Greenlee H4802-3 User manual

SERVICE MANUAL
H4802-3 and H4802-5
Pole Tampers
99910446 REV 8 © 2016 Greenlee Textron Inc. 12/16
Serial Codes FKD, FKE, FZL, and FZM
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Safety
Safety is essential in the use and maintenance of
Greenlee 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 Greenlee
Utility tools:
H4802-3 Serial Codes FKD and FZL
H4802-5 Serial Codes FKE and FZM
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
Other Publications
Instruction Manual: Publication 99930196
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Loctite and 242 are registered trademarks of Loctite Corporation.
KEEP THIS MANUAL
Table of Contents
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Other Publications......................................................... 2
Important Safety Information .....................................3–5
Disassembly .................................................................. 6
Inspection...................................................................... 6
Assembly....................................................................... 7
Illustrations and Parts Lists ......................................8–13

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool. Refer also to the
Instruction Manual, which is listed
under “Other Publications.”
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are injured
by escaping oil, seek medical atten-
tion 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.

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Do not exceed the maximum hydraulic ow,
pressure relief, or back pressure listed in the
Specications and Parts manual.
Failure to observe this warning could result in severe
injury or death.
Do not disconnect tool, hoses, or ttings while the
power source is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the pressure (supply) hose and tank (return)
hose to the proper ports.
Failure to observe this warning could result in severe
injury or death.
Do not change accessories, inspect, adjust, or
clean tool when it is connected to a power source.
Accidental startup can result in serious injury.
Failure to observe this warning could result in severe
injury or death.

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
IMPORTANT SAFETY INFORMATION
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 may result in
injury.
Procedure for connecting or disconnecting hydraulic
hoses, ttings, or components:
1. Move the ow 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, ttings, or components slowly.

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Disassembly
Complete disassembly of the tool is not recommended.
If a complete overhaul is necessary, return the tool to
your nearest Greenlee Utility Authorized Service Center.
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 at, clean surface. Take care
not to lose or damage any parts that may fall free during
disassembly.
Tube
1. Remove the cap screws that fasten the tube (25) to
the valve body (10).
2. Remove the cap screws from the guard (31).
Remove both halves of the guard.
3. On newer models, remove two cap screws (32) from
the tube (25).
On older models, remove two nuts (36), double
washers (33), washers (34), and cap screws (35).
4. Slide the tube (25) away from the valve body (10)
to expose the hose connections. Mark the end of
the pressure hose for correct assembly. Disconnect
the hoses (29) from the adapters (24) on the tamper
unit. Slide the tube over the hoses.
5. Mark the end of the pressure hose for correct
assembly. Disconnect the hoses from the adapters
(30) on the handle (45). If necessary, remove the
adapters from the handle.
Valve Body and Components
1. Remove the roll pin (41). Remove two nuts (40),
cover plates (38), and cap screws (39). If necessary,
remove the trigger lever (37), trigger lock (44), and
sleeve (43).
1a. Cool Grip—Remove retaining ring (41) and pins (40).
Remove screws (36, 37) and nuts (38). Remove grip
halves (34, 35).
2. Remove the retaining ring (50) and washer (49) from
the trigger side of the handle. Slide the control spool
(46) and spring (47) out of the handle. Remove the
O-ring (52) from the control spool. Remove the
retaining ring (50), end cap (48), and O-ring (51) from
the handle.
2a. Cool Grip—Remove washer (44), spring (45), and
retaining ring (43). Slide trigger spool (45) from
handle (33). Remove O-ring (46) from trigger spool
and O-ring (50) and backup (51).
3. Cool Grip—Remove retaining ring (52) from spool
(47). Turn OC/CC spool (49) counterclockwise to
remove from spool (47).
Tamper Unit
1. Scribe a line across the valve body (10) and tamper
body (1) for correct assembly.
2. Loosen the cap screw (23) that fastens the foot (21)
to the ram. Loosen it so that it protrudes far enough
from the bottom surface of the tamper foot to be
struck with a hammer or pressed against with a
hydraulic press.
3. Slide the ram (2) out of the tamper body as far as
it will go. Refer to 3a to remove the tamper foot
manually. Refer to 3b to remove the tamper foot
with a hydraulic press.
3a. Taking care not to damage the ram surface, secure
the tamper foot in a vise with the bottom of the foot
upward. Set a block of wood on the cap screw (23)
and strike the block with a heavy mallet until the
tamper foot is released from the ram. Remove the
cap screw (23) and washer (22). Remove the tamper
foot.
3b. Taking care not to damage the ram surface, secure
the tamper foot in a hydraulic press and apply
force to the cap screw (23) until the tamper foot is
released from the ram. Remove the cap screw and
washer (22). Remove the tamper foot.
4. Remove the cap screws (18) that secure the valve
body (10) to the tamper body (1). Remove the valve
body from the tamper body. Remove the O-rings
(16, 17) from the valve body.
5. Remove the plugs (11, 14) from the valve body.
Remove the spring (13), stop (12), and spool (9)
from the valve body. Remove the O-ring (15) from
the plug. If necessary, remove the adapters (24).
6. Unscrew the packing nut (3) from the bottom end
of the tamper body (1). Remove the rod wiper (7),
U-cup seals (4, 5), and O-ring (6) from the
packing nut.
7. Remove the ram (2) and shaft (8) from the tamper
body.
Inspection
Clean all parts with solvent and dry them thoroughly.
Inspect each component. Replace any component that
shows wear or damage.

