Installation Directions
2014-09-04
: Pdf 585883-Installationsheet 585883-InstallationSheet 783310 Batch7 unilog
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INSTRUCTION MANUAL Serialnummer GATOR Plus ESG45GL Battery-powered Cable Cutter ® Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Register this product at www.greenlee.com 99944669 © 2010 Greenlee Textron Inc. IM 1519 REV 5 9/10 ESG45GL Battery-powered Cable Cutter Table of Contents Description Description..................................................................... 2 Safety............................................................................. 2 Purpose of this Manual.................................................. 2 Important Safety Information...................................... 3-4 Identification................................................................... 5 Specifications................................................................. 5 Operation........................................................................ 6 Maintenance................................................................... 7 Troubleshooting.............................................................. 8 Service............................................................................ 8 Disassembly................................................................... 9 Reassembly.................................................................. 10 Illustrations.............................................................. 11-13 Parts List................................................................. 14-16 Greenlee GATOR® Plus cable cutters are hand-held, battery-operated tools designed for cutting ACSR, guy strand, and wire rope. 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 tool: ESG45GL Battery-powered Cable Cutter Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at www.greenlee.com. All specifications 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 Greenlee Textron Inc. AVIA is a registered trademark of Avia International. Mobil is a registered trademark of Mobil Oil Corporation. NUTO is a registered trademark of Exxon Corporation. Tellus is a registered trademark of Shell Oil Company. KEEP THIS MANUAL Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL Electric shock hazard: This tool is not insulated. When using this unit on or near energized electrical lines, use proper personal protective equipment. Failure to observe this warning could result in severe injury or death. 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. 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. Immediate hazards which, if not avoided, WILL result in severe injury or death. Hazards which, if not avoided, COULD result in severe injury or death. Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. Do not use solvents or flammable liquids to clean the tool body. Solvents or flammable liquids could ignite and cause serious 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. Greenlee / A Textron Company Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter 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 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 cut cable under tension. Failure to observe this warning could result in severe injury or death. Do not dispose of the battery in a fire. The battery will vent fumes and it could explode. Failure to observe this warning could result in severe injury from harmful fumes or burns from flying debris. • Do not store the battery at more than 60 °C (140 °F). 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. Inspect tool before use. Replace any worn or d amaged parts. A damaged or improperly assembled tool can break and strike nearby p ersonnel. Failure to observe this warning could result in severe injury or death. 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. • 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. • Protect the tool from moisture. Any moisture inside the housing can damage internal circuitry. • 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 Note: Keep all decals clean and legible, and replace when necessary. 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Identification 4 3 9 10 8 Battery-powered Cable Cutter 5 1. Trigger 2. Retract Button 3. Pull Pin 6 4. Cutting Head 5. Housing 6. Battery Load Display 2 1 7. Battery Cartridge 8. Blades 9. Oil Reservoir 10. Oil Plug 7 Specifications Weight (with battery)............................................................................... 5.8 kg (12.5 lb) Overall Length........................................................................................ 39.4 cm (15.5") Width.............................................................................................................80 mm (3") Height..................................................................................................... 31.8 cm (12.5") Maximum Cable Cutting Diameter ........................................................ 45 mm (1-3/4") Motor..................................................................Direct-Current Permanent Field Motor Motor Voltage..................................................................................................... 12 VDC Charging Voltage..................................................................................................... 12 V Charging Time...................................................................................................... 1 hour Cutting Performance...............................................................approximately 70/charge Hydraulic Oil............................................................... 50 ml (0.1 pint) Shell Tellus® T 15 Sound Level.................................................................................... 