Greenlee GATOR ESR1000LX Bedienungsanleitung

INSTRUCTION MANUAL

GATOR®Battery-powered

Ratcheting Cable Cutters

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

(ESR1000LX shown)

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Description

Greenlee's Battery-powered Cable Cutters are hand-

held, self contained cutting tools intended to cut the

following:

ESR25LX: Up to 636 kcmil Grosbeak ACSR cable. It is

not intended to cut Egret ACSR cable.

ESR1000LX: Copper cable up to 1000 kcmil and alumi-

num cable up to 1500kcmil.

The ratcheting cable cutters are powered with 18V

Li-ION rechargeable batteries and feature over-current

and low voltage protection.

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.

Purpose of this Manual

This manual is intended to familiarize all personnel with

the safe operation and maintenance procedures for the

following Greenlee tools:

ESR1000LXB Cutter, battery ratchet soft w/ case

ESR25LXB Cutter, battery ratchet ACSR w/ case

ESR1000LX11 Cutter, battery ratchet soft 120v

ESR25LX11 Cutter, battery ratchet ACSR 120v

ESR1000LX12 Cutter, battery ratchet soft 12v

ESR25LX12 Cutter, battery ratchet ACSR 12v

ESR1000LX22 Cutter, battery ratchet soft 230v

ESR25LX22 Cutter, battery ratchet ACSR 230v

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge at www.greenlee.com.

Do not discard this product or throw away!

For recycling information, go to www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

GATOR is a registered trademark of Greenlee Tools, Inc.

KEEP THIS MANUAL

Table of Contents

Description .................................................................... 2

Safety ............................................................................ 2

Purpose of this Manual ................................................. 2

Important Safety Information .....................................3–4

Identication.................................................................. 5

Specications................................................................ 6

Operation....................................................................... 7

Maintenance.................................................................. 8

Troubleshooting............................................................. 9

Illustration and Parts List........................................10–13

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

IMPORTANT SAFETY INFORMATION

SAFETY

ALERT

SYMBOL

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, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

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.

Note: Keep all decals clean and legible, and replace

when necessary.

Do not use solvents or ammable

liquids to clean tool body. Solvents

or ammable liquids could ignite

and cause serious injury or property

damage.

Failure to observe this warning could

result in severe injury or death.

Cable Cutter

Electric shock hazard:

This tool is not insulated. When using

this unit near energized electrical

lines, use proper personal protective

equipment.

Failure to observe this warning could

result in severe injury or death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from ying

debris.

• Keeps hands away from blade.

• Remove the battery before

inspecting or servicing the tool.

Failure to observe these warnings

could result in severe injury or death.

• Inspect the tool before each use. Replace any

worn, damaged, or missing items with Greenlee

replacement parts. A damaged or improperly

assembled tool can break and strike nearby

personnel.

• Carrying strap is for carrying only, not to be used to

hang or suspend tool.

Failure to observe these warnings could result in

severe injury or death.

Do not dispose of battery in a re. The battery will

vent harmful vapors and can explode.

Failure to observe this warning could result in severe

injury or death.

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

IMPORTANT SAFETY INFORMATION

Battery

• Use this tool for manufacturer’s intended use only.

Use other than that which is described in this

manual can result in injury or property damage.

• Do not cut guy wire or steel rod.

• Do not cut ACSR with he ESR1000LX

• Do not exceed the rated capacity of the tool.

Failure to observe these precautions may result in

injury or property damage.

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.

• This tool is not designed for continuous use. After

40 cutting cycles or if tool becomes hot, allow the

cutting tool to rest for 30 minutes.

• Do not secure this tool in a vice. This is a tool

designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may result

when the tool is operated prior to thorough drying

when electrical components are soaked.

• Use this tool for the manufacturer's intended

purpose only

Failure to observe these precautions may result in

injury or property damage.

• Do not store the battery at more than 122 F (50 C)

or less than -4 F (-20 C). Damage to the battery can

result.

• Do not attempt to open the battery. It contains no

user-serviceable parts.

• Do not use another manufacturer’s charger. Other

manufacturers’ chargers may overcharge and

damage the battery.

Failure to observe these precautions may result in

injury or property damage.

• Do not perform any service or maintenance other

than described in this manual. Injury or damage to

the tool may result.

Failure to observe these precautions may result in

injury or property damage.

Note: Keep all decals clean and legible, and replace

when necessary.

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

1. Movable blade

2. Stationary blade

3. Driver

4. Forward/reverse switch

5. Trigger

6. Reset button

Identiﬁcation

ESR25LX

ESR1000LX

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Identiﬁcation (cont'd)

Speciﬁcations

ESR1000LX

Length (with battery)........................................................................ 15.29” (388 mm)

Width………………............................................................................ 7.78” (198 mm)

Depth………………............................................................................ 4.33” (110 mm)

Weight (with battery)............................................................................ 7.6 lb (3.4 kg)

Cutting Capacity

Copper.................................................................................................. Up to 1000 kcmil

Aluminum.............................................................................................. Up to 1500 kcmil

Battery

Type...............................................................................Rechargeable Lithium-Ion

Voltage............................................................................................................. 18 V

Charger

Voltage.................................................................... 120 VAC, 220 VAC and 12 VDC

ESR25LX

Length (with battery)........................................................................ 15.41” (391 mm)

Width………………............................................................................ 7.33” (186 mm)

Depth………………............................................................................ 4.33” (110 mm)

Weight (with battery)............................................................................ 8.0 lb (3.6 kg)

Cutting Capacity

ACSR.................................................................. Up to Grosbeak 636 kcmil (Except Egret)

Battery

Type...............................................................................Rechargeable Lithium-Ion

Voltage............................................................................................................. 18 V

Charger

Voltage........................................................... .......... 120 VAC, 220 VAC and 12 VDC

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation

• Inspect tool and blades before use. Replace any

worn or damaged parts. A damaged or improp-

erly assembled tool can break and strike nearby

personnel.

