Greenlee ES750 User manual

99926288 © 2007 Greenlee Textron Inc. IM 1322 REV 7 2/07
INSTRUCTION MANUAL
Read and understand all of the instructions
and safety information in this manual before
operating or servicing this tool.
ES750
Battery-powered Cable Cutter
45380—with 120 V Charger
45381—with 220 V Charger

2
KEEP THIS MANUAL
Table of Contents
Description, Safety, and Purpose of this Manual .............................................................. 2
Important Safety Information .......................................................................................... 3–8
Specifications ..................................................................................................................... 9
Operation .......................................................................................................................... 10
Charger ............................................................................................................................. 11
Troubleshooting ................................................................................................................ 12
Maintenance ..................................................................................................................... 13
Illustration ......................................................................................................................... 14
Parts List ..................................................................................................................... 15–16
Description
The Greenlee Battery-powered Cable Cutter is intended to cut up to 750 Kcmil copper
and aluminum cable. The cable cutter is driven by a 12-volt motor and is powered by a
rechargeable NiCd (nickel cadmium) battery. The motor is protected by a circuit breaker.
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 Greenlee ES750 Battery-powered Cable Cutter.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no charge.
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.
Do not discard this product or throw away!
For recycling information, go to www.greenlee.com.

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ES750
IMPORTANT SAFETY INFORMATION
SAFETY ALERT SYMBOL
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.
Read and understand all of the instructions and safety informa-
tion in this manual before operating or servicing this tool.
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.

4
IMPORTANT SAFETY INFORMATION
Cable Cutter
• Use this tool for manufacturer’s intended use only. Use other than that which is
described in this manual can result in injury or property damage.
• Do not cut steel or ACSR.
• Inspect the tool before each use. Replace any worn, damaged, or missing
items with Greenlee replacement parts. A damaged or improperly assembled
tool can break and strike nearby personnel.
Failure to observe these precautions may result in injury or property damage.
• Keeps hands away from blade.
• Remove the battery before inspecting or servicing the tool.
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 flying debris.
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.

5
ES750
Battery
IMPORTANT SAFETY INFORMATION
• Do not charge the battery if it is cooler than 50 °F (10 °C) or warmer than
95 °F (35 °C). Damage to the battery can result.
• Do not store the battery at more than 140 °F (60 °C). Damage to the battery
can result.
• Do not use another manufacturer’s charger. Other manufacturers’ chargers
may overcharge and damage the battery.
Failure to observe these precautions may result in injury or property damage.
Do not allow any object to contact the battery terminals.
• Do not immerse batteries in liquid. Liquid may create a short circuit and
damage the battery.
• 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 dispose of battery in a fire. The battery will vent harmful vapors and
can explode.
Failure to observe this warning could result in severe injury or death.

6
Battery (cont’d)
IMPORTANT SAFETY INFORMATION
• Do not expose the battery to liquids such as water, oil, or solvents. Liquids
will damage the battery.
• Do not attempt to open the battery. It contains no user-serviceable parts.
• Use this battery for manufacturer’s intended use only. Use other than that
which is described in this manual can result in injury or property damage.
• Inspect the battery before each use. Do not use a damaged battery.
Failure to observe these precautions may result in injury or property damage.

7
ES750
Charger
IMPORTANT SAFETY INFORMATION
• Do not obstruct the ventilation slots. This device generates heat while
charging. Excessive internal heat can result in a fire.
• Do not use or store the charger near a heat source. This device generates
heat while charging. Excessive internal heat can result in a fire.
Failure to observe these warnings could result in severe injury or death.
Greenlee recommends plugging the charger directly into a receptacle. If an
extension cord must be used:
• Select an extension cord with a configuration that exactly matches that of the
charger’s plug.
• Inspect the extension cord for wear or damage.
Use of an improper or damaged extension cord could result in electric shock or fire.
Electric shock hazard:
• Use indoors only.
• Do not expose the charger to rain, snow, or wet conditions.
• Unplug the charger from the power source before cleaning
the charger.
Failure to observe these warnings could result in severe
injury or death.

