Hose End Valve Tampers Part List & Operation
Contents
1. 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 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 82 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 control spool If necessary remove the other machine screw and button from the opposite end of the control spool Greenlee Textron Subsidiary of Textron Inc 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 ta2. 451 2632 815 397 1865 Canada Fax 800 524 2853 www greenlee textron com Printed in the USA
3. H4802 1 ee eeeeseeeeesneeeesneeeeeneees 2 37 41715 F018627 Screw cap 10 24 x 500 flat head H4802 and H4802 1 2 38 41587 F016578 Ty plastic H4802 H4802 1 and H4802 6 00 e eee eeeeeteeeteeeeeeeteees 4 38 41587 F016578 TYs Plastic AB227 ATETEA 4 39 40400 117961 Hose 5 16 x 38 75 with 9 16 18 UNF JIC swivel at both ends H4802 and H4802 6 rear aa aea raa Ea aaaea EAEn rE RAEE 2 39 48368 504 8368 4 Hose 5 16 x 68 75 with 9 16 18 UNF JIC swivel at both ends H4802 1 and 43227 areara eet a aeaa aeien neseka oas apga stio iare ra 2 Repair Kits 40290 111952 Control valve assembly H4802 and H4802 1 only includes items 32 37 40317 112875 Packing kit includes items marked with an asterisk Greenlee Textron Subsidiary of Textron Inc 9 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairm nt 4802 H4802 1 H4802 6 and 43227 Pole Tampers Accessories 2 1 UPC No Key 78 3310 Part No Description Qty 1 40371 114255 Foot round 6 diameter eeceeeeseeeeseeeeeeneeeeeeeeesneeseneeeeseeeeseaes 1 2 40372 114256 Foot rectangular 4 x 8 81 aa ssnsssisenseneererersnrernnnerureerarnrnnnennennnnnaa 1 40301 111964K Foot kidney shaped 2 5 x 8 GREENLEE DARCI Greenlee Textron Subsidiary of Textron Inc 4455 Boeing Drive Rockford IL 61109 2988 USA Customer Service International 815 397 7070 Fax 815 397 9247 Customer Service North America 800 435 0786 USA Fax 800
4. listed under Other Publications e Operation Manual e Specifications and Parts Failure to observe this warning can result in severe injury or death Greenlee Textron Subsidiary of Textron Inc 3 AWARNING 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 e Do not hold hose or couplers while the hydraulic system is pressurized e Depressurize the hydraulic system before servicing AWARNING 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 AWARNING 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 AWARNING 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 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairmont H4802 H4802 1 H4802 6 and 43227 Pole Tampers IMPORTANT SAFETY INFORMATION AWARNING Do not reverse hydraulic flow Operation with hydraulic flow reversed can cause tool malfunction Connect the pressure Supply hose and tank return h
5. 1 in lb 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairm nt 4802 H4802 1 H4802 6 and 43227 Pole Tampers Illustration Apply a thread sealant such as Loctite 242 Threadlocker and torque to 3 5 Nm 31 in Ib Apply a thread sealant such as Loctite 242 Threadlocker Greenlee Textron Subsidiary of Textron Inc 7 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairm nt 4802 H4802 1 H4802 6 and 43227 Pole Tampers Parts List UPC No Key 78 3310 Part No Description Qty 1 40293 111955 BOOy Tampere s secs EEEE EET 1 2 40180 104367K2 te a Saiee tit tdeeds Sear bled elidel iened ghicl eit eat teas lagii ise Ree 1 3 40377 114651 Gland packing includes items 4 7 oe eeeeeeeeeeeeeeeeeeeteeeeeeteeeeeneeees 1 4 40367 114223K Seal U cup 750 x 1 250 X 375 eeecceeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeee 1 5 41485 FO015226K1 Seal U cup 750 x 1 000 x 250 ooo eecececeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeaes 1 6 41399 F012879 O ring 1 475 x 1 711 x 118 90 oe eee e ete teee tees teeeeeseetsaeeeeeesaees 1 7 41480 F014954 Wiper rod 750 1 125 X 281 30 a dein ssi eet anne 1 8 40295 111957K1 E ees EEA AE EA TA 1 9 40297 111960 SOOM P EE E A A AEE E E A E 1 10 40296 111958 Body valV einen a nd detest 1 11 42072 F023649 Plug 7 8 14 UNF SAE O ring boss socket head steel 24 1 12 40
6. 298 111961 SLOPAS POO lna marsas drein toed ened Aintree ae alts tensed Ament 1 13 40299 111962 Spring compression 330 x 500 X 1 250 ssssssseseereereeererreerrereee 1 14 40300 111963K Plug 7 8 14 UNF SAE O ring boss hex head eeeeeeeseeeeeee 1 15 41398 FO12815 O ring 755 x 949 x 097 90 oo ceeceeeseceeeeeseeeseeeeeeseaeeeeeseeeeeeeeeaees 1 16 41372 F011796 O ring 750 x 937 X 094 70 oo eee cceeeeeeeseeeeseeeeeeeaeeeseeseaeeeeneteaees 3 17 41331 F010777 O ring 375 X 500 X06270 iieo aaeeea ad a oie 1 18 41691 F018347 Screw cap 5 16 18 x 1 000 socket head cccsceessseeeesteeeeees 4 21 40301 111964K Foot tamper e a a ae del iain eee eed 1 22 41257 F001362 Washer flat 375 xX 875 X 075 arinei ienaiiino ie 1 23 41320 F010276 Screw cap 5 16 24 x 1 250 hex head 0 0 eee eeeeeeeeeeeeeeeeeteeeeeeeees 1 24 41341 F010994 Adapter 1 4 M NPT x 9 16 18 M JIC H4802 H4802 1 and H4802 6 eeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeseeeeeeeens 2 25 48944 504 8944 5 Tube handle H4802 and H4802 6 0 0 eeeeceeeeeseeeeeeeeteeeeeneeeeeeees 1 25 40358 113696 Tube handle H4802 1 and 43227 o eeecececeeseeeeeeeeeeeeeteeeeeeeetaees 1 26 48303 48303 AD ADS i ss esi a ches sit ale eae ee hee eens AaS a ace 1 27 41632 F017341 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 fe
