Greenlee GATOR CSG45GL User manual

INSTRUCTION MANUAL
999 4503.7 © 2002 Greenlee Textron IM 1512 8/02
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®
CSG45GL Cable Cutter
120 Volt and 230 Volt

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron shall not be liable for damages
resulting from misapplication or misuse of its products.
GATOR is a registered trademark of Greenlee Textron.
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.
KEEPTHIS MANUAL
Table of Contents
Description .....................................................................2
Safety .............................................................................2
Purpose of this Manual ..................................................2
Important Safety Information......................................3–5
Identification ................................................................... 6
Specifications ................................................................. 6
Operation .......................................................................7
Maintenance...................................................................8
Troubleshooting .............................................................9
Disassembly.................................................................10
Assembly......................................................................11
Illustrations .............................................................12–14
Parts List ................................................................15–17
Description
The CSG45GL Cable Cutter is a hand-held tool intended
to cut 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 tools:
CSG45GL11 120 Volt Cable Cutter
CSG45GL22 230 Volt Cable Cutter
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
IMPORTANT SAFETY INFORMATION
Read and understand all of the
instructions and safety information in
this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
Electric shock hazard:
• Connect the power cord to a
receptacle of proper voltage for the
tool in use on a ground fault-
protected circuit only.
• Do not modify the power cord or
plug.
• Inspect the power cord before use.
Repair or replace the cord if
damaged.
• Do not pull or carry by cord, use
the cord as a handle, close a door
on the cord, run over the cord, or
pull the cord around sharp edges
or corners. Keep the cord away
from heated surfaces.
• Do not unplug by pulling on the
cord. To unplug, grasp and pull the
plug—not the cord.
• Disconnect from power before
servicing.
Failure to observe these warnings
can result in severe injury or death.
Do not use this cable cutter in a
hazardous environment. Hazards
include flammable liquids, gases, or
other materials. Using this cable
cutter in a hazardous environment
can result in a fire or explosion.
Failure to observe this warning will
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.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
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 can
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 stan-
dards 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 this warning will result in severe
injury or death.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
IMPORTANT SAFETY INFORMATION
Do not operate the tool while wearing loose clothing.
Loose clothing can get caught in moving parts.
Failure to observe this warning can result in severe
injury or death.
Do not use solvents or flammable
cleaners to clean the tool body.
Solvents could ignite, causing
serious injury or property damage.
Inspect tool before use. Replace any worn or
damaged parts with Greenlee replacement parts. A
damaged or improperly assembled tool can break
and strike nearby personnel.
Failure to observe this warning can result in severe
injury or death.
• Do not expose to rain.
• Do not use in wet or damp
locations.
Failure to observe these warnings
can 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 can
result in serious injury, gangrene, or
death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Keep hands away from closing
blades.
Failure to observe this warning can
result in severe injury or death.
Extension cords:
• Use only 16, 14, or 12 AWG
extension cords.
• Do not use extension cords that
are longer than 30 m (100').
• Repair or replace damaged
extension cords.
Failure to observe these warnings
can result in severe injury or death.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
Note: Keep all decals clean and legible, and replace
when necessary.
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 can result in
injury and property damage.
IMPORTANT SAFETY INFORMATION
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 could result in personal injury or
property damage.
•This tool is not designed for continuous use.
After 30 to 40 cutting cycles, allow the tool to
cool for 15 minutes.
•Do not place the tool in a vise. The cable cutter
is designed for hand-held operation.
•Ensure that all bystanders are away from the
work area when operating the tool.
•Ensure that the work area is clean, dry,
uncluttered, and well-lit.
•Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions can result in
injury or property damage.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Identification
Specifications
CSG45GL
1. Housing
2. Retract Button
3. Power Cord
4. Trigger
5. Blades
6. Cutting Head
7. Pull Pin
8. Oil Reservoir
9. Oil Plug
Length ...................................................................................................394 mm (15.5")
Width ............................................................................................................76 mm (3")
Height....................................................................................................318 mm (12.5")
Mass/Weight ......................................................................................... 5.2 kg (11.5 lb)
Sound Level ...............................................................................< 75 dB (A) at 1 meter
Vibration ........................................................................................................ < 2.5 m/s2
Motor Voltage
CSG45GL11 ......................................................................... 120 VAC, 60 Hz, 2.1 A
CSG45GL22 ......................................................................... 230 VAC, 50 Hz, 1.1 A
Hydraulic Oil.........................................................50 ml (0.1 pint) of Shell Tellus®T 15
Maximum Cable Cutting Diameter ....................................................... 45 mm (1-3/4")
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.................................................8002mm (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.)
2
4
1
3
67
8
9
5