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Assembly
Refer to the illustrations and parts lists for correct
orientation and placement of parts.
Replace any O-rings, V-rings, seals, and gaskets on
parts that have been disassembled. Apply hydraulic
uid or O-ring lubricant to all O-rings and all metal
surfaces which they must slide over. When installing an
O-ring which must slide over sharp surfaces, use a
rolling motion and be careful not to damage the O-ring.
Wherever the assembly results in metal-to-metal
contact, coat the surfaces with hydraulic uid or O-ring
lubricant.
Tamper Unit
1. Assemble the O-ring (6), U-cup seals (4, 5), and rod
wiper (7) to the packing nut (3).
2. Install the ram (2) into the tamper body (1).
3. Thread and tighten the packing nut into the end of
the tamper body.
4. Install the shaft (8) into the center bore in the tamper
body, as shown.
5. Install the plug (11) into the valve body (10).
6. Install the O-ring (15) into the plug (14).
7. Slide the spool (9) into the valve body, as shown.
Set the stop (12), anged end rst, into the spool.
Install the spring (13) over the stop and secure with
the plug (14).
8. Install the O-rings (16, 17) into their appropriate
bores in the bottom of the valve body (10).
9. Set the valve body (10) on top of the tamper body
(1) and align the scribed marks that were made
during disassembly. Fasten the valve body with four
cap screws (18).
10. Install the adapters (24) into the ports on the top of
the valve body.
11. Install the tamper foot (21) onto the end of the ram.
Install the cap screw (23) with washer (22) and
tighten the cap screw securely.
Valve Components
1. Install the O-ring (51) into the groove in the spool
bore of the handle (45), as shown.
2. Install the end cap (48) into the handle, anged side
rst, on the side of the handle opposite the trigger.
Secure the end cap into position with a retaining
ring (50).
3. Set the spring (47) into the spool bore of the handle.
Install the O-ring (52) onto the control spool (46).
4. Align the control spool so that the 3 mm (0.125")
diameter indentation in the spool indicates the
appropriate hydraulic system designation (OC or
CC). Slide the control spool into the spool bore.
Install the at washer (49) onto the control spool and
secure the spool components with a retaining ring
(50).
5. Install the trigger lever (37) onto the control spool,
and secure with the roll pin (41).
6. Install the cover plates (38) with cap screws (39) and
stop nuts (40).
7. Insert the sleeve (43) and install the trigger lock (44).
Install the adapters (30) into the end of the handle.
Valve Components—Cool Grip
1. Install O-ring (48) onto OC/CC spool (49). Insert
OC/CC spool into trigger spool (47). Install retaining
ring (52). Adjust OC/CC spool to desired setting.
2. Install O-ring (50) and backup ring (51) into valve
handle (33). Install O-ring (46) onto trigger spool
(47). Slide the trigger spool assembly into the handle
from the trigger mount side of the handle.
3. Install spring (45), washer (44), and retaining ring
(43). Install pins (40) and retaining clips (41). Check
trigger spool operation.
4. Hold grip halves (34, 35) against handle (33) and
fasten in place with screws (36, 37) and nuts (38).
Do not overtighten.
Tube
1. Refer to the parts illustration and the markings on
the pressure hose for appropriate hose connection.
Connect the hoses (29) to the adapters (30) on the
end of the handle. Slide the hoses through the tube.
Connect the hoses to the adapters (24) on the valve
body.
2. Fasten the tube to the valve body with four cap
screws.
3. Slip the handle assembly into the end of the tube
(25).
On newer models, fasten with two cap screws (32).
On older models, fasten with the cap screws (35),
countersink washers (34), double washers (33), and
nuts (36).
Torque the cap screws to 14.9 Nm (11 ft-lb).
4. Apply a thread sealant, such as Loctite®242®
Threadlocker, to the threads of the cap screws.
Follow the manufacturer’s instructions for curing.
Install both halves of the guard (31) and secure with
the cap screws.

