Greenlee Textron 1990 Crimping Tool
Contents
1. Install the relief valve cover 90 and adjust it so that the stepped rod moves freely Secure the cover with two machine screws 91 Serial Code YM Install set screw 93 and secure it with jam nut 92 GREENLEE 1990 Dieless Hydraulic Crimping Tool Assembly cont d Assembly of Cylinder to Cylinder Cap 1 Push the stepped rod 84 out until the adjustment roller 88 drops into the notch in the guide roller 88 which will produce an audible click 2 Apply a threadlocking compound such as Loctite 222 Threadlocker or equivalent to the threads of the driving rod 94 Screw the driving rod into the roller guide 83 until the driving rod just bottoms on the cylinder cap This setting is critical to the proper operation of the tool Hint For ease of assembly screw the driving rod clockwise until the flats are aligned as shown Flat Sides 3 Pull the driving rod out 38 mm 1 1 2 Note Pulling the rod out too far will cause the roller 88 to fall off of the stepped rod If this happens disassemble and start over at Step 1 4 Hook the head of the driving rod 94 into the groove of the ram 38 5 Apply a threadlocking compound such as Loctite 222 Threadlocker or equivalent to the threads of the rod retaining screw 95 Screw the retaining rod in until it is 0 81 mm 032 below the back surfac2. 1 83 32558 503 2558 2 Guide Roller 2 25 ath at I EA e PL et ce edad 1 84 32562 503 2562 0 Stepped t 1 RV 85 32572 503 2572 8 Spring Compression 178 x 322 x 875 1 86 32561 503 2561 2 Valve Sptririg 4 ii iie RD EO 1 ev 87 32556 503 2556 6 Relief Valve eerte couse e RE ea 1 88 32564 503 2564 7 Roller Valve Adjustment 197 x 247 sssssssm 1 89 32559 503 2559 0 Slide Dept dre cie pete 2 ev 90 32591 503 2591 4 Cover Relief Valve eo EE eec te 1 91 51462 905 1462 9 Screw Machine 10 32 x 1 25 Round Head 2 ev 92 51286 905 1286 3 Screw Jam 88 32 x 109 Socket ssssssssseeeeeen 1 ev 93 53600 905 3600 2 Screw Set 1 4 20 x 437 Flat Point Socket 1 v 94 32563 503 2563 9 Rod Unit Driving ices petere it eta ines 1 95 32557 503 2557 4 Screw Rod Retaining essen eene 1 96 51245 905 1245 6 Screw Set 1 4 20 x 250 Flat Point 1 v 97 50824 905 0824 6 Plug Pipes 156 i aie cerne ER E IRR Re ants 1 98 RTV 99 53482 905 3482 4 Washer Flat 259 x 393 x 062 Nylon
3. 1 20 32530 503 2530 2 151 1 1 18 10 Ec 1 21 53814 905 3814 5 O ring 1 47 x 1 71 x 118 900 esses 1 22 53599 905 3599 5 SLU GrOOVEd EE 1 23 32518 503 2518 3 Pin Unit Removable 1 24 32517 503 2517 5 n riore o iier AA 1 25 52338 905 2338 5 Screw Set 10 32 x 250 Socket 1 26 32514 503 2514 0 Die Movable 1 27 51379 905 1379 7 Retaining Ring 500 tede de e dre Eta 2 28 32515 503 2515 9 Bolt ioter eee eee eene rs 2 29 53478 905 3478 6 Nuit Jam 7 1620 2 iio te Die o fe He tite ete 2 30 33015 503 3015 2 Die Replacement Kit two inner and two outer die plates 1 31 32499 503 2499 3 Plate Die Support emeret tee ids 2 32 32516 503 2516 7 Spacer iui esso piu er Sith e Rip eee ex 2 33 32491 503 2491 8 Oylinder s eerte re ees de Ed 1 34 53464 905 3464 6 tan eee tat eae M a Biel IUe 1 35 35651 503 5651 8 Guide Blair usce Ie dea Ded cete 1 V 36 50888 905 0888 2 O ring 1 62 x 2 00 x 187 1 V 37 50889 905 0889 0 Backup Ring Spiral 1 62 x 1 99 x 033 1 38 32509 503 2509
