ESG50GL Battery-powered, High-speed Cable Cutter
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Assembly
Motor, Gearbox, and Bearing
1. Install two Fillister head screws (112) into the spacer
(not numbered) and motor (90). Tighten the screws.
2. Install four screws (not numbered) into the gear
housing (94). Tighten the screws.
3. Install four screws (93) into the mounting block (109)
and gear housing (94). Tighten the screws.
4. Replace the grooved ball bearing (101) and snap
ring (100) subassembly.
5. Replace the eccentric (103). Use a fiber mallet to
tap the eccentric onto the shaft. Replace the ball
bearing (91).
6. Align the end cap (102). Use a fiber mallet to tap the
cover until it is flush on the mounting block (109).
Install two screws (92).
7. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mount-
ing block (109) and makes contact with the grooved
bearing (101). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. Insert the seal (122) and unloading valve assem-
bly into the pump housing. Grasp the needle valve
subassembly by the pressure relief (126) and twist
it several turns clockwise. Stop when the piece of
tape is facing up.
3. Assemble the pump piston (150), valve stem (156),
washer (153), spring (155), and screw plug (151).
Be sure to replace the sealing washer (154). Torque
the screw plug (151) to 101 Nm (75 ft-lb).
4. Install the release lever (107) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (99) and washer (104).
5. Insert the threaded bushing (79) and feed tube sub-
assembly (77, 78, 82). Screw in until snug.
6. Install the reservoir (74). Slip the O-ring (80) over
the reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
7. Insert the plug (76) into the reservoir.
Main Components
1. Remove the protective plastic bag from the
electronics subassembly. Insert the LED into the
LED bushing (8).
2. Lay the gear housing/motor subassembly into the
left half of the housing. Insert the circuit board into
the circuit board slot so that the wires and chip face
in the direction of the trigger.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the battery clip so that the
battery wires lay on top of the electronics box;
install the battery clip so the red wire is upward.
5. Install the trigger cover (56). Press and release the
trigger to be sure that it operates freely.
6. Locate the right housing half (59) on top of the left
housing half (60). Check for pinched wires.
7. Install the housing screws (51, 53).
Note: The handle screw (51) must engage the
nut (52).
8. Install the piston (18).
9. Install the spring (17).
10. Replace the front head assembly. Twist the cutting
head base (30) until it stops; back off 3/4 of a turn
and tighten the screws (29). Be sure that the cutting
head assembly rotates freely approximately 350°.
11. Install the cutting blade (26). Insert the pin (19)
through the ram.
12. Clamp the head assembly into a vise with the res-
ervoir plug facing upward. Remove the fill plug (76)
and fill the reservoir with hydraulic oil.
13. Install the battery.
14. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the fill plug (76).
15. Replace the tank cover (58) and tank cover
screws (53).
