48200, 48520, and 48525 Pruners 48520, and 48525 Pruners Greenlee Textron / Subsidiary of Textron Inc. 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070 Table of Contents

SERVICE MANUAL

999 1296.1 REV 10 © 2001 Greenlee Textron 11/01

Read and understand all of the instructions andsafety information in this manual before operatingor servicing this tool.

48200, 48520, and 48525Pruners

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

48200, 48520, and 48525 Pruners

Greenlee Textron / Subsidiary of Textron Inc. 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

Model 48520 (Serial Code FRK) andModel 48525 (Serial Code FRL) ......................... 18–19

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

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

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

KEEP THIS MANUAL

All specifications are nominal and may change as design improve-ments occur. Greenlee Textron shall not be liable for damagesresulting from misapplication or misuse of its products.

Super Sleeve is a trademark of Greenlee Textron.

Safety

Safety is essential in the use and maintenance ofFairmont tools and equipment. This manual and anymarkings on the tool provide information for avoidinghazards and unsafe practices related to the use of thistool. Observe all of the safety information provided.

Purpose of this Manual

This manual is intended to familiarize all personnel withthe safe service procedures for the following Fairmonttools:

48200 Open/Closed-Center Hydraulic PrunerSerial Codes FRJ and FNY

48520 Open-Center Hydraulic PrunerSerial Codes FRK and FPK

48525 Closed-Center Hydraulic PrunerSerial Codes FRL and FPL

Keep this manual available to all personnel.

Replacement manuals are available upon request at nocharge.

Other Publications

Operation Manual: Publication 999 3033.1

Specifications and Parts:

48200 (Serial Code FRJ): Publication 999 3034.0

48520 (Serial Code FRK): Publication 999 3035.8

48525 (Serial Code FRL): Publication 999 3035.8

SAE Standard J1273 (Hose and Hose Assemblies):Publication 999 3032.3

48200, 48520, and 48525 Pruners


IMPORTANT SAFETY INFORMATION

This symbol is used to call your attention to hazardsor unsafe practices which could result in an injury orproperty damage. The signal word, defined below,indicates the severity of the hazard. The messageafter the signal word provides information forpreventing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,MAY result in injury or property damage.

Hazards which, if not avoided, COULD result insevere injury or death.

Immediate hazards which, if not avoided, WILLresult in severe injury or death.

SAFETYALERTSYMBOL

Read and understand all of theinstructions and safety information inthis manual before operating orservicing this tool. Refer also to thefollowing manuals, which are listedunder “Other Publications”:

• Operation Manual

• Specifications and Parts

Failure to observe this warning canresult in severe injury or death.

Electrical shock hazard:

• When using this tool near energizedelectrical lines, use only certifiednonconductive hoses and properpersonal protective equipment.

• Keep fiberglass extension cleanand dry when working aroundenergized electrical lines.Accumulated grease and dirtreduce insulating properties of tool.

Failure to observe these warningscan result in severe injury or death.

Skin injection hazard:

Oil under pressure easily puncturesskin, causing serious injury,gangrene, or death. If you are injuredby escaping oil, seek medicalattention immediately.

• Do not use hands to check forleaks.

• Do not hold hose or couplers whilethe hydraulic system is pressurized.

• Depressurize the hydraulic systembefore servicing.

Wear eye protection when operatingor servicing this tool.

Failure to wear eye protection canresult in serious eye injury fromflying debris or hydraulic oil.

48200, 48520, and 48525 Pruners


IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replacewhen necessary.

• Keep all parts of the body away from the cutterhead when the tool is connected to a powersource.

• Do not dress the blade or inspect, adjust, or cleantool when it is connected to a power source.Accidental start-up can result in serious injury.

• Inspect the blade every operating day. Removeand destroy the blade if cracks, chips, or gougesare evident. A damaged blade can break andstrike nearby personnel.

• Maintain a firm grip on tool, using both hands atall times. Serious injury can result if an operatordoes not control the tool.

• Do not lock the trigger in the Power-ON position.Operator cannot stop tool when trigger is locked.

• Wear protective gloves when handling,sharpening, or adjusting the blade. The blade cancut even when stationary.

Failure to observe these warnings can result insevere injury or death.

Do not exceed the maximum hydraulic flow,pressure relief, or back pressure listed in theSpecifications and Parts manual.

Failure to observe this warning can result in severeinjury or death.

Do not disconnect tool, hoses, or fittings while thepower source is running or if the hydraulic fluid ishot. Hot hydraulic fluid can cause serious burns.

Do not reverse hydraulic flow. Operation withhydraulic flow reversed can cause tool malfunction.Connect the pressure (supply) hose and tank(return) hose to the proper ports.

Failure to observe this warning can result in severeinjury or death.

• Inspect hydraulic hoses and couplings everyoperating day. Repair or replace if leakage,cracking, wear, or damage is evident. Damagedhoses or couplings can fail resulting in injury orproperty damage.

