Greenlee GATOR ESG50GL User manual

GATOR®
ESG50GL Battery-powered
Cable Cutter
INSTRUCTION MANUAL
99922088 © 2006 Greenlee Textron Inc. IM 1293 REV 2 2/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Español; p. 11
Français; p. 21

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Table of Contents
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
KEEP THIS MANUAL
Description
The Greenlee GATOR cable cutter is a hand-held,
battery-operated tool designed for cutting copper and
aluminum cable up to 1-3/4" in diameter. This tool is
intended to cut most low and medium voltage copper
and aluminum cable.
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
ESG50GL Battery-powered Cable Cutter
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
Important Safety Instructions ......................................2-4
Intended Use .................................................................. 5
Identification ................................................................... 5
Location of Decals.......................................................... 6
Specifications ................................................................. 6
Operation ....................................................................7-8
Maintenance................................................................... 9
Troubleshooting ........................................................... 10
Service ......................................................................... 10
Spanish instructions ..................................................... 11
French instructions ....................................................... 21
Disassembly / Reassembly ..................................... 31-32
Exploded Views.......................................................33-34
Parts Lists ...............................................................35-36

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
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.
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
IMPORTANT SAFETY INFORMATION
This tool is not insulated. When
using this tool near energized
electrical lines use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Keep hands away from blades.
Failure to observe this warning
could result in serious injury.
Wear eye protection when using
this tool.
Failure to wear eye protection
could result in serious eye injury
from flying debris or hydraulic oil.
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.
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.
Do not use solvents or flammable
cleaners to clean the cutter. Solvents
could ignite and cause serious injury
or death.
Do not cut cable under tension. Cable will fall and
may strike nearby personnel.
Failure to observe this warning could result in
severe injury or death.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
IMPORTANT SAFETY INFORMATION
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.
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 steel or ACSR. Use this tool for cutting
copper and aluminum cable only.
• Do not use this tool for continuous use. After
30 – 40 cutting cycles, allow the tool to cool for
15 minutes.
• Do not secure this tool in a vise. A vise can
damage the housing.
• Do not use this tool in rain or wet conditions.
Any moisture inside the housing can damage
internal circuitry.
• Use this tool for manufacturer’s intended use
only.
Failure to observe these precautions may result in
injury or property damage.
• 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 manufacturer’s 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.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Identification
3
10
4
6
1
8
9
7
2
5
12
11
1. Trigger
2. Retract Button
3. Locking Flange
4. Cutting Head
5. Housing
6. Battery Load Display
7. Battery Cartridge
8. Trigger Lock
9. Hand Guard
10. Blades
11. Oil Reservoir
12. Oil Plug

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Location of Decals
Specifications
Weight (with battery) .............................................................................. 9.0 lb (4.1 kg)
Overall Length ....................................................................................15.94" (405 mm)
Width ...........................................................................................................3" (76 mm)
Height .................................................................................................12.60" (320 mm)
Cutting Power......................................................................................5.5 tons (50 kN)
Maximum Cable Cutting Diameter ....................................................... 1-3/4" (45 mm)
Motor ................................................................. Direct-Current Permanent Field Motor
Motor Voltage ....................................................................................................12 VDC
Charging Voltage ................................................................................................... 12 V
Charging Time.................................................................................................... 1 Hour
Cutting Time ................................................................................................ 22 seconds
Cutting Speed ......................................................................... 3/32"/sec (2.4 mm/sec)
Cutting Performance .............................................................. approximately 50/charge
Hydraulic Oil ............................................................... .1 pint (50 ml) Shell Tallus T 15
Cutting Head ......................................................................................................... Steel
Sound Level .................................................................................. 75 dB (A) at 1 meter
Vibrations ...................................................................................................... <2.5 m/s2
Warning
500 2942.8
500 2944.7
500 2946.0

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Operation
This tool is not insulated. When
using this tool near energized
electrical lines use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Keep hands away from blades.
Failure to observe this warning
could result in serious injury.
• Do not cut steel or ACSR. Use this tool for
cutting copper and aluminum cable only.
• Do not use this tool for continuous use. After
30 – 40 cutting cycles, allow the tool to cool for
15 minutes.
• Do not secure this tool in a vise. A vise can
damage the housing.
• Do not use this tool in rain or wet conditions.
Any moisture inside the housing can damage
internal circuitry.
• Use this tool for manufacturer’s intended use
only.
Failure to observe these precautions may result in
injury or property damage.
Do not cut cable under tension. Cable will fall and
may strike nearby personnel.
Failure to observe this warning could result in
severe injury or death.
Wear eye protection when using
this tool.
Failure to wear eye protection
could result in serious eye injury
from flying debris or hydraulic oil.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Pull trigger to cut
Push trigger lock down
to release
Push to retract blades
Operation (cont’d)
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.
Cutting Cable
1. Open the head by lifting the locking flange.
2. Position the cable in the open cutting head.
3. Close the cutting head.
4. Push down on the trigger lock. Pull the trigger.
The blades will begin to close.
5. Release the trigger when the cut is complete.
6. Push the retract button.
7. Return trigger lock to its original locked position.

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Each Operating Day
Before Use:
Inspect blades for damage, such as cracks, gouges or
chips.
Maintenance
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
3. Oil the bolt joints.
Annually
1. Change the hydraulic oil
2. Return the tool to an authorized Greenlee service
center for inspection.
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.
Recommended Hydraulic Oils
AVIA HVI 15
Shell Tellus T 15
MOBIL DTE 11
NUTO H 15
• Keep hands and fingers away
from closing blades.
• Lock trigger when not in use.
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.
After Use:
1. Clean all exposed surfaces with a slightly damp cloth
and a mild detergent. Dry all exposed surfaces.
2. Check the charge level of the battery. Charge if
necessary. See the battery charger instructions.
3. Fully retract and lock the blades. Place the cable
cutter in the carrying case and store in a cool, dry
place.
Do not use solvents or flammable
cleaners to clean the cutter.
Solvents could ignite and cause
serious injury or death.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
BEFORE YOU BEGIN
1. Make sure that the battery is charged. Recheck the
battery after several minutes to make sure the
battery is holding its charge.
Troubleshooting
Problem Probable Cause Possible Remedy
Tool doesn’t operate. Crimper battery contacts are bent. Reform contacts.
Dirt or other contaminants in the Clean tool.
cutting head of the tool.
Blade stops before operation Oil level is low. Check oil level. Fill reservoir if
is complete. necessary.
Air in hydraulic system. Pull trigger and hold release lever
simultaneously. Hold for approximately
10 seconds.
LED flashes constantly. Battery charge is low. Recharge battery.
Low battery life. Battery is exhausted. Replace battery.
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
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.