8
IMPORTANT SAFETY INFORMATION
Charger (cont’d)
• Do not connect the charger to a generator. Voltage fluctuations can damage
the charger.
• Inspect the charger before each use. Replace the unit if either the charger or
cord show signs of damage or wear.
• Do not attempt to repair the charger. It contains no user-serviceable parts.
• Use this tool for manufacturer’s intended use only. Use other than that which
is described in this manual can result in injury or property damage.
Failure to observe these precautions may result in injury or property damage.
Do not place anything other than the supplied 12-volt rechargeable NiCd (nickel
cadmium) battery into the battery pocket.
• Keep dirt and foreign objects out of the battery pocket.
• Do not create a short circuit across the contacts in the battery pocket.
Failure to observe this precaution may result in injury or property damage.
Use this charger to charge the supplied 12-volt rechargeable NiCd (nickel
cadmium) batteries only. Other batteries may burst if charged with this charger.
Failure to observe this warning could result in severe injury or death.

9
ES750
Specifications
Cutter
Weight (with battery) ......................................................................................... 5 lb, 8 oz
Weight (with battery, charger, and case) ........................................................ 9 lb, 10 oz
Height ................................................................................................................... 13-5/8"
Width ....................................................................................................................... 6-1/2"
Depth ...................................................................................................................... 4-1/8"
Wire Type ........................................................................................Copper or aluminum
Maximum Wire Size ......................................................................................... 750 Kcmil
Motor .................................................................................................................... 12 VDC
Battery
Type ................................................................................ Rechargeable nickel-cadmium
Voltage...................................................................................................................... 12 V
Charger
Voltage........................................................................................... 120 VAC or 220 VAC
Trigger
RESET
(yellow button)

10
Operation
1. Slide the direction control lever to select either FORWARD or REVERSE. Press the
switch to activate the cable cutter. Release the switch after the movable blade is
disengaged from the driver.
2. Place the cable to be cut against the stationary blade until it is engaged by the driver.
Close the movable blade around the cable.
3. Slide the direction control lever to FORWARD. Press the switch. After the cable is
completely cut, release the switch.
4. Slide the direction control lever to the center (LOCK) position.
Circuit Breaker
The following may cause the circuit breaker to trip:
• Cutting material that is too large
• Cutting material that is too hard
• Overheating due to continuous use
• Drawing excessive current
If the circuit breaker trips, the tool will stop. If necessary, allow the tool to cool down.
Press the RESET button. (Wait 10 seconds to 1 minute before resetting.)
REVERSE
Driver
Fixed Blade
Movable Blade
FORWARD
LOCK
Do not cut steel or ACSR.

11
ES750
Charger
The battery charger will recharge the battery in approximately one hour.
Do not connect the charger to a generator. Voltage fluctuations may damage
the charger.
1. Set the charger on a firm level surface out of direct sunlight. Be sure that the
charger’s ventilation slots are not blocked.
2. Connect the charger to an appropriate power supply.
3. Insert the battery into the battery pocket of the charger. The LED will light to indicate
that the battery is charging. After approximately one hour, the LED will turn off to
indicate that the battery is fully charged.
4. Remove the battery from the charger.
Note: Allow the charger to cool for at least 15 minutes before charging another battery.

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Troubleshooting
Cutter does not operate. Battery is discharged. Charge the battery.
The internal circuit breaker Reset the circuit breaker.
has tripped.
Movable blade is not Push movable blade until
completely engaged. it is completely engaged
with the drive.
Control lever in LOCK Move to FORWARD or
position. REVERSE position.
Charging LED does not The battery contacts are dirty. Clean the battery contacts
illuminate. on the battery and in the
battery charger.
The battery cartridge is too Allow battery to cool.
warm.
Battery life has decreased. The battery will not hold a Replace the battery.
charge.
Blades are dull. Replace the blades.
Problem Probable Cause Probable Remedy