• Make sure all bystanders are clear of the workarea when operating the tool. Nearby personnelcan be injured by falling debris.

Failure to observe these precautions can result ininjury.

Hydraulic oil can cause skin irritation.

• Handle the tool and hoses with care to preventskin contact with hydraulic oil.

• In case of accidental skin contact with hydraulicoil, wash the affected area immediately to removethe oil.

Failure to observe these precautions can result ininjury.

Procedure for connecting or disconnecting hydraulichoses, fittings, or components:

1. Move the flow lever on the hydraulic powersource to the off position.

2. Stop the hydraulic power source.

3. Follow the sequence under “Hose Connections”in the Operation Manual to prevent pressurebuildup. In case some pressure has built up,loosen hoses, fittings, or components slowly.

Emergency stop/power failure procedure:

1. Release the trigger.

2. Shut off the hydraulic power source.

48200, 48520, and 48525 Pruners


Service

The service life of the tool will be maximized by propercare and maintenance. The maintenance schedule thatfollows is recommended.

Maintenance Schedule

Daily

1. Wipe all tool surfaces clean, especially the fiberglassextension, of grease, dirt and foreign material. If thefiberglass extension cannot be wiped clean, use anyapproved fiberglass cleaning products.Do not use solvents or gasoline to clean thefiberglass extension.

2. Inspect the cutter unit. Check for wear at the pivotingand sliding surfaces. Repair blades with nicks orgouges with a very fine file and a pocket whetstone.Remove and destroy any cutter blade withsevere cracks, chips, or gouges.

3. Lubricate the pivoting and sliding surfaces severaltimes every operating day with 20W or 30W oil.Apply a heavy coating to these surfaces beforestoring.

4. Several times a day the blade and hook must bedressed with a pocket whetstone. This keeps thecutting edge from rolling and chipping.

5. Make sure the extension tube connector nut andthe cutter mounting bracket bolts are tightenedsecurely.

6. Inspect hydraulic system hoses and fittings for signsof leaks, cracks, wear, or damage.

7. To prevent contamination, always install dust capsover couplers when tool is disconnected.

Monthly

Perform a thorough inspection of the hydraulic hosesand fittings as described in publication 999 3032.3,SAE J1273 (Hose and Hose Assemblies).

Lubrication

Lubricate the indicated pivoting and sliding surfacesseveral times every operating day with 20W or 30W oil.Apply a heavy coating to these surfaces before storing.

Wear eye protection when operatingor servicing this tool.

Failure to wear eye protection canresult in serious eye injury fromflying debris or hydraulic oil.

• Do not dress the blade or inspect, adjust, or cleantool when it is connected to a power source.Accidental start-up can result in serious injury.

• Inspect the blade every operating day. Removeand destroy the blade if cracks, chips, or gougesare evident. A damaged blade can break andstrike nearby personnel.

Failure to observe these warnings can result insevere injury or death.

Inspect hydraulic hoses and couplings everyoperating day. Repair or replace if leakage, crack-ing, wear or damage is evident. Damaged hoses orcouplings can fail resulting in injury or propertydamage.

Failure to observe this precaution can result ininjury.

oil

48200, 48520, and 48525 Pruners


Service (cont’d)

Blade and Hook Maintenance Tension Adjustment

The tension adjustment should be checked after aboutone hour of use on a new cutter. A wearing-in processtakes place during this time and the cutter pivot nut mayneed tightening.

The cutter hook and cutter blade must fit togethersnugly. If they are too tight, the cutter will not performproperly. If the fit is too loose, the tool will not cutcleanly, and damage to the tool may occur.

1. Disconnect the tool from the power source.

2. Remove hex nuts (1), shoulder bolts (2), and guideroller (3).

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

4. Remove the cutter bolt lock (6).

5. Tighten shoulder bolt (7) to a very heavy drag whenthe blade is opened or closed. This drag can betested manually without hydraulic power. Whenheavy drag has been set, loosen shoulder bolt (7)one-quarter (1/4) turn.

6. Using one wrench on the shoulder bolt (7) and asecond wrench on the nut, tighten the nut. Thetension is correct when a moderate drag is felt whenmoving the cutter blade by hand.

Dressing the Cutter Blade and Hook

A buildup of metal, referred to as a wire edge, will formon the edge of a new blade as it seats across the face ofthe hook. This wire edge must be removed severaltimes, until the blade seats itself to the hook.

Rough and dull edges may form on the cutter blade andthe cutter hook from normal usage. Both componentsmust be dressed with a pocket whetstone several timeseach operating day. This keeps the cutting edges sharpand prevents them from rolling and chipping.

1. Stop the power source.

2. Use the provided pocket whetstone (L046108) toremove the wire edge by rubbing the whetstoneback and forth on the blade and hook until thesurface irregularities are smooth and the bladeedge is sharp.

Sharpening the Cutter Blade

When a blade has acquired deep nicks and gouges orhas become too dull to be sharpened with a whetstone,remove the cutter blade and sharpen it with a fine metal-cutting file.