4. 1 A 10 53475 905 3475 1 Pin Roll 156 X 1 97 ace eg emere ete eed eite reas 2 A 11 35688 503 5688 7 Grip Rubber 1 25 x 1 68 x 6 62 1 12 32493 503 2493 4 Pivot Lever C dene ti 1 13 51265 905 1265 0 Screw 1 4 20 750 Socket Head 2 A 14 35676 503 5676 3 Pin Fulcrum 310 X 1 60 1i ie prete eulos eer e e ca 1 Av 15 52336 905 2336 9 Ring Retaining S127 e e ais 2 16 RTV v 17 51241 905 1241 3 Screw Set 10 32 x 187 Flat Point 1 18 35680 503 5680 1 Handle Beservolr 5 ic cnni terne ks coo eii rre En iced 1 19 32488 503 2488 8 Plug Bladder Rubber Black eeenenen 1 20 35686 503 5686 0 Bladder Reservoir enne nnne 1 21 53814 905 3814 5 O ring 1 47 x 1 71 x 118 900 1 B 22 53962 905 3962 1 Detent a 1 23 35678 503 5678 0 Pini Unit Removable siiis ina reis cei dws rero e E Cert ra eoi 1 E 24 35673 503 5673 9 Pin Pivot 468X 2 05 ied dte e ded cage e reca teo ep s 1 V 25 52338 905 2338 5 Screw Set 10 32 x 250 Socket
5. 1 26 32514 503 2514 0 Die Movable tiet 1 BV 27 51379 905 1379 7 Retaining Rittg 500 5 iie ie RCRUM IO HER 2 E 28 35677 503 5677 1 Head Dieii orison 1 vv 29 51215 905 1215 4 O ring 437 x 562 x 062 1 w 30 35683 503 5683 6 Washer Flat 343 x 437 x 046 1 31 53689 905 3689 4 O ring 334 475 x 070 same as items 56 and 63 1 32 52475 905 2475 6 Backup Ring Spiral 437 562 055 1 33 35675 503 5675 5 CVI Tp 1 34 53464 905 3464 6 Wiper Ram eee rere er rece ec e d e 1 35 35651 503 5651 8 Guide pep hdi polar Ibat eto 1 V 36 50888 905 0888 2 O ring 1 62 x 2 00 x 187 Nitrile sss 1 V 37 50889 905 0889 0 Backup Ring Spiral 1 62 x 1 99 x 033 1 38 32509 503 2509 4 ed 1 39 32519 503 2519 1 Spring Compression 1 49 1 82 x 6 06 1 vv 40 53958 905 3958 3 Seal 2 562 Quad hirg bee ertet te leas Ts tens etd 1 w 41 53470 905 3470 0 Backup Ring Single Turn 2 37 x 2 55 x 050 Teflon
6. 1 V 100 53481 905 3481 6 Screw 1 4 20 x 250 Fillister Head 1 101 RTV 102 33730 503 3730 0 Spacer 549 997 x 025 Stainless ae A 103 35462 503 5462 0 Decal Warning se iii i CHEER dun 1 104 22726 502 2726 2 gm E 1 No longer available See the list of kits at the end of this parts list to retrofit the tool Quantity of one or two if necessary To determine if this item is necessary see Die Replacement procedure Decals 32792 503 2792 5 Decal Identification 35463 503 5463 9 Decal Connector Chart 35757 503 5757 3 Decal Instruction 35758 503 5758 1 Decal Pressure Check Procedure 35759 503 5759 0 Decal Safety 06233 500 6233 6 Decal Safety Lid Liner 06243 500 6243 3 Decal Operating Instructions Accessory 32791 503 2791 7 Case Carrying Repair Kits Retrofit Kits and Supplies Replace worn or broken items with newer YM style components Some WH style components are no longer available corresponding retrofit kits are marked Required 32891 503 2891 3 Slug Test Kit includes one Go No Go Gauge and 30 test slugs V 33013 503 3013 6 Hydraulic Repair Kit 33737 503 3737 8 Relief Valve Repair Kit Recommended 35671 503 5671 2 Pump Handle Unit Required e 36150 503 6150 3 Valve Cap and Cover Repair Retrofit Kit Required 36151 503 6151 1 R
7. 1 v 42 35674 503 5674 7 iei E ect Ge tet ud n 1 vv 43 50055 905 0055 5 Backup Ring Spiral 187 x 312 x 055 Teflon 1 44 51046 905 1046 1 O ring 187 x 312 x 062 Nitrile essen 1 v 46 35687 503 5687 9 Block PUMP ee ceret EN gei i ne ea seite vag 1 wv 47 50678 905 0678 2 Ball Steel 187 Diameter Grade 25 same as item 51 1 vv 48 16141 501 6141 5 Spring Compression 194 x 214 x 500 1 v 49 35691 503 5691 7 Body Inlet Check cce ie eie eie recreo 1 v 50 51253 905 1253 7 O Ring 218 x 343 x 062 Nitrile essen 1 vv 51 50678 905 0678 2 Ball Steel 187 Diameter Grade 25 same as item 47 1 vv 52 51204 905 1204 9 Pind HRoll 062 9755 4 uidet RERO EPIRI RR stent 1 w 53 50679 905 0679 0 Ball Steel 250 Diameter Grade 25 1 w 54 35693 503 5693 3 Washer Flat 156 x 281 x 062 1 vw 55 35694 503 5694 1 Washer Flat 204 x 375 x 062 1 w 56 53689 905 3689 4 O ring 334 x 475 x 070 same as items 31 and 63 1 57 53959 905 3959 1 Spring Compression 188 x 240 x 625
