Greenlee ESG105LU, ESC85L, ESG50L, ESG55L, ESG45L User Manual

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Page 1

OPERATION MANUAL

Serial Number

(ESG45L shown)

GATOR®

Battery-powered

Pistol Grip Cable Cutters

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

Page 2

Battery-powered Pistol Grip Cable Cutters

Table of Contents

Description ..................................................................... 2

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

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

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

Identication ................................................................... 5

Specications ................................................................. 6

Operation .................................................................... 7–8

Maintenance ................................................................... 9

Troubleshooting ............................................................ 10

Description

Greenlee’s Battery-powered Pistol Grip Cable Cutters are hand-held tools intended to cut the following:

• ESG45L: ACSR and guy strand.

• ESG50L: Copper and aluminum cable up to 2" (50mm) in diameter. This tool is intended to cut most low- and medium-voltage copper and aluminum cable found on most job sites.

• ESG55L: ACSR and guy strand.

• ESC85L: Copper and aluminum cable up to 3.3" (85mm) in diameter. This tool is intended to cut most low- and medium-voltage stranded copper and aluminum cable.

• ESC105L and ESG105LU: Copper and aluminum cable up to 4.13" (105 mm) in diameter. This tool is intended to cut most low- and medium-voltage stranded copper and aluminum cable as well as lead or soft steel armored cable found on job sites.

These tools have a retraction stop feature, which allows the operator to stop the retraction motion of the ram to shorten cycle time.

These tools are protected by U.S. Patent No. 6,206,663, 6,276,186, 6,401,515, and 6,718,870.

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 operation and maintenance procedures for the following Greenlee tools:

ESG45L Battery-powered Cable Cutter

ESG50L Battery-powered Cable Cutter

ESG55L Battery-powered Cable Cutter

ESC85L Battery-powered Cable Cutter

ESC105L Battery-powered Cable Cutter

ESG105LU Battery-powered Cable Cutter

Keep this manual available to all personnel.

Replacement manuals are available upon request at no charge at www.greenlee.com.

Do not discard this product or throw away! For recycling information, go to www.greenlee.com.

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.

GATOR is a registered trademark of Textron Innovations Inc.

KEEP THIS MANUAL

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 3

Battery-powered Pistol Grip Cable Cutters

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 preventing 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.

• Electric shock hazard: The owner of this cutter must be certain that all users of this tool are trained in the applicable safety codes and standards as well as in the safe use of this tool and its accessories.

• Do not cut cable under tension.

• Use the tool for its intended purpose, which is cutting cable.

Failure to observe these warnings 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.

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.

Failure to observe this warning could result in severe injury or death.

Electric shock hazard:

This tool is not insulated. When using this unit near energized electrical lines, use proper personal protective equipment.

Failure to observe this warning could result in severe injury or death.

Skin injection hazard:

Do not use hands to check for oil leaks. Oil under pressure easily punctures skin. If injured, seek medical attention immediately to remove oil.

Failure to observe this warning could result in serious injury, gangrene, or death.

Do not use solvents or ammable liquids to clean the tool body. Solvents or ammable liquids could ignite and cause serious injury or property damage.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 4

Battery-powered Pistol Grip Cable Cutters

IMPORTANT SAFETY INFORMATION

Cutting hazard:

• Remove battery before changing dies, adapters, or jaws.

• Keep hands away from the cutting head when cutting.

Failure to observe these warnings could result in severe injury or death.

Do not dispose of batteries in a re. They will vent fumes and may explode.

Failure to observe this warning could result in severe injury from harmful fumes or burns from ying debris.

• Inspect tool and blades before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

• Carrying strap is for carrying only, not to be used to hang or suspend tool.

Failure to observe these warnings could result in severe injury or death.

Do not allow anything to contact the battery terminals.

• Do not immerse the batteries in liquid. Liquid may create a short circuit and damage the battery. If batteries are immersed, contact your service center for proper handling.

• Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive objects may create a short circuit and damage the battery.

• Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery.

Failure to observe these precautions may result in injury or property damage.

• Do not store the battery at more than 122 °F (50°C) or less than –4 °F (–20 °C). Damage to the battery can result.

• Do not use another manufacturer’s charger. Other manufacturers’ chargers may overcharge and damage the battery.

• Do not attempt to open the battery. It contains no user-serviceable parts.

Failure to observe these precautions may result in injury or property damage.

• Do not use this tool for continuous use. After 30 to 40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is designed for hand-held operation.

• This tool may be used in damp or wet environments; however, air-drying is recommended before use if the tool becomes soaked. Damage may result when the tool is operated prior to thorough drying when electrical components are soaked.

• Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions may result in injury or property damage.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Use all appropriate and applicable personal safety equipment as required such as safety shoes, hard hat, and safety glasses. Follow all safety rules and regulations for the job.

Failure to comply may result in personal injury or property damage.

Do not perform any service or maintenance other than as described in this manual. Injury or damage to the tool may result.

Failure to observe this precaution may result in injury and property damage.

Note: Keep all decals clean and legible, and replace when necessary.

Page 5

Identiﬁcation

Battery-powered Pistol Grip Cable Cutters

ESG45L ESG50L

ESG55L

ESC85L

ESC105L ESG105LU

1. Pull Pin (ESG45L, ESG55L, and ESG105LU)

Locking Flange (ESG50L)

Handle (removable)

(ESG55L, ESC85L, ESC105L, and ESG105LU)

2. Blades

3. Lanyard Ring

4. Housing

5. Retract Button

6. LED Indicator (red)

7. LED Work Light (white)

8. Battery

9. Trigger

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 6

Speciﬁcations

Battery-powered Pistol Grip Cable Cutters

All Models

Cutting Tool

Hydraulic Oil ......................... 52057878 biodegradable

hydraulic uid

Recommended Operating

Temperature Range ................................ 5 °F to 122 °F

(–15 °C to 50 °C)

Battery Charger ............... Read the instructions supplied

with the battery charger

ESG45L

Cutting Tool

Length ................................................15.75" (400 mm)

Width ...................................................2.87" (72.9 mm)

Height ..............................................12.75" (323.8 mm)

Weight .................................................. 12.6 lb (5.7 kg)

Cutting Capacities

Maximum Cable Cutting Diameter

(copper and aluminum) ..........................1.75" (45 mm)

ACSR ................................. Falcon 54/19 (1590 kcmil)

Guy Strand ........................................5/8" (16 mm) dia.

EHS Guy Strand ................................1/2" (13 mm) dia.

Ground Rod ......................................5/8" (16 mm) dia.

Rebar (Schedule 60) ..........................1/2" (13 mm) dia.

Wire Rope .........................................5/8" (16 mm) dia.

ESG50L

Cutting Tool

Length ...............................................16.0" (406.4 mm)

Width ...................................................2.87" (72.9 mm)

Height ................................................14.5" (368.3 mm)

Weight .................................................. 10.4 lb (4.7 kg)

Cutting Capacity

Maximum Cable Cutting Diameter

(copper and aluminum) ...............................2" (50 mm)

ESG55L

Cutting Tool

Length ................................................18.12" (461 mm)

Width ......................................................3.12" (80 mm)

Height .................................................13.25" (337 mm)

Weight ..................................................... 17.5 lb (8 kg)

Cutting Capacities

Maximum Cable Cutting Diameter

(copper and aluminum) ..........................2.12" (55 mm)

ACSR ................................... Joree 76/19 (2515 kcmil)

Guy Strand ........................................5/8" (16 mm) dia.

EHS Guy Strand ..............................9/16" (14 mm) dia.

3/4" Ground Rod ...............................3/4" (19 mm) dia.

Rebar (Schedule 60) ..........................5/8" (16 mm) dia.