1. Disconnect the tool from the power source.

2. Remove the cutter blade from the tool. Refer to“Cutter Head” in the “Disassembly” section of thismanual.

3. Sharpen the blade with a fine metal-cutting file.Note: When sharpening with a file, it is important tomaintain the original shape and contour of the blade.An equal amount of material must be removed fromall parts of the blade. Do not sharpen the blade to athin, razor edge. This reduces the strength andshortens the service life of the blade. Do not overusethe file. It is not advisable to remove large amountsof metal from the blade.

4. After the contoured side of the blade has beensharpened, turn it over so that the flat side is facingup. Dress the blade with a whetstone just enough tosmooth away any nicks and irregular sharp edgesthat may have formed during sharpening of thecontoured side of the blade.

5. Remove any nicks or rough edges on the hook witha pocket whetstone. The inner curve of the hookshould have a beveled cutting edge. This can beachieved with the whetstone also. Failure to do thiscan ruin a new or sharpened blade.

Do not dress the blade or inspect, adjust or cleantool when it is connected to a power source.Accidental start-up can result in serious injury.

1, 2 7

6

4, 5

1, 2, 3

48200, 48520, and 48525 Pruners


Service (cont’d)

Closure Adjustment

Proper closure adjustment of the cutter is set at thefactory and should not be readjusted until repeatedsharpening of the blade or installation of a new bladerequires it. When open, the flat edge of cutter bladeshould be flush with an imaginary line between the twoprotrusions on the connector link as shown below.

Flat Edge ofCutter Blade

Imaginary Line

When closed, the blade should cover 5 mm (3/16") onthe face of the cutter hook.

If the blade is improperly adjusted, blade closuremust be readjusted while the blade is in the fullyopen position.

1. Stop the power source and disconnect the tool fromthe power source.

2. Loosen jam nut on lower end of outer extensiontube.

• If blade overlaps less than 5 mm (3/16"), or ifblade opening is too great, thread the outerextension tube further onto the actuator end.

• If blade overlaps more than 5 mm (3/16"), or ifblade is not opening far enough, unscrew theouter extension tube from the actuator end.

3.Tighten the nut.

Connect the tool to power source and actuateseveral times. Blade action should be smooth anduniform from fully-open position to fully-closedposition [5 mm (3/16") beyond the hook edge]. Thereshould be no sloppiness in the cutter unit linkage.

Repeat the above procedure until blade closureis correct.

Troubleshooting

Before You Begin

1. Tool must be connected to the correct power sourcesystem. Refer to the Specifications and Partsmanual for the type of hydraulic system required.Verify the power source hydraulic system.

2. Verify that the pressure and return hoses areconnected properly to the tool and power sourceports.

3. Power source reservoir must be filled to FULL markwith hydraulic fluid.

4. Start the power source. All power source shut-offdevices must be engaged or opened (clutch-engaged, separate ON/OFF valves open, etc.).

5. After verifying all of the above, check the tool to seeif it operates.

If the tool does not operate, it will be necessaryto pinpoint the tool, hose, or power source as theproblem area. The following steps will help todetermine the problem area.

Determine the Problem Area

1. Check the power source and pressure if the propergauges and tools are available. If these items arenot available, proceed to the next step.


3. Disconnect the tool from the hoses and powersource.

4. Connect a known working tool to the hoses andpower source. Refer to the tool’s operator’s manualfor correct hookup procedure. Start the powersource.

• If the known working tool operates, the problem isin the disconnected tool. Refer to the Trouble-shooting charts in this manual.

• If the known working tool does not operate, theproblem is likely to be in the hoses or the powersource. Proceed to next step.


6. Disconnect the existing hoses from the knownworking tool and power source.

7. Connect a different set of hoses to the knownoperating tool and power source. Start the powersource.

• If the known working tool operates with thedifferent set of hoses, the problem is in thedisconnected hoses.

• If the known working tool does not operate, theproblem is in the power source. Refer to yourpower source operator’s manual fortroubleshooting.

48200, 48520, and 48525 Pruners


Troubleshooting (cont’d)

Probable CauseProblem Probable Remedy

Tool inoperative. Tool connected to improper power Verify that the power source meetssource hydraulic system. the specifications. Refer to the

Specifications and Parts manual.

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

Incorrect fluid viscosity. Use fluid viscosity recommended.Refer to the Specifications andParts manual.

Tool components loose. Tighten component hardware.

Dirt, contaminants, etc., in tool Disassemble tool and cleancomponents. components.

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

Tool operates erratically. Hydraulic fluid cold. Viscosity of oil may be too high at startof tool operation. Allow oil to warm tooperating temperature. Actuating toolintermittently will reduce time requiredto warm oil to an efficient operatingtemperature.

Air in hydraulic system. Check pump suction line for damageor loose clamps. Tighten clamps orreplace components if necessary.Fill reservoir.

