push the directional spool (28) all
the way through the bore in one direction will
cause damage to the O-rings (37) and could allow
particles of the O-rings to get into the motor.
Blade Guard and Handle
1. Remove the four nuts (56) from the four screws (65)
that secure the blade guard (3) and handle (4) to
arm (14).
When disconnecting tool, removing hydraulic lines,
fittings, or components the following procedure must
be adhered to:
1. Stop the power source.
2. Always wear appropriate personal safety
equipment.
3. Depressurize the hydraulic system.
4. Disconnect hydraulic hoses from tool.
5. Do not remove fittings or components when
hydraulic fluid is hot. Exposure to hot hydraulic
fluid can cause serious personal burns.
6. Remove lines, fittings or components slowly
to release any trapped pressure.
7. If injury results from escaping fluid, see a doctor
at once. Serious reaction or infection may result
if proper medical attention is not obtained
immediately.
Failure to observe these warnings could result in
severe injury or death.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 18
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Disassembly (cont’d) Assembly
Inspection
Hydraulic Motor and Arm
1. Remove nut (69) from pivot shaft (12) and disas-
semble from arm (14).
2. Remove the eight screws (51) from motor guard
(19). Remove the two screws (52) and washer (54)
from arm (14).
3. Remove nut (66), flanges (15 & 18) from drive shaft
(13).
4. Remove two screws (50) from motor and arm (14).
Disassemble motor (14) from the drive shaft (13).
5. Remove fittings (23 & 21) from motor (20).
Drive Shaft
1. Bend the locking tab on washer (49) from nut (48).
Remove nut (48) from drive shaft (13). Remove
washer (49).
2. Remove retaining ring (46) from drive shaft (13).
Remove drive shaft (13) from bearings (45).
3. Remove retaining rings (47) from arm (14) housing.
Remove bearings (45) from arm housing (14).
1. O-Ring 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.
2. Valve Spool (28 & 29): All surfaces must be smooth
and free of grooves, nicks or scratches. If it has
grooves, nicks or scratches, replace the spool.
3. Blade Flanges (16 & 15): Face surfaces must be
free of nicks. Remove nicks or burrs with a flat file or
replace.
4. Drive Shaft (13): Check threads on blade end of
drive shaft (13). They must have good form without
any flat areas, etc. Replace if necessary.
5. Outer Flange (16): Be sure pin (75) is properly
installed in flange. Replace if necessary.
When assembling parts refer to the Parts illustrations for
correct placement and orientation of parts.
Clean all parts with solvent (take care to protect eyes),
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 O-ring.
Whenever assembled parts cause metal to metal con-
tact, coat the surfaces with hydraulic fluid or O-ring
lubricant.
Drive Shaft
1. Install the two retaining rings (47) in the motor
housing in the arm (14).
2. Install the two bearings (45) in the motor housing in
the arm (14).
Note: It may require a minimum press to fit properly
install bearing (45).
3. Place retaining ring (46) on the drive shaft (13).
Install drive shaft (13) into bearings (45).
4. Install washer (49) and nut (48). Torque nut (48) to
20 lbs. ft. Hold drive shaft (13) securely and loosen
nut (48) only to allow drive shaft (13) to move freely
in the bearing and not allow any axial or radial
movement of drive shaft (13) - (Approximately 5
degree movement of nut [48]). Secure nut (48) in
place by bending locking tab on washer (49) into slot
on nut (48).
Hydraulic Motor and Arm
1. Install the square key on motor (20) drive shaft.
Install motor (20) drive shaft into saw drive shaft (13).
Secure motor (20) to arm (14) with two bolts (50) .
2. Install fittings (22 & 23) in motor (20) return and
pressure ports.
3. Install guard (5) onto arm (20) using the two washers
(54) and two screws (52). Also install the two covers
(19) onto the guard (5) using the eight screws (51).
4. Place key (67) on drive shaft (13) and install blade
flanges (16 & 15) and secure in place using nut (66).
Blade Guard and Handle
1. Install blade guard (3) and handle (4) to the arm
(14), using the four screws (65) and four nuts (53).

Greenlee Textron Inc. / Subsidiary of Textron Inc. 19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
H4645 Rail Cut-Off Saw
Directional Spool
1. Slide the directional spool (28) into the appropriate
bore in the insulated handle (11).
2. Install one O-ring (37) onto the directional spool (28).
Slide the directional spool (28) through the insulated
handle (11) just far enough to install the remaining
O-ring (37) onto the directional spool (28).
3. Apply Loctite®242-05 sealant or equivalent on the
#10 x 1/2 inch flat socket head cap screws (41).
Follow the manufacturer’s instructions for curing.
Secure the buttons (31) onto the end of the direc-
tional spool (28) with the flat socket head cap screws
(28). Torque to 30-35 lbs. in.
Trigger Components
1. Install a new O-ring (36) in the O-ring groove inside
the spool bore in the outer side of the insulated
handle (11). Install a new O-ring (37) onto the valve
spool (29). Install valve spool (large diameter end
first) into the trigger side of the insulated handle (11).
2. Install the spring (32), cap (33), and one retaining
ring (35) into the outer side of the handle (11). Install
the washer (30) and the remaining retainer ring (35)
onto the trigger end of the valve spool (29).
3. Install trigger (34) on insulated handle (11), securing
trigger (34) to valve spool (29) with connecting link
(39), and to insulated handle (11) with #10 x 1-1/4
inch slotted round head machine screw (38) and #10
stop nut (40).
Saw Valve Handle
1. Install insulated valve handle (11) onto arm (14)
using the four screws (24).
2. Install fittings (22) in insulated valve handle (11).
Connect the two hoses (9 & 10) on valve fittings (22)
and motor fittings (23).
3. Connect whip hoses (1) to insulated valve handle
(11).
Clamp Base and Pivot Arm
1. Secure handle (26) to clamping screw (18) using
screw (55) and nut (56) install clamping screw (18)
in base (8).
2. Install bolt (22) in valve handle (11). Connect hoses
(9 & 10), valve fittings (22) and motor fitting (23).
3. Connect the whip hoses (1) to the valve handle (11).
Assembly (cont’d)
Clamp Base and Pivot Arm
1. Secure handle (26) to screw (18) using screw (55)
and nut (56) install clamping screw (18) in base (8).
2. Install bolt (72) into base (8) using nut (69) and apply
Loctite® 242 sealant or equivalent.
3. Place washers (27 & 17) and pivot arm (7) onto bolt
(72) using a generous amount of grease between
washers (27 & 17) and pivot arm (7). Secure into
position with nut (44). Torque to approximate
30 lbs. ft., then loosen only to achieve proper radial
movement.
4. Install rotating arm (6) and washer (27 & 17) using
bolt (25) and nut (44). Torque to approximately 30
lbs. ft., then loosen only to achieve proper radial
movement. Apply a generous amount of grease
between washers (27 & 17) and rotating arm.

Greenlee Textron Inc. / Subsidiary of Textron Inc. 20
H4645 Rail Cut-Off Saw
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
ExplodedView
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24
24
65
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65
51 51
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10
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9
21 23 21
19
5
51
19
52
54
20
48
13
49
45
47
4
50
14
47
45
46
40
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38 39
35
30
37
29
36
32
41
31
57
1
60
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60
59 1 57 11 35 33
41
31
37
28
37
3
67
15
71
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66
55
26
56
18
44
72
27
17
17
8
69
2 42 43 42
12
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70
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7
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