Greenlee ES85 User manual

INSTRUCTION MANUAL
ES85 Battery-powered
Cable Cutter
11839–with 120 V Charger
11854–with 220 V Charger
Read and understand all of the instructions and
safety information in this manual before operating
of servicing this tool.
99952327 REV 5 © 2007 Greenlee Textron Inc. 7/07

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The Greenlee ES85 Battery-powered Cable Cutter
is intended to cut up to 24 AWG, 1800 pair
communications cable.
The cable cutter is driven by a 14.4 V 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
following Greenlee tools:
ES85-11 Battery-powered Cable Cutter, 120 V
ES85-22 Battery-powered Cable Cutter, 220 V
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.
KEEP THIS MANUAL
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information .....................................3–5
Identication.................................................................. 6
Specications................................................................ 6
Operation....................................................................... 7
Maintenance.................................................................. 8
Troubleshooting............................................................. 9
Illustration and Parts List........................................10–11

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
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 pre-
venting 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.
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.
Note: Keep all decals clean and legible, and replace
when necessary.
Cable Cutter
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.
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.
•
•
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 replace-
ment 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.
•
•
•

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Battery
Do not dispose of battery in a re. The battery will
vent harmful vapors and can explode.
Failure to observe this warning could result in severe
injury or death.
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 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 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.
•
•
•
•
IMPORTANT SAFETY INFORMATION

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Charger
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.
•
•
•
Greenlee recommends plugging the charger directly
into a receptacle. If an extension cord must be used:
Select an extension cord with a conguration 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 re.
•
•
Do not obstruct the ventilation slots. This device
generates heat while charging. Excessive internal
heat can result in a re.
Do not use or store the charger near a heat
source. This device generates heat while charging.
Excessive internal heat can result in a re.
Failure to observe these warnings could result in
severe injury or death.
•
•
Use this charger to charge the supplied 14.4 V
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.
Do not place anything other than the supplied 14.4 V
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.
•
•
Do not connect the charger to a generator. Voltage
uctuations 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.
•
•
•
•
IMPORTANT SAFETY INFORMATION

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Identification
21
3
4
5
Specifications
Cable Cutter
Weight (with battery) ............................................................................3.5 kg (7.7 lb)
Wire Type............................................................... 1800 pair communications cable
Maximum Wire Size ....................................................................... 85 mm (24 AWG)
Motor.......................................................................................................... 14.4 VDC
Battery
Type...........................................................................Rechargeable nickel-cadmium
Voltage ............................................................................................................ 14.4 V
Charger
Voltage ..................................................................................... 120 VAC or 220 VAC
1. Movable blade
2. Stationary blade
3. Driver
4. Trigger
5. Reset button

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation
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.
Do not cut steel or ACSR.
Failure to observe this precaution may result in injury
or property damage.
1. Activate the switch to open the movable blade.
2. Place the cable to be cut onto the stationary blade
and close the movable blade around the cable.
Feed the movable blade by hand so that the gear
teeth engage the drive mechanism of the tool.
3. Slide the direction control lever to FORWARD.
Press and hold the trigger switch until the cable is
completely cut.
4. Slide the direction control lever to the center (LOCK)
position.
5. When nished, remove any dust or particles that
may have become attached to the brush.
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 one minute before resetting.)
•
•
•
•
Removing the Battery
Do not dispose of battery in a re. The battery will
vent harmful vapors and can explode.
Failure to observe this warning could result in severe
injury or death.
1. Press the battery latch on the battery.
2. Pull the battery down and out of the tool.
Charging the Battery
Do not connect the charger to a generator. Voltage
uctuations can damage the charger.
Failure to observe this precaution may result in injury
or property damage.
•
The battery charger will recharge the battery in approxi-
mately one hour.
1. Set the charger on a rm 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 red LED will light to indicate that the
battery is charging. The red LED turns off and
the green LED turns on when the battery is at
80% capacity. To reach 100% capacity will take
approximately 13 to 15 hours after the green LED
switches on.
Note: It is acceptable to use the battery after the
red LED turns off and the green LED turns on.
4. Remove the battery from the charger.
Note: Allow the charger to cool for at least 15 minutes
before charging another battery.