75 dB (A) at 1 meter Vibrations......................................................................................................... <2.5 m/s2 Capacity: ACSR................................................................................ 1590 kcmil (Falcon 54/19) Guy Strand............................................................................... 16 mm dia. (5/8" dia.) EHS Guy Strand....................................................................... 13 mm dia. (1/2" dia.) Copper and Aluminum Cable.................................................. 8002 mm (1500 kcmil) Ground Rod.............................................................................. 16 mm dia. (5/8" dia.) Rebar (Schedule 60)................................................................. 13 mm dia. (1/2" dia.) Wire Rope................................................................................ 16 mm dia. (5/8" dia.) Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Operation Charging the Battery Read the instructions supplied with the charger for explanation of proper use. Testing the Battery A flickering battery load display indicates a low charge level. A constant light when the tool is in neutral also indicates a low charge. Note: It is normal for the battery load display to light at both the beginning of a cutting cycle and at the point of maximum pressure. Push to retract blades Pull trigger to cut Cutting Cable 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. Note: At any time during cutting, pushing the return button will result in a complete return of the ram. Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Maintenance Each Operating Day Before use: 1. Inspect blades for defects, such as cracks, gouges or chips. 2. Inspect the cutter for damage or leaks. If damage is detected, return the tool to an authorized Greenlee service center. Monthly 1. Thoroughly clean all surfaces. 2. Check the oil level. 3. Oil the bolt joints. Annually or Every 8000 Cutting Cycles 1. Change the hydraulic oil 2. Return the tool to an authorized Greenlee service center for inspection. 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. 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. After use: 1. With a slightly damp cloth and a mild detergent, wipe clean and dry all exposed surfaces. General The hydraulic oil needs to be changed annually or every 8000 cuts. Store the cable cutter in the carrying case when it is not in use. Checking the Oil Level 1. Remove the two screws holding the tank housing cover. 2. Remove the tank housing cover. 3. Point the cutting head towards the ground and remove the oil plug. Refill reservoir if necessary. 4. Replace the oil plug and the tank housing cover. Do not use solvents or flammable liquids to clean the tool body. Solvents or flammable liquids could ignite and cause serious injury or property damage. 2. Fully retract blades, Place the cable cutter in the carrying case. Store in a cool, dry place. 3. Fully discharged batteries should be recharged so that they are ready for use. (Refer to battery charger instructions.) Greenlee / A Textron Company Recommended Hydraulic Oils AVIA® HVI 15 Shell Tellus T 15 Mobil® DTE 11M NUTO® H 15 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Troubleshooting Before you begin 2. Use a NONFLAMMABLE contact cleaner or pencil eraser to clean the electrical contacts on the battery and cable cutter. 3. Reinstall battery and check the tool again. 1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge. Problem Probable Cause Probable Remedy Tool is inoperative. Dirt, contaminants, etc., in ram area of tool. Clean tool. Crimper battery contacts damaged. Reform contacts. Tool components worn or damaged. Return tool to an authorized Greenlee service center. Cutting blades stop during Oil level is low. operation. Air in hydraulic system. Check oil level. Refill reservoir. Battery load display flashes constantly. Charge or replace battery. Pull trigger and hold retract button simultaneously. Hold for approximately 10 seconds. Battery charge low. Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee service center. Refill reservoir and replace plug. Oil plug not installed properly. Service Should your battery-powered cable cutter require service, return it to an authorized Greenlee service center. Customer Center and Field Service: 800/435-0786 Fax (24 Hour) Customer Center: 800/451-2632 or 815/397-1865 Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Disassembly (refer to Illustrations) Motor / Gearbox / Bearing Disassembly 23. Remove tamper-proof paper seal (96). 24. Remove two screws (92). Remove end cap (102). 25. Apply pressure evenly at three points around the ball bearing (91) and gently pry the bearing up to remove it. 26. Remove eccentric (103), grooved ball bearing (101), and snap ring (100) subassembly from shaft. 27. Remove four screws (93). Remove mounting block (109) from gear housing (94). 28. Use a snap-ring removal tool to remove the snap ring (100). 29. Unscrew four bolts (not numbered) from the gear housing (94). Separate gear housing from spacer (not numbered). Unscrew two Fillister head screws (112) to separate spacer from motor (90). 1. Remove battery. 2. Remove pin (31). Remove cutting blade (26). 3. Loosen two screws (17). 4. Unscrew and remove head assembly. 5. Remove spring (18) and piston (21). Replace the piston O-ring (15) and piston backup ring (16). 6. Unscrew two tank cover screws (53) and remove tank cover (58). 7. Remove the hydraulic reservoir plug (76) and drain hydraulic fluid. 8. Reinstall plug. 9. Remove the remaining housing screws (51, 53). 10. Remove right housing half (59). 11. Remove trigger cover (56). 12. Lift pump/motor assembly and circuit card from left housing half (60). Lift LED from its housing (8). 