Soft Steel Bolts .................................3/4" (19 mm) dia.

ESC85L

Cutting Tool

Length .............................................19.25" (488.9 mm)

Width ...................................................2.87" (72.9 mm)

Height .................................................14.25" (362 mm)

Weight .................................................. 13.8 lb (6.3 kg)

Cutting Capacities

Maximum Cable Cutting Diameter

(copper and aluminum) ............................3.3" (85 mm)

ESC105L

Cutting Tool

Length ...............................................24.0" (609.6 mm)

Width ...................................................2.87" (72.9 mm)

Height ...................................................14.8" (376 mm)

Weight .................................................. 19.4 lb (8.8 kg)

Cutting Capacities

Maximum Cable Cutting Diameter (copper, aluminum, lead armored,

and soft steel armored cable) ..............4.13" (105 mm)

ESG105LU

Cutting Tool

Length ...............................................24.0" (609.6 mm)

Width ...................................................2.87" (72.9 mm)

Height ...................................................14.8" (376 mm)

Weight ................................................ 23.1 lb (10.5 kg)

Cutting Capacities

Maximum Cable Cutting Diameter (copper, aluminum, lead armored,

and soft steel armored cable) ..............4.13" (105 mm)

All Models

52047087 120 VAC corded adapter

52047088 230 VAC corded adapter

52049189 18 V, 3 Ah lithium-ion battery

52049201 120 VAC, 18 V charger

52049202 230 VAC, 18 V charger

52049204 12 VDC, 18 V charger

52054992 Li (18 V) to NiCd, NiMH (12 V)

charger adapter

50122746 Carrying strap

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 7

Operation

Battery-powered Pistol Grip Cable Cutters

• Inspect tool and blades before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

• Carrying strap is for carrying only, not to be used to hang or suspend tool.

Failure to observe these warnings could result in severe injury or death.

Electric shock hazard: This tool is not insulated. When

using this unit near energized electrical lines, use proper personal protective equipment.

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.

Cutting hazard:

• Remove battery before changing dies, adapters, or jaws.

• Keep hands away from the cutting head when cutting.

Failure to observe these warnings could result in severe injury or death.

• Do not use this tool for continuous use. After 30 to 40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is designed for hand-held operation.

• Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions may result in injury or property damage.

Charging the Battery

Read the instructions supplied with the battery charger.

LED Work Light (white)

This LED automatically turns on when the trigger is pulled. It remains on for 10 seconds after the trigger is released.

LED Indicator (red)

This tool is equipped with a special circuit board incorporating several important features to inform the user about the current status of the unit. The LED signals in the following cases:

What happens Signal What it means

Flashing light for 2seconds

Constant light for 20seconds at end of cycle

Tool will not start, and constant light for 20seconds when trigger is released

Tool will stop, and constant light for 20seconds after trigger is released

Tool will stop, and ﬂashing light for 20seconds when trigger is released

Battery is inserted in tool

Battery charge is below 17V at beginning of cycle

Battery charge is below 16V at beginning of cycle

Battery voltage drops below 13V during cycle

Motor current exceeds 20A during cycle

Circuit has become too hot

• Do not cut cable under tension.

Failure to observe these warnings could result in severe injury or death.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 8

Battery-powered Pistol Grip Cable Cutters

Operation (cont’d)

Cutting Cable —ESG45L, ESG55L, and ESG105LU

1. Open the head by using the pull pin.

2. Position the cable in the open cutting head.

3. Close the cutting head and insert pull pin.

4. Pull the trigger. The blades will begin to close.

5. When the cut is completed, the ram will retract completely.

6. To stop the ram from returning fully, activate the trigger for a brief moment. This activation will close the retraction valve and stop the retraction motion.

Note: At any time during cutting, pushing the retract button will result in a complete return of the ram.

