Greenlee GATOR ESG85GL User manual

INSTRUCTION MANUAL
GATOR®
ESG85GL Battery-powered
Cable Cutter
99935481 © 2006 Greenlee Textron Inc. IM 1443 REV 3 1/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Description ..................................................................... 2
Purpose .......................................................................... 2
Important Safety Information .......................................3-4
Identification ................................................................... 5
Location of Decals.......................................................... 6
Specifications ................................................................. 6
Operation ....................................................................7-8
Maintenance................................................................... 9
Troubleshooting ........................................................... 10
Disassembly/Reassembly .......................................11-12
Service ......................................................................... 13
Exploded Views and Parts Lists .............................. 14-18
Table of Contents
Description
Greenlee GATOR®cable cutters are hand-held,
battery-operated tools designed for cutting copper and
aluminum cable up to 3-1/4" (85 mm) in diameter. This
tool is intended to cut most low and medium voltage
copper and aluminum cable found on most job sites.
Purpose
This instruction manual is intended to familiarize person-
nel with the safe operation and maintenance procedures
for the Gator ESG85GL Battery-Powered Cable Cutter
with 2-speed ram.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction 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.
KEEP THIS MANUAL
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.
GATOR is a registered trademark of Greenlee Textron.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
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
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.
IMPORTANT SAFETY INFORMATION
Electrical Shock Hazard: This tool
is not insulated. Use protective
equipment when utilizing this unit
near energized electrical lines.
Failure to observe this warning could
result in severe injury or death.
• Electrical 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 could result in severe
injury or death.
High Pressure Hazard:
Do not use fingers or hands to
check for oil leaks. High pressure
oil easily punctures skin causing
serious injury, gangrene or death.
If injured seek medical help immedi-
ately to remove oil.
Do not use solvents or flammable
cleaners to clean cutter body.
Solvents could ignite causing
serious injury or property damage.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
• Do not immerse batteries in water or any conduc-
tive liquid. If batteries are immersed, contact your
service center for proper handling.
• Never short between the battery terminals.
• Use only the manufacturer-supplied charger rated
for 12 volt nickel cadmium batteries.
• Do not disassemble or perform modifications to
the battery. (There are no user serviceable compo-
nents in the battery.) Failure to comply may result
in injury or damage to the battery from rapid
discharge of battery energy.
• Do not place battery into pocket or toolbox with
conductive objects (coins, keys, tools, etc.).
Failure to observe this precaution could result in
burn injury from rapid discharge of battery energy.
• A battery placed on its nose on damp ground or
grass may be damaged by an electrical short.
• Do not store batteries above 60°C/140°F for
extended periods. Battery damage may result.
Failure to observe these warnings may result in
personal injury or damage to the battery from rapid
discharge of battery energy.
Use all appropriate and applicable personal safety
equipment as required, such as: safety shoes, hard
hat, safety glasses, etc. Follow all safety rules and
regulations for the job.
Failure to comply may result in personal injury or
property damage.
IMPORTANT SAFETY INFORMATION
• Keep hands and fingers away
from closing blades.
• Lock trigger when not in use.
Do not dispose of batteries in a fire. They will vent
vapors and may explode.
Failure to observe this warning may result in injury
from inhalation of vapors or burns from flying debris.
• Do not cut steel or ACSR. Cut only copper and
aluminum cable.
• This tool is not designed for continuous use. After
30 – 40 cutting cycles, allow the cutter to cool for
15 minutes.
• Do not place tool in a vise. The cutter is designed
for hand-held operation.
• Keep water from inside of cutter. Water inside
cutter or battery may damage internal circuitry.
• Store tool in case when not in use.
Failure to observe these precautions could result in
injury and property damage.
Wear safety glasses when using
this cable cutter.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Identification
ESG85 Cable Cutter
1. Housing 6. Trigger
2. Retract Button 7. Battery Load Display
3. Battery 8. Locking Arm
4. Hand Guard 9. Moveable Blade
5. Trigger Lock 10. Fixed Blade
8
9
10
1
4
2
5
3
6
7

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Specifications
Location of Decals
Weight (with battery) ............................................................................ 7.3 kg (16.1 lb)
Overall Length .................................................................................... 49.2 cm (19.37")
Width ...........................................................................................................76 mm (3")
Height ......................................................................................................... 33 cm (13")
Cutting Power......................................................................................60 kN (6.6 tons)
Maximum Cable Cutting Diameter .........................................................85 mm (3.25")
Motor ................................................................. Direct-Current Permanent Field Motor
Motor Voltage ....................................................................................................12 VDC
Charging Voltage ................................................................................................... 12 V
Charging Time.................................................................................................... 1 Hour
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
500 6764.8
Identification
(500 6765.6
Warning - opposite side)

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Operation
• Electrical 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.
Failure to observe this warning could result in severe
injury or death.
• Keep hands and fingers away
from closing blades.
• Lock trigger when not in use.
Wear safety glasses when using
this cable cutter.
• Do not cut steel or ACSR. Cut only copper and
aluminum cable.
• This tool is not designed for continuous use. After
30 – 40 cutting cycles, allow the cutter to cool for
15 minutes.
• Keep water from inside of cutter. Water inside
cutter or battery may damage internal circuitry.
Failure to observe these precautions may result in
injury and property damage.
Electrical Shock Hazard: This tool is
not insulated. Use protective equip-
ment when utilizing this unit near
energized electrical lines.
Failure to observe this warning could
result in severe injury or death.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
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 pushing on the locking arm.
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. When the cut is completed, press the retract button
to return ram. Hold button until the ram is returned to
desired position.
Note: At any time during cutting, pushing the return
button will result in the ram returning.
6. Return trigger lock to its original locked position.
Operation (cont’d)
Push to open Head

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Maintenance
Each Operating Day
Before Use:
1. Inspect blades for defects, such as cracks, gouges
or chips.
2. Inspect the cutter for damage or leaks. If damage is
detected, return the tool to an authorized Greenlee
service center.
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
High Pressure Hazard:
Do not use fingers or hands to
check for oil leaks. High pressure
oil easily punctures skin causing
serious injury, gangrene or death.
If injured seek medical help immedi-
ately to remove oil.
Do not use solvents or flammable
cleaners to clean cutter body.
Solvents could ignite causing
serious injury or property damage.
• Keep hands and fingers away
from closing blades.
• Lock trigger when not in use.
After Use:
1. Wipe clean and dry all exposed surfaces.
Note: Use a slightly damp cloth and a mild detergent to
clean the cutter body. Solvents can damage the cutter
body and may ignite.
2. Fully retract and lock blades, Place the cable cutter
in the carrying case. Store in a cool, dry place.
3. Fully discharged batteries should be recharged so
that they are ready for use. (See battery charger
instructions.)
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.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
GATOR®Battery-powered Cable Cutter
Troubleshooting
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Crimper battery contacts damaged. Reform contacts.
Tool components worn or Return tool to an authorized
damaged. 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.
Battery load display flashes Battery charge low. Charge or replace battery.
constantly.
Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee
service center.
Oil plug not installed properly. Refill reservoir and replace plug.
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.
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.
Problem Probable Cause Probable Remedy