7. 61109 2988 USA 815 397 7070 Fairmont Assembly 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 fluid 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 con tact coat the surfaces with hydraulic fluid 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 flanged end first 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 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 Install the adapters 24 i
8. A 6 fs EA ae E A eee ee 4 27 43095 F015251 Screw cap 1 4 20 x 75 flat head H4802 serial code FKA03500 and above H4802 1 serial code FKM00020 and above and H4802 6 serial code FKF01500 and above eeeeeeseeeeneeeeeeees 4 28 41691 F018347 Screw cap 5 16 18 x 1 000 socket head eeeeeeeeeeeeeeeeeeeeeneees 4 29 48369 48369 Hose 3 8 x 56 with 9 16 18 JIC swivel at both ends 2 30 41413 F013326 Adapter pipe 9 16 18 UNF SAE O ring boss x 9 16 18 M JIC H4802 and H4802 1 oo eee eee cceeeeeeeceeeeeseeeeaeeseeteaeesseeeeaeeeeaeeeaeete 5 30 41413 F013326 Adapter pipe 9 16 18 UNF SAE O ring boss x 9 16 18 M JIC H4802 6 and 43227 a iee reour hene aape iaro E AE eaea A et iaia 4 31 41422 F013518 Adapter pipe 9 16 18 M JIC x 3 4 16 UNF SAE O ring boss H4802 and H4802 1 eee eeeceeeeeeeneeeeeeeeeetseeeseeeenaees 1 Greenlee Textron Subsidiary of Textron Inc 8 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairm nt 4802 H4802 1 H4802 6 and 43227 Pole Tampers Parts List UPC No Key 78 3310 Part No Description Qty 32 40291 111953K Valve body remote ON OFF H4802 and H4802 1 n se 1 33 41888 F021673 Plug pipe 1 16 M NPT H4802 and H4802 1 seses 2 34 40340 113418 Spool H4802 and H4802 1 oo eeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeesneeeeaeeeeeeees 1 35 41489 F015257 O ring 437 x 562 x 062 68 H4802 and H4802 1 eee 2 36 40228 106576 Button spool end H4802 and
9. SERVICE MANUAL Fairment H4802 H4802 1 H 4802 6 and 43227 Pole Tampers Serial Codes FKA FKF FKM FZP FZR FZT and FZV Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 999 1042 0 REV 4 2001 Greenlee Textron 8 01 Fairmont Table of Contents Safely reir ie aanre aa a etd a A las a LAAT dies 2 Purpose of this Manual seeeeseeeseeersseeeressrrnsssrnnn 2 Other PublicatonS isinira aeiiae a aiaa 2 Important Safety Information cccceeeeeeeeeeeeeneees 3 4 Disassembly aeoaea ei ea i 5 IMS POCTION oar a aa E AEE E ANE E PAEA 5 ASSOMDIY A a a R NAE 6 Illustration and Parts List 7 9 ACCESSOMNES E E A E r Aa E AE D H4802 H4802 1 H4802 6 and 43227 Pole Tampers 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 H4802 Serial Codes FKA and FZP H4802 1 Serial Codes FKM and FZR H4802 6 Serial Codes FKF and FZT 43227 Serial Code FZV Keep this manual available to all personnel Replacement manuals are available upon reque
10. mper 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 5 4455 Boeing Dr e Rockford IL
11. nto the ports on the top of the valve body Install the tamper foot 21 onto the end of the ram 10 11 Greenlee Textron Subsidiary of Textron Inc 6 H4802 H4802 1 H4802 6 and 43227 Pole Tampers 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 onto the control spool Slide the control spool through the valve body so that it protrudes just far enough to install the other O ring 35 4 Install the buttons 86 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 3
12. ose to the proper ports Failure to observe this warning can result in severe injury or death AWARNING Do not change accessories inspect adjust or clean tool when it is connected to a power source Accidental start up can result in serious injury Failure to observe this warning can result in severe injury or death ACAUTION Hydraulic oil can cause skin irritation e 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 IMPORTANT Procedure for connecting or disconnecting hydraulic hoses fittings or components Move the flow lever on the hydraulic power source to the off position Stop the hydraulic power source 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 4 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 Greenlee Textron Subsidiary of Textron Inc Fairmont 4802 H4802 1 H4802 6 and 43227 Pole Tampers 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
13. st at no charge Other Publications Operation Manual Publication 999 3019 6 Specifications and Parts Publication 999 3112 5 SAE Standard J1273 Hose and Hose Assemblies Publication 999 3032 3 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 Loctite and 242 are registered trademarks of Loctite Corporation KEEP THIS MANUAL Greenlee Textron Subsidiary of Textron Inc 2 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 Fairmont H4802 H4802 1 H4802 6 and 43227 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 defined below indicates the severity of the hazard The message after the signal word provides information for preventing or avoiding the hazard ADANGER Immediate hazards which if not avoided WILL result in severe injury or death AWARNING Hazards which if not avoided COULD result in severe injury or death ACAUTION Hazards or unsafe practices which if not avoided MAY result in injury or property damage AWARNING 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
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