13. Slide a plastic bag over the circuit card and electronic subassemblies. Tape the bag shut to protect the subassemblies from hydraulic oil and other contamination. 14. Unscrew shoulder bolt (99) and remove release lever (107). 15. Remove screws (108) and separate the gear housing/motor subassembly from pump housing. 16. Use a hooked tool to remove the reservoir O-ring (80). Gently tug it over the reservoir. 17. Remove the reservoir (74). 18. Remove pump piston (152). 19. Remove screw plug (151), washer (153), pump piston (150), valve stem (156), and spring (155). Replace sealing washer (154). 20. Use a piece of tape to mark the side of the relief (126) that is facing up. (This is a reference point for reassembly.) Remove unloading valve by unscrewing the plug (126). 21. Remove feeder tube subassembly by unscrewing feeder tube (78). Replace the oil filter (77). Remove metal chips from magnet (82). 22. Remove threaded bushing (72) and replace O-ring (73). Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Reassembly Misc. Components Reassembly 15. Remove the protective plastic bag from the electronics subassembly. Insert the LED into the LED bushing (8). 16. Lay the gear housing/motor subassembly into the left half of the housing. Insert the circuit board into the circuit board slot, so that the wires and chip face in the direction of the trigger. 17. Lay the wires into case. Be sure that the wires will not be pinched. 18. Guide the wires for the battery clip so the battery wires lay on top of the electronics box; install the battery clip so the red wire is upward. 19. Install the trigger cover (56). Depress and release the trigger to be sure that it operates freely. 20. Locate the right housing half (59) on top of the left housing half (60). Check for pinched wires. 21. Install the housing screws (51, 53). Note: Handle screw (51) must engage the nut (52). 22. Install the piston (21). 23. Install the spring (18). 24. Replace the front head assembly. Twist the cutting head base (30) until it stops; back off 3/4 of a turn and tighten the screws (17). Be sure that the cutting head assembly rotates freely approximately 350°. 25. Install the cutting blade (26). Insert the pin (31) through the ram. 26. Clamp the head assembly into a vise with the reservoir plug facing upward. Remove the fill plug (76) and fill the reservoir with hydraulic oil. 27. Install the battery. 28. Squeeze the trigger while depressing the release lever for 45–60 seconds. Fill the reservoir with hydraulic oil. Replace the fill plug (76). 29. Replace the tank cover (58) and tank cover screws (53). Motor / Gearbox / Bearing Reassembly 1. Install two Fillister head screws (112) into spacer (not numbered) and motor (90). Tighten screws. 2. Install four screws (not numbered) into gear housing (94). Tighten screws. 3. Install four screws (93) into mounting block (109) and gear housing (94). Tighten screws. 4. Replace grooved ball bearing (101) and snap ring (100) subassembly. 5. Replace eccentric (103). Use a fiber mallet to tap eccentric onto shaft. Replace ball bearing (91). 6. Align end cap (102). Use a fiber mallet to tap cover until it is flush on mounting block (109). Install two screws (92). 7. Align gear housing/motor subassembly so that the pump piston (152) extends through the mounting block (109) and makes contact with the grooved bearing (101). Locate and start the screws (108) through the mounting block and into the pump housing. Tighten the screws. Pump Subassembly 8. Insert pump piston (152) into pump housing. 9. Insert seal (122) and unloading valve assembly into pump housing. Grasp needle valve subassembly by the pressure relief (126) and twist it several turns clockwise. Stop when the mark or piece of tape is facing up. 10. Assemble pump piston (150), valve stem (156), washer (153), spring (155) and screw plug (151). Be sure to replace sealing washer (154). Torque screw plug (151) to 75 ft-lb. 11. Install release lever (107) so that the forked end engages the unloading valve subassembly between the pressure relief (126) and the support ring (127). Install screw (99) and washer (104). 12. Insert threaded bushing (79) and feed tube subassembly (77, 78, 82). Screw in until snug. 13. Install reservoir (74). Slip the O-ring (80) over the reservoir. Using a hooked tool, carefully slip the O-ring over the lip of the pump housing. 14. Insert the plug (76) into the reservoir. Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter 11 57 9 53 56 51 59 53 60 53 8 52 12 58 10 Illustration Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter 28 17 29 35 26 25 31 36 37 34 32 27 39 38 17 33 19 30 20 18 21 16 15 Illustration Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 72 Greenlee / A Textron Company 140 73 13 92 141 83 91 79 151 153 150 154 156 155 96 122 102 101 77 152 78 75 123 82 93 103 129 120 100 124 109 121 81 70 126 108 125 105 130 80 74 99 127 128 71 107 76 104 112 94 111 110 97 98 90 95 ESG45GL Battery-powered Cable Cutter Illustration 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Parts List Key Part No. Description Qty 1 2 3 4 5 6 7 50103946 50013459 50013467 50013491 50059033 50013475 50013483 Head and Ram Unit (15–39) Housing Unit (51–61) Pump Housing, Reservoir Assembly (70–83) Motor Assembly (90–112) Relief Valve Assembly (120–130) Electrical Assembly (140–144) Piston Pump Assembly (150–156) 8 9 10 11 12 13 50042416 50071769 50103086 50103094 50062140 50063340 Bushing LED.............................................................................................. 1 Circuit board, programmed . ..................................................................... 1 Decal, identification.................................................................................... 1 Decal, warning........................................................................................... 