13
ES750
Replacing Blade Brush
1. Remove the two screws (38) and lift out brush (13).
2. Insert new brush (13). Align hole in brush with holes in housing, install screws (38),
and tighten.
Replacing Movable Blade
1. Rotate blade so that it is clear of pinion gear (9).
2. Secure lock nut (7) with wrench. Remove shoulder screw (5).
3. Install new blade by reassembling shoulder screw (5) and lock nut (7).
Replacing Stationary Blade and Internal Components
1. Remove battery.
2. Remove the two screws (38) holding the brush (13).
3. Remove the screws (42) from the housing (1B). Place the housing (1B) down on
bench. Lift off housing (1A).
4. Remove the internal parts from the housing.
5. Remove the screws (40) from the bearing case (12). Remove the bearing case (12),
bearing (11), and pinion gear (9).
6. Remove screws (39), gear cover (35), and sprocket, pin and gear plates (34, 33, 32).
Remove the stationary (2) and moving blades (3) by removing the screws (40).
7. Remove the two Phillips screws to remove the motor (37) if required.
8. If gear box disassembly is required, use the “Illustration” for directions.
9. Reassemble the cutting blades (2, 3) with screws (40). Reassemble sprocket, pin,
and gear plates (32, 33, 34). Attach gear cover (35) with screws (39).
10. Assemble bearing (11) and pinion gear (9). Use screws (40) to reattach the bearing
case (12).
11. Install the internal component in the right housing (1B). Carefully place left housing
(1A) on top. Make sure circuit breaker button is in its proper location. Also make sure
the internal wires are not pinched. Turn unit over and tighten screws (42). Do not
overtighten screws. Make sure hanging ring is reattached.
12. Install brush (13) with screws (38). Use pin to align holes before reassembling
screws.
Maintenance

14
1A
38
76
2
3
25
21
24 x 4
23
22
21
20 x 7
19
40 x 5
26
36
37
44
43
45
42 x 6
1B
27
35
34
33
32
39 x 3
28
29
30
31
18
17
4
41
8
910
11 12
39 x 2
40 x 5 13
16 x 7
15
14
4
41
5
38
Illustration

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ES750
Parts List
Key Part No. Description Qty
50109910 Housing Kit (includes items 1A - 1B)
1A Left housing ........................................................................ 1
1B Right housing ..................................................................... 1
2 50453335 Stationary blade ..................................................................... 1
3 50453343 Moving blade .......................................................................... 1
4 50453351 Gear guides set...................................................................... 1
5 50453360 Shoulder screw M6 ................................................................ 1
6 50453378 Washer M6 ............................................................................. 1
7 50453386 Lock nut M6............................................................................ 1
8 50453394 Bearing ................................................................................... 1
9 50453408 Pinion bearing ........................................................................ 1
10 50453416 Cutter plate............................................................................. 1
11 50453424 Bearing ................................................................................... 1
12 50453432 Bearing case .......................................................................... 1
13 50453440 Brush ...................................................................................... 1
50101358 Planetary Gear Box (includes items 14–26)
14 Aluminum circlip ..................................................................... 1
15 Gear plate .............................................................................. 1
16 Gear ....................................................................................... 7
17 Gear ....................................................................................... 1
18 Gear ....................................................................................... 1
19 Gear ....................................................................................... 1
20 Gear ....................................................................................... 7
21 Gear ....................................................................................... 2
22 Plastic circle ........................................................................... 1
23 Gear plate .............................................................................. 1
24 Gear ....................................................................................... 4
25 Washer ................................................................................... 1
26 Gear case............................................................................... 1
50101366 Ring Gear Kit (includes items 27–31)
27 Bearing ................................................................................... 1
28 Gear ....................................................................................... 1
29 Pin .......................................................................................... 2
30 Gear washer........................................................................... 1
31 Gear ....................................................................................... 1
32 50453637 Gear plate .............................................................................. 2

16
50101374 Transfer Gear (includes items 33 and 34)
33 Gear pin ................................................................................. 1
34 Gear ....................................................................................... 1
35 50453661 Gear cover ............................................................................. 1
50101382 Motor and Gear (includes items 36 and 37)
36 Motor gear .............................................................................. 1
37 Motor ...................................................................................... 1
38 50453696 Screw M3 ............................................................................... 1
39 50453700 Screw M3 ............................................................................... 5
40 50453718 Screw M5 .............................................................................. 10
41 50453726 Screw M3 ............................................................................... 2
42 50453734 Screw M3 ............................................................................... 6
43 50453769 Switch ..................................................................................... 1
44 50453750 Circuit breaker ........................................................................ 1
45 50453777 Contact ................................................................................... 1
46 52021541 Decal, WEEE recycle symbol ................................................ 1
50453785 12 V battery
50453793 120 V charger
50453823 220 V charger
50122207 Plastic case
Parts List (cont’d)
Key Part No. Description Qty
USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
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