Greenlee Textron / Subsidiary of Textron Inc.
10
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
ESG45GL Battery-powered Cable Cutter
Motor / Gearbox / Bearing Reassembly
1. Install two fillister head screws (112) into spacer
(not numbered) and motor (90). Tighten screws.
2. Install four screws (not numbered) into gear housing
(94). Tighten screws.
3. Install four screws (93) into mounting block (109)
and gear housing (94). Tighten screws.
4. Replace grooved ball bearing (101) and snap ring
(100) subassembly.
5. Replace eccentric (103). Use a fiber mallet to tap
eccentric onto shaft. Replace ball bearing (91).
6. Align end cap (102). Use a fiber mallet to tap cover
until it is flush on mounting block (109). Install two
screws (92).
7. Align gear housing / motor subassembly so that the
pump piston (152) extends through the mounting
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 Subassembly
8. Insert pump piston (152) into pump housing.
Be sure to replace O-ring (153).
9. Insert seal (122) and unloading valve assembly into
pump housing. Grasp needle valve subassembly by
the pressure relief (126) and twist it several turns
clockwise. Stop when the mark or piece of tape is
facing up.
10. Assemble pump piston (150), valve stem (156),
spring (155) and screw plug (151). Be sure to
replace sealing washer (154). Torque screw plug
(151) to 75 foot-pounds.
11. Install release lever (107) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install screw (99) and washer (104).
12. Insert threaded bushing (79) and feed tube sub-
assembly (77, 78, 82). Screw in until snug.
13. Install 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.
14. Insert the plug (76) into the reservoir.
Misc. Components Reassembly
15. Remove the protective plastic bag from the elec-
tronics subassembly. Insert the LED into the LED
bushing (59).
16. Lay the gear housing / motor subassembly into the
right 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.
17. Lay the wires into case. Be sure that the wires will
not be pinched.
18. Guide the wires for the battery clip so the battery
wires lay on top of the electronics box; install the
battery clip so the red wire is upward.
19. Install the trigger cover (53) and plug (60). Depress
and release the trigger to be sure that it operates
freely.
20. Locate the right housing half on top of the left
housing half. Check for pinched wires.
21. Install the housing screws (51, 56-58).
Note: Handle screw (51) must engage the nut (52).
22. Install the piston (21).
23. Install the spring (18).
24. 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 (17). Be sure that the cutting
head assembly rotates freely approximately 350
°
.
25. Install the cutting blade (26). Insert the pin (31)
through the ram.
26. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the fill plug
(76) and fill the reservoir with hydraulic oil.
27. Install the battery.
28. Squeeze the trigger while depressing the release
lever for 45–60 seconds. Fill the reservoir with
hydraulic oil. Replace the fill plug (76).
29. Replace the tank cover and tank cover screws (55).
Reassembly