1 Decal, pinch hazard................................................................................... 1 Oil (not shown)........................................................................................... 1 15* 16* 17 50041681 18 50058258 19 50058371 20* 21 50103962 25 50103970 26 50103989 27 50103997 28 50104004 29 50104012 30 50104020 31 50106600 32 50104039 33 50104047 34 50104055 35 50104063 36 50104071 37 50104080 38 50104098 39 50104101 O-ring......................................................................................................... 3 Backup ring, piston.................................................................................... 1 Screw......................................................................................................... 2 Compression spring................................................................................... 2 Adapter disk............................................................................................... 2 O-ring......................................................................................................... 1 Piston ........................................................................................................ 1 Stationary blade......................................................................................... 1 Cutting blade............................................................................................. 1 Screw......................................................................................................... 4 Snap ring.................................................................................................... 2 Cutting head.............................................................................................. 1 Cutting head base...................................................................................... 1 Pin, 8 x 20.................................................................................................. 1 Sleeve........................................................................................................ 2 Pin 1 Guide plate................................................................................................. 1 Side plate................................................................................................... 2 Pull pin....................................................................................................... 1 Brace plate................................................................................................. 1 Pin, 3 x 18.................................................................................................. 1 Screw......................................................................................................... 1 50013459 Housing unit (green) (includes item 51-60)................................................ 1 51 50042203 Screw.................................................................................................... 1 52 50042211 Nut........................................................................................................ 1 53 50042076 Screw.................................................................................................. 12 56 Switch cover (black).............................................................................. 1 57 Trigger guard......................................................................................... 1 58 Reservoir cover..................................................................................... 1 59 Housing, right side................................................................................ 1 60 Housing, left side.................................................................................. 1 Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Parts List (cont’d) Key Part No. Description Qty 70 50103407 71 50071777 72 50041444 73* 74 50058738 75 50041983 76 50058789 77 50058800 78 50058827 79 50058851 80* 81 50058290 82 50058983 83 50103644 Ring tie....................................................................................................... 1 Cable tie..................................................................................................... 1 Threaded bushing...................................................................................... 1 O-ring......................................................................................................... 1 Hydraulic reservoir..................................................................................... 1 Ring............................................................................................................ 1 Reservoir plug............................................................................................ 1 Filter........................................................................................................... 1 Filter adapter.............................................................................................. 1 Threaded bushing...................................................................................... 1 O-ring......................................................................................................... 1 Attachment ring......................................................................................... 1 Magnet....................................................................................................... 1 Pump housing............................................................................................ 1 90 50041320 91 50041380 92 50041550 93 50041576 94 50041339 95 ** 96 * 97 ** 98 ** 99 † 100 50041517 101 50041398 102 50041088 103 50041231 104 † 105 † 107 † 108 50121839 109 50084022 110 50013513 111 50013521 112 50103385 Motor.......................................................................................................... 