8. 1 no advance A Air in hydraulic system 1 2 3 4 A See Air in the Hydraulic System at the end 2 slow advance of this troubleshooting table 3 partial retract with each stroke B Check valve body 1 2 3 B Reseat balls tighten lock screw 4 erratic advance C Release mechanism 1 2 C Replace O rings check ball pin clearance and reseat 69 73 D Low pressure relief 1 2 D Reseat ball 77 E High pressure relief 1 2 E Reseat cone 81 F Plunger O rings 4 F Replace O rings 62 68 Slow pressure buildup 1 Handle springs back A Discharge check ball 1 A Reseat ball 2 No handle response B Check balls body 1 2 B Reseat balls C High pressure relief 1 C Reseat and reassemble D Release mechanism 1 2 D Check clearance and seat body Tool does not achieve high pressure Check valves body A Replace O ring reseat check balls B High pressure relief is not seated B Reseat relief C Pressure control mechanism is C Check the assembly of roller slides stepped improperly assembled rod and adjusting screw 80 86 88 89 Ram does not retract A Wedged connector A Free and remove connector B Die jammed due to misuse B Free die Inspect tool and replace any damaged parts C Release mechanism C Make sure ball is not over traveling D Bent driving rod D Replace rod 94 Ram retracts partially A Too much hydraulic fluid A Bleed off excess oil B Air in hydraulic system B See Air in t
9. Greenlee Textron Subsidiary of Textron Inc 3 GREENLEE 1990 Dieless Hydraulic Crimping Tool Identification The WH series and YM series crimping tools have See Retrofit Kits in this manual for an explanation of several distinguishing characteristics which are listed interchangeable parts here But be aware that since many parts are inter changeable a tool sent to you for repair may be a hybrid if it has been repaired previously it may have a mixture of parts from the WH series and YM series Most of the instructions in this service manual apply to both WH series and YM series However some indi vidual steps and some procedures apply to only one or the other and are so noted 1990 Dieless Crimping Tool Serial Code WH Serial Code YM 1 The crimping head is slightly tapered 1 The crimping head is more steeply tapered 2 The fixed die is a bolt on assembly which includes 2 The fixed die is one piece steel casting colored four bright zinc plated die plates black 3 The two arms on the cylinder each have two 3 The two arms on the cylinder are not slotted machined slots for the die assembly to engage 4 Serial number begins with YM prefix Serial number begins with prefix 5 The pump block is covered with a green rubber 5 The pump block is covered with a black rubber coating coating 6 The handles are one piece cast aluminum covered 6 The handles are bonded assemblies and include with g