Cutting Cable —ESG50L

1. Opentheheadbyliftingthelockingange.

2. Position the cable in the open cutting head.

3. Close the cutting head.

4. Pull the trigger. The blades will begin to close.

5. When the cut is completed, the ram will retract completely.

6. To stop the ram from returning fully, activate the trigger for a brief moment. This activation will close the retraction valve and stop the retraction motion.

Note: At any time during cutting, pushing the retract button will result in a complete return of the ram.

Push to retract blades

Pull trigger to cut

Push to retract blades

Pull trigger to cut

Cutting Cable —ESC85L and ESC105L

1. Position the cable in the open cutting head.

2. Pull the trigger. The blades will begin to close.

3. When the cut is completed, the ram will retract completely.

4. To stop the ram from returning fully, activate the trigger for a brief moment. This activation will close the retraction valve and stop the retraction motion.

Push to retract blades

Note: At any time during cutting, pushing the retract button will result in a complete return of the ram.

Pull trigger to cut

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 9

Maintenance

Battery-powered Pistol Grip Cable Cutters

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.

Skin injection hazard:

Do not use hands to check for oil leaks. Oil under pressure easily punctures skin. If injured, seek medical attention immediately to remove oil.

Failure to observe this warning could result in serious injury, gangrene, or death.

Daily

Before use:

1. Inspect the tool for wear or damage, such as cracks, gouges, or chips.

2. Inspect the tool for damage or leaks.

3. Inspect the rotation of the head assembly. Fully retract the ram. The head should rotate no more than 360°. If damage is detected, send the tool to a Greenlee Authorized Service Center for inspection.

After use:

1. Use a damp cloth and mild detergent to clean the housing. Allow the housing to dry.

2. Place the tool in the carrying case and store in a cool, dry place.

3. If necessary, recharge the batteries. Refer to the instructions supplied with the battery charger.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

Do not use solvents or ammable liquids to clean the tool body. Solvents or ammable liquids could ignite and cause serious injury or property damage.

Cutting hazard:

• Remove battery before changing dies, adapters, or jaws.

• Keep hands away from the cutting head when cutting.

Failure to observe these warnings could result in severe injury or death.

Annually or After 10,000 Cuts

1. Replace the hydraulic oil.

2. Send the tool to a Greenlee Authorized Service Center for inspection.

Checking the Oil Level

1. Remove the screws holding the housing cover together.

2. Point the cutting head downward and remove the oil reservoir plug. Fill reservoir if necessary.

3. Replace the oil plug and housing cover.

Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.

Relief valve adjustments must be done by an authorized service center.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 10

Troubleshooting

Battery-powered Pistol Grip Cable Cutters

Before You Begin

1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge.

Problem Possible Cause Probable Remedy

Tool is inoperative. Dirt, contaminants, etc., in

ram area oftool.

Tool components worn or damaged.

Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative battery may be

Broken switch components. Return tool to a Greenlee Authorized Service Center.

Motor runs but tool will not complete a cycle.

Oil level low. Return tool to a Greenlee Authorized Service Center.

Air in hydraulic system. Pull trigger and hold retract button simultaneously.

2. Use a nonﬂammable contact cleaner or pencil eraser to clean the electrical contacts on the battery and tool.

3. Reinstall the battery and check the tool again.

Clean tool.

Return tool to a Greenlee Authorized Service Center.

discharged or may have reached life expectancy.

Run for approximately 10 seconds, and then attempt to cut. If unsuccessful, return tool to a Greenlee Authorized Service Center.

Cold oil. Pull trigger and hold retract button simultaneously to

warm oil. Store tool in warm area.

Dies stop during operation.

LED glows for 20 seconds.

Tool loses oil. Damaged internal seal. Return tool to a Greenlee Authorized Service Center.

Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.

Oil level low. Return tool to a Greenlee Authorized Service Center.

Air in hydraulic system. Pull trigger and hold retract button simultaneously.

Hold for approximately 10 seconds.

Battery charge low. Charge or replace battery.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 11

Battery-powered Pistol Grip Cable Cutters

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 12

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