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
P
T
23
22
7
21
5
3
6
4
2
1
18
17
11
8
16
10
14
15
13
12
9
25
18
29
24
24
29
32*
18*
30
31
31
* Apply a thread sealant, such as
Loctite 242 Threadlocker
32*
36
37
35
42
52
51
50
49
48
47
46
45
44
43
39
41
40
34
36
38
33
41
Illustration—H4802-3 Serial Code FKD06200 and above,
and H4802-5 Serial Code FKE02000 and above

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Parts List—H4802-3 Serial Code FKD06200 and above,
and H4802-5 Serial Code FKE02000 and above
UPC No.
Key 78-3310- Part No. Description Qty
1 40293 50402932 Body, tamper ......................................................................... 1
2 40180 50401803 Ram........................................................................................ 1
3 40377 50403771 Gland, packing (includes items 4–7) ...................................... 1
4* Seal, U-cup, .750 x 1.250 x .375 ........................................... 1
5* Seal, U-cup, .750 x 1.000 x .250 ........................................... 1
6* O-ring, 1.475 x 1.711 x .118–90 ............................................ 1
7* Wiper, rod, .750 x 1.125 x .281.............................................. 1
8 40295 50402952 Shaft....................................................................................... 1
9 40297 50402971 Spool...................................................................................... 1
10 40296 50402961 Body, valve............................................................................. 1
11 42072 50420722 Plug, 7/8–14 UNF SAE O-ring boss, socket head, steel ....... 1
12 40298 50402981 Stop, spool ............................................................................ 1
13 40299 50402991 Spring, compression, .330 x .500 x 1.250 ............................. 1
14 40300 50403005 Plug, 7/8–14 UNF SAE O-ring boss, hex head ...................... 1
15* O-ring, .755 x .949 x .097–90 ................................................ 1
16* O-ring, .750 x .937 x .094–70 ................................................ 3
17* O-ring, .375 x .500 x .062–70 ................................................ 1
18 Screw, cap, 5/16–18 x 1.000 socket head............................. 9
21 40301 50403014 Foot, kidney-shaped.............................................................. 1
22 Washer, at, .375 x .875 x .075.............................................. 1
23 Screw, cap, 5/16–24 x 1.250 hex head.................................. 1
24 41341 50413413 Adapter, 1/4 M NPT x 9/16–18 M JIC.................................... 2
25 49536 50495364 Tube, handle (H4802-3).......................................................... 1
40386 50403861 Tube, handle (H4802-5).......................................................... 1
29 40400 50404004 Hose, 3/8 x 38.75 with 9/16–18 JIC swivel
at both ends (H4802-3) ...................................................... 2
40002 50400025 Hose, 3/8 x 30.00 with 9/16–18 JIC swivel
at both ends (H4802-5) ...................................................... 2
30 41413 50414133 Adapter, pipe, 9/16–18 UNF SAE O-ring boss
x 9/16–18 M JIC ................................................................. 2
31 40374 50403742 Guard, two-piece ................................................................... 1
32 Screw, cap, 1/4–20 x .750 at head socket........................... 6
33 Handle.................................................................................... 1
34 Grip, left ................................................................................. 1
35 Grip, right............................................................................... 1
36 Screw, #8-32 x .375 soc hd cap ............................................ 2
37 Screw, #8-32 x 1 btn hd cap ................................................. 2
38 Nut, #8-32 lock ...................................................................... 2
39 Trigger .................................................................................... 1
40 42547 50425471 Pin, pivot ................................................................................ 2
41 42827 50428270 Retaining ring......................................................................... 4
42 Bail ......................................................................................... 1
43 41648 50416480 Retaining ring......................................................................... 1
44 48310 50483102 Washer, Ø.76 x .73 x .03........................................................ 1
45 00399 52060673 Spring, compression.............................................................. 1
46* O-ring, .500 x .625 x .062 ...................................................... 1
47 00380 52060643 Spool...................................................................................... 1
48* O-ring, .375 x .500 x .062 ...................................................... 1
49 00917 52063610 Spool, OC/CC........................................................................ 1
50* O-ring, .612 x .818 x .103 ...................................................... 1
51* Back-up ring .......................................................................... 1
52 Retaining ring......................................................................... 1
Repair Kits
* 41120 50411204 Packing kit (includes items marked with an asterisk)
07230 52081225 Valve unit (includes items 33-52)
06613 52079544 Grip kit (includes items 34-38)

H4802-3 and H4802-5 Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Illustration—H4802-3 Serial Code FKD02100 to 06199,
and H4802-5 Serial Code FKE00600 to 01999
P
T
23
22
7
21
5
3
6
4
2
1
18
17
11
8
16
10
14
15
13
12
9
25
18
29
24
24
29
32*
18*
41
39 38
40
30
37
45
5148 50
46
47
31
31
44
50 49
43
52
* Apply a thread sealant, such as
Loctite 242 Threadlocker
32*