• Carrying strap is for carrying only, not to be used to

hang or suspend tool.

Failure to observe this warning could result in severe

injury or death.

Electric shock hazard:

This tool is not insulated. When using

this unit near energized electrical

lines, use proper personal protective

equipment.

Failure to observe this warning could

result in severe injury or death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from ying

debris.

• Keeps hands away from blade.

• Remove the battery before

inspecting or servicing the tool.

Failure to observe these warnings

could result in severe injury or death.

Cutting Procedure

1. Activate the switch to open the movable blade.

2. Place the cable to be cut onto the stationary blade

and close the movable blade around the cable.

Feed the movable blade by hand so that the gear

teeth engage the drive mechanism of the tool.

3. Slide the direction control lever to FORWARD.

Press and hold the trigger switch until the cable is

completely cut.

4. Slide the direction control lever to the center (LOCK)

position.

Circuit Breaker

The following may cause the circuit breaker to trip:

• Cutting material that is too large

• Cutting material that is too hard

• Overheating due to continuous use

• Drawing excessive current

If the circuit breaker trips, the tool will stop. If necessary,

allow the tool to cool down. (Wait 10 seconds to one

minute before resuming cutting.) The circuit breaker will

automatically reset.

• This tool is not designed for continuous use. After

40 cutting cycles or if tool becomes hot, allow the

cutting tool to rest for 30 minutes.

• Do not secure this tool in a vice. This is a tool

designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may result

when the tool is operated prior to thorough drying

when electrical components are soaked.

• Use this tool for the manufacturer's intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

Charging the Battery

Read the instructions supplied with the battery charger

Battery Capacity Display

On the base of the tool handle there is a 4 LED indicator.

If 4 LEDs are lit while in operation the battery has a full

charge. If only 1 or 2 LEDs are lit while in operation the

battery will need to be charged soon.

See following page for additional safety boxes and text

to be added to this page. Follow numbered boxes.

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 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 could

result in serious eye injury from ying

debris.

• Keeps hands away from blade.

• Remove the battery before

inspecting or servicing the tool.

Failure to observe these warnings

could result in severe injury or death.

Daily Maintenance

• Store the tool in a cool, dry area to prevent rust.

• Inspect the blades for damage or burrs. Remove burrs

on the back side of the blades with a at grinding

stone.

• Clean the plastic housing with a soft, soaped cloth.

Replacing the Flexible Gear Guides

1. This tool has two gear guides — left and right.

Operate the cutter in either the forward or reverse

direction to move the blade completely out of the

gear mechanism.

2. Remove the battery from the cutter.

3. Use an M2.5 Allen wrench to loosen and remove

the screw that secures the gear guide and install the

replacement guides on the movable blade.

4. Tighten the screw securely.

5. Re-install the battery and operate the cutter.

Replacing the Blade

Hinged blade comes pre-assembled, see exploded view

and replacement part kits on p.10 and p.12.

1. Remove battery.

2. Remove 9 Phillips head screws (3) from case and

separate case.

3. Pull the motor (8) and blade assembly(20-25) from the

case.

4. Remove the 4 visible M5x14 screws (16) holding on

the blade assembly to the motor.

5. Remove the 3 small Phillips head screws and cover

from the back of the motor (8) and remove the

middle gear.

6. Remove the remaining 2 M5x14 screws (16)

accessible under the middle gear, this will allow the

blade and bearing case assembly to separate from

the motor.

7. Remove the 5 M5x12 screws (15) from the blade and

bearing case assembly (17).

8. Separate the dull or damaged blade assembly from

the bearing case.

9. Attach the new blade assembly to the bearing case

and secure with the 5 M5x12 screws (15), torque to

70.8 in-lbs (8Nm).

10. Secure the blade and bearing case assembly to the

motor using the 6 M5x14 screws (16), torque to 70.8

in-lbs (8Nm).

11. Replace the middle gear and cover, secure with the

3 small Phillips head screws.

12. Return the motor and blade assembly to the plastic

tool case, ensure that direction selector switch and

trigger are in their correct locations and that no

wires will be pinched in the case.

13. Re-assemble case.

14. Re-install battery and verify cutter operates.

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Troubleshooting

Problem Probable Cause Probable Remedy

Cutter does not operate. Battery is discharged. Charge battery.

Blades are too loose or too tight. Loosen and then re-torque lock nut.

Movable blade is not completely

engaged.

Push movable blade until it is

completely engaged with drive.

Dust or foreign matter lodged at

battery contacts.

Clean battery contacts.

Battery life has

decreased. Battery will not hold a charge. Replace battery.

Blades are dull. Replace blades.

Battery-powered Ratcheting Cable Cutters

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

ESR25LX

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