Tool components sticking or binding. Check for dirt or gummy deposits.Clean components. Check for worn ordamaged components. Replacecomponents.

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

Tool operates slowly. Power source components not Refer to power source operator’sadjusted correctly. manual for recommended speed, flow,

and pressure settings.

Hydraulic fluid cold. Viscosity of oil may be too high at startof tool operation. Allow oil to warm tooperating temperature. Actuating toolintermittently will reduce time requiredto warm oil to an efficient operatingtemperature.

48200, 48520, and 48525 Pruners



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

Hydraulic fluid viscosity too heavy. Use fluid viscosity recommended.Refer to the Specifications andParts manual.

Tool components loose. Tighten component hardware.



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


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

Hydraulic fluid viscosity exceeds Use fluid viscosity recommended.specifications. Refer to the Specifications and

Parts manual.

Hydraulic fluid dirty. Drain reservoir, flush and fill with cleanfluid. Change filter.

Tool control valve stuck in partial Free spool so it returns to neutralpower-ON position. position.

Power source components not adjusted Refer to power source operator’scorrectly. manual for recommended speed,

flow, and pressure settings.


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



48200, 48520, and 48525 Pruners



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

Misalignment or binding of control Correct alignment. Lubricate linkagelinkage. joints. Replace damaged components.

Valve components worn or damaged. Disassemble valve and replace wornor damaged components.

Tool operates backwards. Hydraulic flow reversed to tool. Reverse flow to tool. Check forvalve in system that has reversed flow.Check hoses for proper flow.

Hydraulic pressure and return lines Disconnect hoses. Reverse couplers.connected to opposite tool ports. Reconnect hoses to proper tool ports.

Tool components assembled incorrectly. Disassemble tool. Reassemblecorrectly.

Tool operates, but blade does Cutter blade loose. Tighten cutter blade nut and boltnot cut. securely. Refer to “Tension Adjustment”

in the “Service” section of this manual.

Cutter blade not closing properly. Readjust blade closure. Refer to“Closure Adjustment” in the “Service”section of this manual.

Cutter blade dull. Remove blade and sharpen, or installa sharp, new blade.

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


48200, 48520, and 48525 Pruners


Disassembly

Complete disassembly of the tool is not recommended.If a complete overhaul is necessary, return the tool toyour nearest authorized Fairmont distributor or toFairmont.

The disassembly procedure is divided into sections ofthe tool. Disassemble only the section(s) necessary tocomplete the repair.

Disassemble the tool on a flat, clean surface. Take carenot to lose or damage any parts that may fall free duringdisassembly.

Inspect all parts as they are disassembled and matingparts in tool that are not removed for signs of damage,wear, cracks, etc. Replace any parts which appear to bedamaged.

When removing O-rings which must slide over sharpsurfaces, be careful not to damage the O-rings. Use arolling motion, and apply hydraulic fluid to ease removalof O-rings if necessary.

Cutter Head

1. Remove hex nut (51), shoulder bolt (49), and guideroller (50).

2. Remove hex nut (51) and shoulder bolt (63).Remove connector link (48).

3. Remove socket head cap screw (60) and lockwasher (59). Remove bolt lock (56).

4. Remove elastic stop nut (58), hex head cap screw(57), and shim (54). Remove shear blade (53).

5. Remove hex head cap screws (62), lock washers(61), cutter hook (52), and cutter brace (55).

6. Loosen connector nut and unscrew cutter mount(47) from extension tube (45). Remove O-ring (46).

Outer Extension Tube and Inner Pull Rod

1. Loosen jam nut (68) and remove outer extensiontube (45) from upper end actuator (27).

2. Remove retainer sleeve (44) and pin (43) from lowerextension rod end to disconnect the inner pull rod(42).

Skin injection hazard:

Oil under pressure easily puncturesskin, causing serious injury,gangrene, or death. If you are injuredby escaping oil, seek medicalattention immediately.

• Do not use hands to check forleaks.

• Do not hold hose or couplers whilethe hydraulic system is pressurized.

• Depressurize the hydraulic systembefore servicing.

Do not disconnect tool, hoses, or fittings while thepower source is running or if the hydraulic fluid ishot. Hot hydraulic fluid can cause serious burns.

Procedure for connecting or disconnecting hydraulichoses, fittings, or components:

1. Move the flow lever on the hydraulic powersource to the off position.

2. Stop the hydraulic power source.

3. Follow the sequence under “Hose Connections”in the Operation Manual to prevent pressurebuildup. In case some pressure has built up,loosen hoses, fittings, or components slowly.

48200, 48520, and 48525 Pruners


Ram and Piston Actuator

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

2. Use a strap wrench to unscrew cylinder (19) fromupper end (27). The piston and rod assembly (20)will remain in cylinder (19) when unscrewing andremoving from upper end (27).

3. Remove internal retaining ring (32), seal retainer(31), rod seal (30), rod seal support (29), feltbreather filter (28), and O-ring (15) from upper end(27).

