SERVICE MANUAL
H4802, H4802-1, and H4802-6
Pole Tampers
Serial Codes FKA, FKF, FKM, FZP, FZR, and FZT
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
99910420 REV 8 © 2011 Greenlee Textron Inc. 6/11
H4802, H4802-1, and H4802-6 Pole Tampers
Table of Contents
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Other Publications ......................................................... 2
Important Safety Information .....................................3–4
Disassembly .................................................................. 5
Inspection ...................................................................... 5
Assembly ....................................................................... 6
Illustration and Parts List ............................................7–9
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 Serial Codes FKA and FZP
H4802-1 Serial Codes FKM and FZR
H4802-6 Serial Codes FKF and FZT
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 specications 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
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
H4802, H4802-1, and H4802-6 Pole Tampers
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
Immediate hazards which, if not avoided, WILL 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.
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.
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 Specications 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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
H4802, H4802-1, and H4802-6 Pole Tampers
IMPORTANT SAFETY INFORMATION
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.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Disassembly
H4802, H4802-1, and H4802-6 Pole Tampers
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 screws (27) that fasten the adapter (26)
to the tube (25). Remove the hose clamps.
2. Remove the cap screws (28) that secure the tube
(25) to the valve body (10).
3. Slide the tube away from the valve body 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 hoses out of the tube.
Control Valve Components
1. Disconnect the hoses (29) from the valve body (32).
If necessary, remove the adapters (30, 31).
2. Remove the cap screw (37) and button (36) from
one end of the control spool (34). Slide the control
spool out of the opposite end of the valve body.
3. Remove the O-rings (35) from the valve body (32).
Remove the other machine screw and button from
the opposite end of the control spool.
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. See 3a to remove the tamper foot manually.
See 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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Assembly
H4802, H4802-1, and H4802-6 Pole Tampers
Refer to the illustration and parts list 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,
lubricant.
Tamper Unit
1. Assemble the O-ring (6), U-cup seals (4, 5), and rod
2. Install the ram (2) into the tamper body (1).
3. Thread and tighten the packing nut into the end of
4. Install the shaft (8) into the center bore in the tamper
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.
8. Install the O-rings (16, 17) into their appropriate
9. Set the valve body on top of the tamper body (1)
10. Install the adapters (24) into the ports on the top of
11. Install the tamper foot (21) onto the end of the ram.
coat the surfaces with hydraulic uid or O-ring
wiper (7) to the packing nut (3).
the tamper body.
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).
bores in the bottom of the valve body (10).
and align the scribed marks that were made during
disassembly. Fasten the valve body with four cap
screws (18).
the valve body.
Install the cap screw (23) with washer (22) and
tighten the cap screw securely.
Tube
1. Refer to the parts illustration and the markings on
the pressure hose for appropriate hose connection.
Thread the hoses onto the adapters (24) in the top
of the valve body.
2. Slide the tube over the hoses. Secure the tube to
the valve body with four cap screws (28).
3. Apply a thread sealant, such as Loctite® 242®
Threadlocker, to the threads of the screws (27).
Follow the manufacturer’s instructions for curing.
Slide both hose clamps (26) into the end of the tube
(25) and secure with four screws (27).
Control Valve Components
1. Install the adapters (30, 31) into the valve body (32).
2. Refer to the parts illustration and the markings on
the pressure hose for appropriate hose connection.
Connect the hoses to the adapters.
3. Slide the control spool (34) into the valve body (32).
Install one O-ring (35) into the valve body. Slide
the control spool through the valve body over the
installed O-ring so that it protrudes just far enough
to install the other O-ring (35). Then push the spool
(34) over the other installed O-ring (35).
4. Install the buttons (36) onto each end of the control
spool. Apply a thread sealant, such as Loctite 242
Threadlocker, to the threads of the machine screws
(37). Follow the manufacturer’s instructions for
curing. Install the machine screws and torque to
3.5 Nm (31 in-lb).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Illustration
H4802, H4802-1, and H4802-6 Pole Tampers
18
35
34
37*
32
38
29
31
42*
40
36
41
33
29
30
27**
30
26
30
39
25
28
1
2
4
6
3
5
14
15
* Apply a thread sealant, such as
Loctite 242 Threadlocker, and
torque to 3.5 Nm (31 in-lb).
** Apply a thread sealant, such as
Loctite 242 Threadlocker.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
10
12
24
16
24
9
P
T
17
8
19
11
7
7
21
22
23
H4802, H4802-1, and H4802-6 Pole Tampers
Parts List
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 ............................. 4
21 40301 50403014 Foot, tamper .......................................................................... 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
(H4802, H4802-1, and H4802-6) ........................................... 2
25 49536 50495364 Tube, handle (H4802 and H4802-6) ....................................... 1
40358 50403582 Tube, handle (H4802-1) .......................................................... 1
26 48303 50483030 Adapter .................................................................................. 1
27 Screw, machine, 1/4–20 x .50 oval head
(H4802 serial codes FZP and FKA03499 and below,
H4802-1 serial codes FZR and FKM00019 and below,
H4802-6 serial codes FZT and FKF01499 and below ........... 4
Screw, cap, 1/4–20 x .75 at head
(H4802 serial code FKA03500 and above,
H4802-1 serial code FKM00020 and above, and
H4802-6 serial code FKF01500 and above) .......................... 4
28 Screw, cap, 5/16–18 x 1.000 socket head ............................. 4
29 48369 50483692 Hose, 3/8 x 56 with 9/16–18 JIC swivel at both ends .......... 2
30 41413 50414133 Adapter, pipe, 9/16–18 UNF SAE O-ring boss
x 9/16–18 M JIC (H4802 and H4802-1) ................................. 5
Adapter, pipe, 9/16–18 UNF SAE O-ring boss
x 9/16–18 M JIC (H4802-6) ................................................... 4
31 41422 50414223 Adapter, pipe, 9/16–18 M JIC x 3/4–16 UNF SAE
O-ring boss (H4802 and H4802-1) ........................................ 1
32 Valve body, remote ON/OFF (H4802 and H4802-1)............... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
H4802, H4802-1, and H4802-6 Pole Tampers
Parts List (cont’d)
UPC No.
Key 78-3310- Part No. Description Qty
33 Plug, pipe, 1/16 M NPT (H4802 and H4802-1) ...................... 1
34 Spool (H4802 and H4802-1) .................................................. 1
35* O-ring, .562 x .750 x .093 (2-113) (H4802 and H4802-1) ...... 2
36 Button, spool end (H4802 and H4802-1) ............................... 2
37
38 41587 50415870 Ty, plastic .............................................................................. 4
39 40400 50404004 Hose, 5/16 x 38.75 with 9/16–18 UNF JIC swivel
at both ends (H4802 and H4802-6) ....................................... 2
48368 50483684 Hose, 5/16 x 68.75 with 9/16–18 UNF JIC swivel
at both ends (H4802-1) .......................................................... 2
40 Snap ring, internal, .461 groove dia. ...................................... 1
41 Spool, OC/CC selection......................................................... 1
42* O-ring, .364 I.D. x .070 (2-012) .............................................. 1
Screw, cap, #10–24 x .500 at head (H4802 and H4802-1
) .... 2
Repair Kits
52057849 Control valve assembly
(H4802 and H4802-1 only; includes items 32–37 and 40–42)
* 40317 50403173 Packing kit (includes items marked with an asterisk)
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
USA Tel: 800-435-0786
Fax: 800-451-2632
Canada Tel: 800-435-0786
Fax: 800-524-2853
International Tel: +1-815-397-7070
Fax: +1-815-397-9247
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