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Operation
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 can
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying 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 can
result in serious injury, gangrene, or
death.
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.
Pull trigger to cut
Push to
retract blades
Keep hands away from closing
blades.
Failure to observe this warning can
result in severe injury or death.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Maintenance
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying 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 can
result in serious injury, gangrene, or
death.
Do not use solvents or flammable
cleaners to clean the tool body.
Solvents could ignite, causing
serious injury or property damage.
Daily
Before use:
1. Inspect blades for wear or damage, such as cracks,
gouges, or chips.
2. Inspect the tool for damage or leaks.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.
2. Fully retract the blade. Place the tool in the carrying
case and store in a cool, dry place.
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
Annually or After 8000 Cuts
1. Replace the hydraulic oil.
2. Send the tool to an authorized Greenlee service
center for inspection.
Checking the Oil Level
1. Remove the two screws that retain the tank housing
cover. Remove the tank housing cover.
2. Point the cutting head downward and remove the oil
reservoir plug. Fill reservoir if necessary.
3. Replace the oil plug and tank housing cover.
Recommended Hydraulic Oils
AVIA®HVI 15
Shell Tellus T 15
Mobil®DTE 15
NUTO®H 15
Keep hands away from closing
blades.
Failure to observe this warning can
result in severe injury or death.

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Troubleshooting
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Tool components worn or damaged. Return tool to an authorized
Greenlee service center.
Cutting blades stop during Oil level is low. Check oil level. Refill reservoir.
operation.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Greenlee service center.
Oil plug not installed properly. Refill reservoir and replace plug.
Probable CauseProblem Probable Remedy

CSG45GL Cable Cutter
Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Disassembly
Main Components
1. Remove the pin (31). Remove the cutting blade (26).
2. Loosen two screws (17).
3. Unscrew and remove the head assembly.
4. Remove the spring (18) and piston (21). Replace the
piston O-ring (16) and piston backup ring (15).
5. Unscrew two tank cover screws (52) and remove the
tank cover.
6. Remove the hydraulic reservoir plug (76) and drain
the hydraulic fluid.
7. Reinstall the plug.
8. Remove the remaining housing screws (52).
9. Remove the housing half.
10. Remove the trigger cover (51) and spring (56).
11. Lift the pump/motor assembly and circuit card from
the housing half.
12. Slide a plastic bag over the circuit card and elec-
tronic subassemblies. Tape the bag shut to protect
the subassemblies from hydraulic oil and other
contamination.
13. Unscrew the shoulder bolt (99) and remove the
release lever (107).
14. Remove screws (108) and separate the gear
housing/motor subassembly from the pump housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring
(80). Gently tug it over the reservoir.
2. Remove the reservoir (74).
3. Remove the pump piston (152).
4. Remove the screw plug (151), washer (153), pump
piston (150), valve stem (156), and spring (155).
Replace the sealing washer (154).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for
reassembly.) Remove the unloading valve by
unscrewing the plug (126).
6. Remove the feeder tube subassembly by unscrew-
ing the feeder tube (78). Replace the oil filter (77).
Remove metal chips from the magnet (82).
7. Remove the threaded bushing (72) and replace the
O-ring (73).
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
2. Remove two screws (92). Remove the end cap
(102).
3. Apply pressure evenly at three points around the ball
bearing (91) and gently pry the bearing up to remove
it.
4. Remove the eccentric (103), grooved ball bearing
(101), and snap ring (100) subassembly from the
shaft.
5. Remove four screws (93). Remove the mounting
block (109) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (100).
7. Unscrew four bolts (not numbered) and hex nuts
(97) from the gear housing (94). Separate the gear
housing from the motor flange (110). Unscrew two
flat head screws (112) to separate the flange from
the motor (90).