4. Remove piston and rod assembly (20) with seal(21, 22), etc., from cylinder (19).

5. Remove the seal (21, 22) from piston and rodassembly (20).

6. Remove the internal retaining ring (18) from inside ofpiston and rod assembly (20). Remove seal body(26) from piston and rod assembly and O-rings(24, 25) from seal body (26).

7. Remove O-ring (15) from handle (1). Removeinternal retaining ring (18) which secures return tubeassembly (17) into the handle (1). Remove returntube assembly. Remove O-ring (16) from return tubeassembly.

8. Remove the round slotted head machine screws(14) and internal tooth lock washers (13). Removetrigger guard (12).

9. Remove the external retaining rings (11) and slidetrigger pivot pin (10) out of handle (1). Removetrigger (9).

10. Remove retaining ring (6) from valve handle (1)opposite trigger side. Also remove washer (8) andspring (7). Remove retaining ring (6) from triggerside, washer (5). Remove spool (3).

SUPER SLEEVE™ (on 48200 Model Only)

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

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

3. Remove ball (37), spring (38), pin (39), and plug (40)from sleeve (35). Remove O-ring (36) from sleeve(35).

Inspection

1. Cutter Blade (53): Cutting surface must be smoothand free of grooves, nicks, or gouges. If blade hasminor grooves, nicks, or gouges, remove them andsharpen blade with a file or the pocket whetstoneprovided with tool. If blade has severe damage,replace the blade. Both holes in blade are pivotholes. If either hole is out-of-round, replace blade.

2. Cutter Hook (52): The surface of the cutter hookwhich mates with the cutter blade (53) must besmooth and free of nicks or gouges. If hook hasminor blemishes, remove them with a file. The innerradius of hook’s cutting surface must be beveledslightly with a pocket whetstone provided with tool.

3. Valve Spool (3): All surfaces must be smooth andfree of grooves, nicks, or scratches. If it has grooves,nicks, or scratches, replace the spool.

4. Piston and Rod Assembly (20): All surfaces mustbe smooth and free of grooves, nicks, or scratches.If either component has grooves, nicks, or scratches,replace the component.

5. Cylinder (19): All inner surfaces must be smoothand free of grooves, nicks, or scratches. If eithercomponent has severe grooves, nicks, or scratches,replace the component.

6. Inner Extension Assembly (42): All componentsmust be straight and free of damage. Replace if bentor damaged.

7. O-Rings and Seals: Always replace O-rings andseals in components that have been disassembledwith new O-rings and seals during assembly. Apacking kit is available that includes all O-rings andseals.

8. Felt Breather Filter (28): Always replace the feltbreather filter with a new breather filter duringassembly.

Disassembly (cont’d)

48200, 48520, and 48525 Pruners


Assembly

When assembling parts, refer to the Illustrations andParts Lists for correct orientation and placement of parts.

Clean all parts with solvent and then dry thoroughly. Donot expose O-rings or other packing components tosolvent for long periods of time.

Inspect all parts as they are assembled for signs ofdamage, wear, cracks, etc. Do not install any partswhich appear to be damaged.

Apply hydraulic fluid or O-ring lubricant to all O-rings andall metal surfaces which O-rings must slide over. Wheninstalling an O-ring over a sharp edge, use a rollingaction to avoid damage to the O-ring.

Wherever assembled parts cause metal-to-metalcontact, coat the surfaces with hydraulic fluid or O-ringlubricant.

Handle and Valve

1. Install O-ring (2), spool (3), spring (7), washer (8),and retaining ring (6) to upper end of insulated valvebody handle (1).

2. Install O-ring (4), washer (5), and retaining ring (6)on lower end of valve body handle (1).

3. Position trigger (9) on valve handle (1), aligningholes in each component. Install trigger pivot pin(10) and secure in place with two external retainingrings (11).

4. Position trigger guard (12) on handle (1) and securewith round slotted head cap screws (14) and internaltooth lock washers (13). On later model pruners, usetwo button-head screws to secure one end guard tothe handle.

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

6. Install O-ring (16) on return tube assembly (17).Install return tube assembly in the handle andsecure in place with internal retaining ring (18).

7. Install felt breather filter (28), rod seal support (29),rod seal (30), and seal retainer (31) into upper end(27). Secure components in place with internalretaining ring (32). Install O-ring (15) on upper end(28).

8. Install ball (37), spring (38), pin (39), plug (40), andO-ring (36) in sleeve (35). Install O-rings (34) oncylinder (19) on 48200 Model only.

9. Install sleeve (35) and retaining rings (33) oncylinder (19) on 48200 Model only.

10. Clamp upper end (27) in a vise and thread cylinder(19) onto upper end (27). Tighten with a strapwrench.

11. Use steps 12 through 22 to install piston seal(21, 22) on piston and rod assembly (20).

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

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

14. Bend the seal over as shown. This will help hold theseal in the groove when installing.

15. Remove the seal from the groove.

48200, 48520, and 48525 Pruners


Assembly (cont’d)

Handle and Valve (cont’d)

16. Place the bent section of the seal in the groove onthe piston as shown.

17. Install seal by using a blunt tool with no sharpcorners or edges, such as the shank portion of anO-ring installation tool.

