Greenlee GATOR CSG85GL User manual

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®

CSG85GL Cable Cutter

120 Volt and 230 Volt

CSG85GL 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 CSG85GL Cable Cutter is a hand-held tool intended

to cut copper and aluminum cable up to 85 mm (3-1/4")

in diameter. This tool is intended to cut most low and

medium voltage copper and aluminum cable found on

most job sites.

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:

CSG85GL11 120 Volt Cable Cutter

CSG85GL22 230 Volt Cable Cutter

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge.

CSG85GL 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

standards 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.

CSG85GL 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.

CSG85GL 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.

•Do not cut steel or ACSR. Cut only copper and

aluminum cable.

•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.

CSG85GL Cable Cutter

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Identification

Specifications

CSG85GL

1. Housing

2. Retract Button

3. Power Cord

4. Trigger

5. Movable Blade

6. Fixed Blade

7. Locking Arm

Length .................................................................................................492 mm (19.37")

Width ............................................................................................................76 mm (3")

Height.......................................................................................................330 mm (13")

Mass/Weight ......................................................................................... 5.8 kg (12.8 lb)

Sound Level ...............................................................................< 75 dB (A) at 1 meter

Vibration ........................................................................................................ < 2.5 m/s2

Motor Voltage

CSG85GL11 ......................................................................... 120 VAC, 60 Hz, 2.1 A

CSG85GL22 ......................................................................... 230 VAC, 50 Hz, 1.1 A

Hydraulic Oil.........................................................50 ml (0.1 pint) of Shell Tellus®T 15

Maximum Cable Cutting Diameter ....................................................... 85 mm (3-1/4")

CSG85GL Cable Cutter

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Operation

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. Pull the trigger. The blades will begin to close.

5. When the cut is completed, push the retract button

to return the ram. Hold the button until the ram

returns to the desired position.

Note: At any time during cutting, pushing the return

button will result in a complete return of the ram.

•Do not cut steel or ACSR. Cut only copper and

aluminum cable.

•This tool is not designed for continuous use.

After 30 to 40 cutting cycles, allow the tool to

cool for 15 minutes.

Failure to observe these precautions can result in

injury or property damage.

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

standards as well as in the safe use of this tool

and its accessories.

•Do not cut cable under tension.

Failure to observe this warning will 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.

Keep hands away from closing

blades.

Failure to observe this warning can

result in severe injury or death.

Pull trigger to cut

Push to retract blades

Push to open head

CSG85GL 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 blades. 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.

CSG85GL 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

CSG85GL 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 (41). Remove the cutting blade (49).

2. Loosen two screws (13).

3. Unscrew and remove the head assembly.

4. Remove the spring assembly (14) and piston (30).

Replace the piston O-ring (28) and piston backup

ring (29).

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).

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