10. Serial Code WH Assemble the fixed die head See the following illustration and the exploded view Side with ide wi grooves faces out Outer Die Plate Inner Die Plate Install the bolts 28 and nuts 29 Torque to 13 5 Newton meters 10 foot pounds Serial Code YM Assemble the detent 22 to the die head 28 Install the spacer s 102 and movable die 26 Secure by tightening set screw 25 Fasten the fixed die to cylinder with pins 23 24 Secure pin 24 with retaining rings 27 GREENLEE 1990 Dieless Hydraulic Crimping Assembly cont d Final Assembly 1 Rotate the cylinder counterclockwise until it stops Fully retract the ram 2 Measure the distance between the outermost blades of the movable and fixed dies The distance should be between 56 and 57 1 mm 2 205 and 2 250 If the dimension is outside of this range remove the set screw 25 and movable die 26 and change the number of spacers as follows to increase the distance remove a spacer 102 to decrease the distance add a spacer 102 3 Install the movable die 26 and secure with the set screw 25 4 With the tool still in the vise pour some hydraulic oil into the pump block Pump the handle until the ram is fully extended Note When the ram is fully extended the handle resistance will increase and some oil will squirt back 5 Install reservoir 20 and O ring 21 Retract the ram
11. hole 2 Clamp the cylinder 33 in a vise with the bore 3 Loosen jam screw 61 Assemble O rings 54 56 upward Install wiper and guide 34 35 bushing 58 and spring 57 to cylinder cap Torque 3 Install spring 39 and ram assembly into cylinder the bushing 58 to 4 Newton meters 3 foot pounds 33 Compress the spring using either an arbor 4 Set cylinder cap in place on the pump block and press or a C clamp install four copper washers 56 and cap screws 59 Torque to 27 Newton meters 20 foot pounds 5 Twist jam screw 61 clockwise until set Pump Block Assembly Serial Code YM Perform this procedure with the pump block 46 secured in the vise with the threaded end downward 1 Assemble the check ball insert assembly 49 as follows Install O rings 50 31 install and seat 3 16 diameter ball 51 and install roll pin 52 Set this assembly aside 2 Assemble 3 16 diameter ball 47 and spring 48 with small end toward ball into the pump block 46 Install check ball insert assembly 49 into pump block Insert 1 4 diameter ball 53 into the check ball insert assembly Seat each ball in its hole 3 Assemble the sleeve 58 with O rings 29 56 backup ring 32 and spring 57 to the pump block Torque the sleeve 58 to 4 Newton meters 4 Slide the ram die 26 into place Tighten set screw 3 foot pounds 25 securely 4 Assem
12. same as item 78 1 v 58 35692 503 5692 5 Sleeve tret i i 1 59 50581 905 0581 6 Screw Cap 1 4 20 x 1 00 Socket Head 4 w 60 32535 503 2535 3 Washer Flat 260 x 390 x 046 4 vw 62 50883 905 0883 1 Backup Ring Spiral 375 485 x 027 Teflon 1 Greenlee Textron Subsidiary of Textron Inc 24 GREENLEE 1990 Dieless Hydraulic Crimping Parts List Serial Code YM cont d UPC NO KEY 78 3310 PART NO DESCRIPTION QTY v 63 53689 905 3689 4 O ring 334 x 475 x 070 same as items 31 and 56 1 v 64 53957 905 3957 5 Seal 1 00 Quad Ring sssssssssseeeee enne 1 v 65 51272 905 1272 3 Backup Ring Spiral 750 x 992 x 027 1 66 32503 503 2503 5 Plunger Eo Pressure edere tet eco ede vade 1 v 67 53477 905 3477 8 Washer Flat 156 x 250 x 046 1 68 32504 503 2504 3 Plunger Hi Pressure enmienda ipee A Dee antec 1 v 69 50722 905 0722 3 O ring 114 x 250 x 068 70D Nitrile sseeeeeee 1 70 35690 503 5690 9 Shaft Pressure Release r e rera arae e e a a e A naaar 1 v 71 50168 905 0168 3 O ring 364 x 500 x 068 90D N