18. Stretch the seal over the outside diameter of thepiston until it is in the groove.Note: Overstretching will break the seal.

19. The piston seal will be stretched out of shape wheninstalled in the groove. Place the piston with the sealinstalled on a clean, flat surface and roll it back andforth to reshape the seal.

20. Use a sizing tube fixture to compress and form theseal back to the original shape. The dimensions forthis fixture are as shown. The tapered surface mustbe smooth—approximately a 16 micro finish.

1.81

DIA

1.00

1.69

0 RE

F

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

48200, 48520, and 48525 Pruners


Outer Extension Tube and Inner Pull Rod

1. Install pull rod (42) to piston assembly (20) with pin(43) and secure with sleeve (44).

2. Slide outer tube assembly (45) over inner pull rod(42) and screw onto upper actuator end (27). Threadthe jam nut (68) onto the outer tube (45). Refer to“Closure Adjustment” in the “Service” section of thismanual.

Cutter Head

1. Screw cutter mount (47) in end of outer extensiontube (45).

2. Fasten cutter hook (52) and cutter brace (55) toopposing sides of cutter mount (47) with hex headcap screws (62) and lock washers (61).

3. Position cutter blade (53) and washer (54) betweencutter hook (52) and cutter brace (55). Secure cutterblade (53) with hex head shoulder bolt (57) and hexnut (58).Note: The cutter hook (52) and cutter blade (53)must fit together snugly. If they are too tight, thecutter will not perform properly. If the fit is too loose,the tool will not cut cleanly and damage to the toolmay occur. Wood may jam in between the hook andcutter blade, springing them apart and permanentlybending either one.

4. Install bolt lock (56) on cutter brace (55) and securewith socket head cap screw (60) and lock washer(59).Note: If slot in bolt lock (56) does not align with holein cutter brace (55), turn bolt lock over. This willallow bolt lock to be positioned so that slot will lineup with matching hole in the cutter brace, allowingsocket head cap screw (60) to secure it in place.

Handle and Valve (cont’d)

22. Place the piston with the seal in the tapered end ofthe fixture and push it down and completely through.

23. Install O-rings (24, 25) on seal body (26). Install sealbody and O-rings (24, 25, 26) in bottom endof piston and rod assembly (20) and secure intoplace with internal retaining ring (18).

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

25. Screw handle assembly (1) onto cylinder (19). Sealretainer (41) into end of the upper end (27). Threadnut (68) onto upper end (27) approximately 25 mm(1").

Assembly (cont’d)

48200, 48520, and 48525 Pruners


Illustration—Model 48200 (Serial Code FRJ)

1269

1314

58

5756

555453

52

51

63

48

61

62

61

59 60

49

50

47

40

39

3837

33

36

35

34

33

19

64

67

41

68

27 66

65

15

28

30

29

31

32

18

17

16

18

22

21

20

24

25

26

43

44

46

45

15

1

11

10

9

65

43

7071

68

72

51

42

48200, 48520, and 48525 Pruners


Parts List—Model 48200 (Serial Code FRJ)

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

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

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

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

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

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

7 40087 094826 Spring, compression,.325 x .427 x 1.27 ................................ 1

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

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

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

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

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

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

14 41677 F018077 Screw, machine, #10–32 x .375,round head .......................................... 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

54 40001 062593 Washer, flat, .484 x 1.50 x .010,brass .................................................... 1

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

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

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

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

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

60 42785 L083028 Screw, cap, #10–32 x .250,socket head ......................................... 1

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

62 42781 L083013 Screw, cap, 1/4–28 x .750,hex head, grade 8 ............................... 2

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

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

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

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

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

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

69 43701 F021676 Screw, cap, #10–32 x .375,socket button head .............................. 2

70 42952 F017347 Adapter, 3/8 NPTF to 9/16-18,1.21 LG ................................................ 1

71 41638 F017348 Adapter, 3/8 NPTF to 3/4-16,1.28 LG ................................................ 1

Repair Kit

* 48208 48208 Packing kit (includes itemsmarked with an asterisk) ..................... 1

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

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

48200, 48520, and 48525 Pruners


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

69

1314

58

5756

555453

52

51

63

48

61

62

61

59

60

49

50

47

19

64

67

41

68

276665

15

28

30

29

31

32

18

17

16

18

22

21

20

242526

43

44

46

45

70

15

1

11

10

9

65

4

3

12

68

72

51

42

26a

23

48200, 48520, and 48525 Pruners


Parts List—Model 48520 (Serial Code FRK) and Model 48525 (Serial Code FRL)UPC No.