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Maintenance
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
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.
•
•
Daily Maintenance
Store the tool in a cool, dry area to prevent rust.
Inspect the blades for damage or burrs. Remove burrs
on the back side of the blades with a at grinding
stone.
Clean the plastic housing with a soft, soaped cloth.
•
•
•
Replacing the Gear Guides
1. This tool has two gear guides — left and right.
Operate the cutter in either the forward or reverse
direction to move the blade completely out of the
gear mechanism.
2. Remove the battery from the cutter.
3. Use an M2.5 Allen wrench to loosen and remove
the screw that secures the gear guide and install the
replacement guides on the movable blade.
4. Tighten the screw securely.
5. Re-install the battery and operate the cutter.
Replacing the Movable Blade
1. Operate the cutter in either the forward or reverse
direction until the movable blade is clear of the
pinion gear.
2. Remote the battery from the cutter.
3. Secure the lock nut with a wrench, and then loosen
the shoulder screw with a screwdriver.
4. Remove the movable blade from the tool. Be sure
not to lose the two curved washers.
5. Use an M2.5 Allen wrench to loosen and remove
the two screws that secure the left and right orange
gear guides to the movable blade.
6. Install the left and right gear guides on the new
movable blade. Put the right gear guide on the right
side of the blade and the left gear guide on the
left side of the blade and tighten securely. A lock
washer is located between the screw head and the
gear guide.
7. Install the new movable blade by reassembling the
shoulder screw and lock nut.
8. Re-install the battery and operate the cutter.

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Troubleshooting
Problem Probable Cause Probable Remedy
Cutter does not operate. Battery is discharged. Charge battery.
Internal circuit breaker has tripped. Reset circuit breaker.
Movable blade is not completely
engaged.
Push movable blade until it is
completely engaged with drive.
Dust or foreign matter lodged at
battery contacts.
Clean battery contacts.
Charging LED does not illuminate. Battery contacts are dirty. Clean battery contacts on battery
and in battery charger.
Battery cartridge is too warm. Allow battery to cool.
Battery life has decreased. Battery will not hold a charge. Replace battery.
Blades are dull. Replace blades.

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Illustration
7
50
37
38
36
58
57
46
2
38
21
22
35
56
55
48
49
47
26
23
24
25
43
45
44
39
45
15
34
32
42
40
41
30
33
31
30
29
16
14
12
11
7
28
27
17
18
1
4
3
13
6
5
53
54
51
52
8
20
19
9
10
21
21
22

ES85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Parts List
Key Part No. Description Qty
1* Left housing .............................................................................................. 1
2* Right housing ............................................................................................ 1
3† 50122100 Screw, M6 x 8 ........................................................................................... 2
4† 50122118 Spring pin, M6 x 10................................................................................... 2
5† 50119885 Screw, M3 x 6 ........................................................................................... 2
6† 50122134 Washer, 3M ............................................................................................... 2
7† 50453351 Gear guides set......................................................................................... 1
8† Gear wheel ................................................................................................ 1
9† 50119893 Shoulder screw, M8-1.25 x 32 .................................................................. 1
10† Plate .......................................................................................................... 1
11† 50122177 Washer, 10.2M .......................................................................................... 1
12† Spacer collar ............................................................................................. 1
13† 50119761 Movable blade kit (includes items 3, 4, 8, and 13).................................... 1
14† 50119770 Stationary blade kit (includes items 10–12, 14, 16, 20, and 21) ............... 1
15† 50119907 Nut, M8-1.25............................................................................................. 1
16–20 50119796 Planetary gearbox..................................................................................... 1
22–45
21 50119966 Screw, M4 x 9 ........................................................................................... 4
46 50119818 Gear, motor ............................................................................................... 1
47 50119800 Motor......................................................................................................... 1
48 50119958 Circuit breaker........................................................................................... 1
49–50 Wires ....................................................................................................1 ea.
52–54
51 50119940 Switch ....................................................................................................... 1
55 50119974 Contact ..................................................................................................... 2
56 50119931 Suspender................................................................................................. 1
57* Screw, M3 x 15 ......................................................................................... 1
58* Screw, M4 x 18 ......................................................................................... 7
Decals
* 50118498 Identication decal.................................................................................... 2
* 50118480 Warning decal ........................................................................................... 1
50118471 Battery decal............................................................................................. 2
50118404 Warning decal ........................................................................................... 1
52021541 Decal, WEEE recycle symbol ................................................................... 1
Kits
50119834 Housing kit (includes items marked with an asterisk)
50119877 Blade kit (includes items marked with †)
50119842 Motor kit (includes items 46 and 47)
50118510 14.4 V battery
50118412 120 V charger
50118560 220 V charger
50118455 Plastic case
50051920 Case decal
52020084 Plastic case clip (service item only)

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