1 Ball bearing................................................................................................ 1 Screw......................................................................................................... 2 Screw......................................................................................................... 4 Gearbox..................................................................................................... 1 Spacer........................................................................................................ 1 Seal............................................................................................................ 1 Ground strap.............................................................................................. 1 Capacitor................................................................................................... 3 Screw, socket head.................................................................................... 1 Retaining ring............................................................................................. 1 Grooved ball bearing.................................................................................. 1 End cap...................................................................................................... 1 Eccentric.................................................................................................... 1 Lock washer............................................................................................... 1 Spring......................................................................................................... 1 Release lever.............................................................................................. 1 Screw......................................................................................................... 2 Eccentric case............................................................................................ 1 Gearbox..................................................................................................... 1 Gear .......................................................................................................... 1 Screw......................................................................................................... 2 Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ESG45GL Battery-powered Cable Cutter Parts List (cont’d) Key 120 50058606 121* 122* 123 50058630 124 50058649 125* 126 50058711 127 50058754 128* 129 50058770 130 50058940 Washer....................................................................................................... 2 O-ring......................................................................................................... 1 Seal............................................................................................................ 1 Valve seat................................................................................................... 1 Plunger....................................................................................................... 1 O-ring......................................................................................................... 1 Pressure relief............................................................................................ 1 Support ring............................................................................................... 1 Retaining ring............................................................................................. 1 Needle valve............................................................................................... 1 Spring......................................................................................................... 1 140 50041266 141 50041274 143 144 Switch ....................................................................................................... 1 Battery contacts......................................................................................... 1 Wire (not shown)........................................................................................ 1 Wire (not shown)........................................................................................ 1 150 50058916 151 50103652 152 50103709 153* 154* 155 50103679 156 50103687 Pump piston............................................................................................... 1 Screw plug................................................................................................. 1 Pump piston............................................................................................... 1 Washer....................................................................................................... 1 Sealing washer........................................................................................... 1 Spring......................................................................................................... 1 Valve stem.................................................................................................. 1 50014072 91871417 50118927 50017586 50104110 50029991 50030469 50030477 50030485 * ** † Part No. Description Qty Seal kit (includes items marked with an asterisk) Capacitor assembly (includes items marked with double asterisks) Release lever assembly (includes items marked with a †) Blade/pin kit (includes items 26 and 31) Case w/inserts 12V Battery NiCd 12V Charger 110 VAC 12V Charger 220 VAC 12V Charger 12 VDC USA 800-435-0786 815-397-7070 Canada 800-435-0786 International +1-815-397-7070 Fax: 800-451-2632 Fax: 815-397-1865 Fax: 800-524-2853 Fax: +1-815-397-9247 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
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