Key 78-3310- Part No. Description Qty1 48813 48813 Handle ................................................. 1

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

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

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

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

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

7 40087 094826 Spring, compression,.325 x .427 x 1.27 ................................ 1

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

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

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

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

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

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

14 41677 F018077 Screw, machine, #10–32 x .375,round head .......................................... 1

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

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

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

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

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

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

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

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

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

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

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

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

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



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

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

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

UPC No.Key 78-3310- Part No. Description Qty32 42841 L085061 Retaining ring ...................................... 1

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


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


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

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

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


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

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

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

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

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

54 40001 062593 Washer, flat, .484 x 1.50 x .010,brass .................................................... 1

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


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

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

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

60 42785 L083028 Screw, cap, #10–32 x .250,socket head ......................................... 1

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

62 42781 L083013 Screw, cap, 1/4–28 x .750,hex head, grade 8 ............................... 2

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

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

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

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

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

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

69 43701 F021676 Screw, cap, #10–32 x .375,socket button head .............................. 2

Repair Kit


48200, 48520, and 48525 Pruners


Illustration—Model 48200 (Serial Code FNY)

58

5756

555453

52

51

63

48

61

62

61

59 60

49

50

47

40

39

3837

33

36

35

34

33

19

6467

41

68

27

15

28

30

29

31

32

18

17

16

18

22

21

20

24

25

26

43

44

46

45

15

1

11

10

9

65

4

3

121314

1314

68

72

51

42

66

65

48200, 48520, and 48525 Pruners


Parts List—Model 48200 (Serial Code FNY)UPC No.


2* 41488 F015255 O-ring .................................................. 1

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

4* 41489 F015257 O-ring .................................................. 1

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

6 41712 F018511 Retaining ring ...................................... 2

7 40087 094826 Spring .................................................. 1

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

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

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

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

12 48180 48180 Trigger guard ....................................... 1

13 42812 L084015 Lock washer #10 ................................. 2

14 41677 F018077 Round head machine screw,#10-32 x 3/8 ........................................ 2

15* 42744 L080035 O-ring .................................................. 2

16* 41331 F010777 O-ring .................................................. 1

17 42537 L060043 Return tube assembly ......................... 1

18 41648 F017595 Retaining ring ...................................... 2

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

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

21* 48204 48204 O-ring .................................................. 1

22* 48205 48205 Piston seal ........................................... 1

24* 41402 F012946 O-ring .................................................. 1

25* 42745 L080036 O-ring .................................................. 1

26 42542 L060052 Seal body ............................................ 1



29* 42686 L060607 Rod seal support ................................. 1

30* 42760 L081004 Rod seal .............................................. 1

31* 42708 L060729 Seal retainer ........................................ 1

32 42841 L085061 Retainer ring ........................................ 1

33 48202 48202 Retaining ring ...................................... 2

34* 43170 F016713 O-ring .................................................. 2

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

UPC No.Key 78-3310- Part No. Description Qty36* 41618 F016876 O-ring .................................................. 1

37 41295 F008541 Ball ...................................................... 2

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

39 48229 48229 Dowel .................................................. 2

40 41850 F021495 Pipe plug/level seal 1/8 NPT ............... 2

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


43 42405 L055153 Piston extension rod pin ...................... 1


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

46* 41335 F010894 O-ring, 9/16 x 3/4 x 3/32 ...................... 1

47 48172 48172 Cutter mount assembly ....................... 1


49 41149 139577 Bolt ...................................................... 1

50 42401 L055060 Connecting link guide roller ................. 1

51 41367 F011686 Hex lock nut ......................................... 2

52 48197 48197 Cutter hook .......................................... 1

53 42508 L060009 Cutter blade ......................................... 1

54 40001 062593 Washer ................................................ 1

55 42510 L060011 Cutter brace ......................................... 1


57 40078 093149K1 Bolt ...................................................... 1

58 41555 F015618 Hex lock nut, 7/16-20 .......................... 1

59 42807 L084001 Lock washer #10 ................................. 1

60 42785 L083028 Socket head cap screw,#10-32 x 1/4 ........................................ 1

61 42808 L084005 Lock washer 1/4 .................................. 2

62 42781 L083013 Hex head cap screw, 1/4-28 x 3/4 ....... 2

63 40080 093150K1 Bolt ...................................................... 1

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

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

66 40580 128066 Decal, warning ..................................... 1

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

68 42551 L60062 Nut ....................................................... 1

Repair Kit


48200, 48520, and 48525 Pruners


Illustration—Model 48520 (Serial Code FPK)

58

5756

555453

52

51

63

48

61

62

61

59

60

49

50

47

19

64

67

65

41

68

27

15

28

30

29

31

32

18

17

16

18

22

21

20

26

43

44

46

4515

1

11

10

9

65

4

3

121314

1314

68

72

51

42

23

66

48200, 48520, and 48525 Pruners


Parts List—Model 48520 (Serial Code FPK)UPC No.


