
ESC85 Battery-powered Cable Cutter
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Assembly
Motor, Gearbox, and Bearing
1. Install two llister head screws (104) into the spacer
(not numbered) and motor (90). Tighten the screws.
2. Install four screws (not numbered) into the gear
housing (94). Tighten the screws.
3. Install four screws (93) into the mounting block (101)
and gear housing (94). Tighten the screws.
4. Replace the grooved ball bearing (97) and snap ring
(96) subassembly.
5. Replace the eccentric (99). Use a ber mallet to
tap the eccentric onto the shaft. Replace the ball
bearing (91).
6. Align the end cap (98). Use a ber mallet to tap the
cover until it is ush on the mounting block (101).
Install two screws (92).
7. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mount-
ing block (101) and makes contact with the grooved
bearing (97). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. Insert the seal (122) and unloading valve assembly
into the pump housing. Grasp the needle valve
subassembly by the pressure relief (126) and twist it
several turns clockwise. Stop when the piece of
tape is facing up.
3. Assemble the pump piston (150), valve stem (156),
washer (153), spring (155), and screw plug (151).
Be sure to replace the sealing washer (154).
Torque the screw plug (151) to 101 Nm (75 ft-lb).
4. Install the release lever (111) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (108) and washer (109).
5. Insert the threaded bushing (79) and feed tube
subassembly (77, 78, 82). Screw in until snug.
6. Install the 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.
7. Insert the plug (76) into the reservoir.
Main Components
1. Remove the protective plastic bag from the
electronics subassembly. Insert the LED into the
LED bushing (8).
2. 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.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the battery clip so that the
battery wires lay on top of the electronics box;
install the battery clip so the red wire is upward.
5. Install the trigger cover (56). Press and release the
trigger to be sure that it operates freely.
6. Locate the right housing half (59) on top of the left
housing half (60). Check for pinched wires.
7. Install the housing screws (51, 53).
Note: The handle screw (51) must engage the
nut (52).
8. Install piston (30) with O-ring (14) and backup ring
(15).
9. Install spring (20) over piston rod (19) and slide into
yoke (25).
10. Place bearing block (21) into piston rod end.
Compress spring and install socket head cap screw
(18).
11. Lubricate bearing surface of blades (26) with
Molykote grease. Slide blades between yoke (25)
and install clevis pin (27) with pin head on opposite
side, as machined for handle (32).
12. Install hex jam nuts (28) to clevis pin. Do not over-
tighten. Lock jam nuts to each other.
13. Install links (22), clevis pins (23) and retaining rings
(24) to blades (26).
14. Install blade guide (29) with socket head cap
screws (30).
15. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the ll plug
(76) and ll the reservoir with hydraulic oil.
16. Install the battery.
17. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the ll plug (76).
18. Replace the tank cover (58) and tank cover
screws (53).
19. Run the blades out until they overlap. Use a feeler
gage and check the gap between the blades at
the blade guide end. If the gap is more than .003"
add a shim between guide and on the side of the
blade.
Use a shim that will bring the gap down to
.003/.002".