2* 41488 F015255 O-ring .................................................. 1

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

4* 41489 F015257 O-ring .................................................. 1

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

6 41712 F018511 Retaining ring ...................................... 2

7 40087 094826 Spring .................................................. 1

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

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

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

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

12 48180 48180 Trigger guard ....................................... 1

13 42812 L084015 Lock washer #10 ................................. 2


15* 42744 L080035 O-ring .................................................. 2

16 43355 F021753 O-ring .................................................. 1


18 41648 F017595 Retaining ring ...................................... 2

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

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

21* 48204 48204 O-ring .................................................. 1

22* 48205 48205 Piston seal ........................................... 1

23* 42539 L060038 Bypass seal ......................................... 1

26 43263 L60039 Seal body ............................................ 1




30* 42760 L081004 Rod seal .............................................. 1

31* 42708 L060729 Seal retainer ........................................ 1

32 42841 L085061 Retainer ring ........................................ 1

UPC No.Key 78-3310- Part No. Description Qty41 42506 L060007 Bushing ............................................... 1




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

46* 41335 F010894 O-ring, 9/16 x 3/4 x 3/32 ...................... 1



49 41149 139577 Bolt ...................................................... 1


51 41367 F011686 Hex lock nut ......................................... 2

52 48197 48197 Cutter hook .......................................... 1

53 42508 L060009 Cutter blade ......................................... 1

54 40001 062593 Washer ................................................ 1

55 42510 L060011 Cutter brace ......................................... 1


57 40078 093149K1 Bolt ...................................................... 1

58 41555 F015618 Hex lock nut, 7/16-20 .......................... 1

59 42807 L084001 Lock washer #10 ................................. 1


61 42808 L084005 Lock washer 1/4 .................................. 2


63 40080 093150K1 Bolt ...................................................... 1

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

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

66 40580 128066 Decal, warning ..................................... 1

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

68 42551 L60062 Nut ....................................................... 1

Repair Kit


48200, 48520, and 48525 Pruners


Illustration—Model 48525 (Serial Code FPL)

58

5756

555453

52

51

63

48

61

62

61

59 60

49

5047

19

64

67

65

41

68

27

15

28

30

29

31

32

18

17

16

18

22

21

20

24

25

26

43

44

46

4515

1

11

10

9

65

4

3

121314

1314

68

72

51

42

66

69

48200, 48520, and 48525 Pruners


Parts List—Model 48525 (Serial Code FPL)UPC No.


2* 41488 F015255 O-ring .................................................. 1

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

4* 41489 F015257 O-ring .................................................. 1

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

6 41712 F018511 Retaining ring ...................................... 2

7 40087 094826 Spring .................................................. 1

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

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

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

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

12 48180 48180 Trigger guard ....................................... 1

13 42812 L084015 Lock washer #10 ................................. 2


15* 42744 L080035 O-ring .................................................. 2

16* 43355 F021753 O-ring .................................................. 1


18 41648 F017595 Retaining ring ...................................... 2

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

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

21* 48204 48204 O-ring .................................................. 1

22* 48205 48205 Piston seal ........................................... 1

24* 41402 F012946 O-ring .................................................. 1

25* 54563 905 4563.0 O-ring .................................................. 1

26 42542 L060052 Seal body ............................................ 1




30* 42760 L081004 Rod seal .............................................. 1

31* 42708 L060729 Seal retainer ........................................ 1

UPC No.Key 78-3310- Part No. Description Qty32 42841 L085061 Retainer ring ........................................ 1

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




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

46* 41335 F010894 O-ring. 9/16 x 3/4 x 3/32 ...................... 1



49 41149 139577 Bolt ...................................................... 1


51 41367 F011686 Hex lock nut ......................................... 2

52 48197 48197 Cutter hook .......................................... 1

53 42508 L060009 Cutter blade ......................................... 1

54 40001 062593 Washer ................................................ 1

55 42510 L060011 Cutter brace ......................................... 1


57 40078 093149K1 Bolt ...................................................... 1

58 41555 F015618 Hex lock nut, 7/16-20 .......................... 1

59 42807 L084001 Lock washer, #10 ................................ 1


61 42808 L084005 Lock washer, 1/4 ................................. 2


63 40080 093150K1 Bolt ...................................................... 1

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

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

66 40580 128066 Decal, warning ..................................... 1

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

68 42551 L60062 Nut ....................................................... 1

69 49230 49230 Decal ................................................... 1

Repair Kit


Printed in the USA

Greenlee Textron / Subsidiary of Textron Inc.4455 Boeing Drive, Rockford, IL 61109-2988 USA

Customer Service (International): 815/397-7070 • Fax: 815/397-9247Customer Service (North America): 800/435-0786 • USA Fax: 800/451-2632, 815/397-1865

Canada Fax: 800/524-2853

www.greenlee.textron.com

Documents

48200, 48520, and 48525 Pruners 48520, and 48525 Pruners Greenlee Textron / Subsidiary of Textron Inc. 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070 Table of Contents