13. 156 x 250 x 046 1 68 32504 503 2504 3 Plunger z Hi PressUte e tice cereus 1 v 69 50722 905 0722 3 O ring 114 x 250 x 068 70D Nitrile same as item 44 1 70 32507 503 2507 8 Shaft Pressure Release 1 v 71 50168 905 0168 3 O ring 364 500 x 068 90D Nitrile 1 72 32506 503 2506 0 Body Pressure Release sse 1 73 32534 503 2534 5 Spring Compression 164 x 240 750 1 74 50436 905 0436 4 Ball Steel 281 Diameter Grade 25 1 v 77 50452 905 0452 6 Ball Steel 218 Diameter Grade 25 1 78 13263 501 3263 6 Spring Compression 184 x 242 815 1 Vv 79 51337 905 1337 1 Screw 5 16 24 x 156 Socket sse 1 80 32523 503 2523 0 Body Pressure Adjusting Valve 1 81 32789 503 2789 5 Pl ng r MValV6 i He UR EE e IRE Hr AED S 1 82 03421 500 3421 9 Washer Flat 440 687 x 064
14. 2 Serial Code WH Note the positions and alignment of the two outer die plates and two inner die plates Remove the jam nuts 29 and bolts 28 Remove the die plates 30 31 Install new die plates ensuring that they are located properly in the appropriate grooves and that they are in the proper sequence Side wi grooves faces out Outer Die Plate Inner Die Plate 3 Serial Code YM Transfer the ball detent 22 and removable pin unit 23 to the new die head Secure with pin 24 and retaining ring 27 4 Rotate the cylinder fully counterclockwise and fully retract the ram Measure the distance between the outermost blades of the movable and fixed dies The distance should be between 56 and 57 1 mm 2 205 and 2 250 If the dimension is outside of this range remove the set screw 25 and movable die 26 and change the number of spacers as follows to increase the distance remove a spacer 102 to decrease the distance add a spacer 102 5 Install the movable die 26 and secure with the set screw 25 Greenlee Textron Subsidiary of Textron Inc 9 Movable Die Either Serial Code aR woh Remove the fixed die See Step 1 under Fixed Die Remove set screw 25 and movable die 26 Install new movable die and set screw Install fixed die Rotate the cylinder fully counterclockwise and fully retract the ram Measure the distance between the outermost blades of the two
15. 4 Bam iie tee cte E RE ORDRE RR 1 39 32519 503 2519 1 Spring Compression 1 49 x 1 82 x 6 06 1 vv 40 53473 905 3473 5 O ring 237 X 2 56 x 098 niea wie te Lilie le ee diez feeds 1 wv 41 53470 905 3470 0 Backup Ring Single Turn 2 37 x 2 55 x 050 Teflon 1 v 42 32508 503 2508 6 Gap Cylinder eet 1 43 53480 905 3480 8 Backup Ring Spiral 125 250 x 049 Teflon 1 v 44 50722 905 0722 3 O ring 114 x 250 x 068 70D Nitrile same as item 69 1 vv 45 51382 905 1382 7 Retaining 312 52 sea al ee hata 1 v 46 32691 503 2691 0 Block PUMP Mis ec ted me ttes aue eto ess 1 v 47 50678 905 0678 2 Ball Steel 187 Diameter Grade 25 same as item 51 1 vw 48 16141 501 6141 5 Spring Compression 194 x 214 x 500 1 v 49 32529 503 2529 9 Check Ball Insert nier ee prete 1 v 50 53688 905 3688 6 1 vw 51 50678 905 0678 2 Ball Steel 187 Diameter Grade 25 same as item 47 1 Vv 52 51204 905 1204 9 Pin Roll 062 375 8 iet odere eb UH eee ree ree es 1 w 53 50679 905 0679 0 Ball Steel 250 Diameter Grade 25 1
16. 6 Retract the ram fully 7 Add oil until the reservoir overflows Vise with Jaw Protectors Rubber Plug 16 2 Retract the ram by pulling the release trigger back while pressing down on the handle 3 Pump the handle one partial stroke 4 Peel out the rubber plug 16 and remove the set screw 17 from the reservoir handle 18 8 Pump the handle several times to advance the ram While holding a clean shop cloth over the reservoir retract the ram fully Repeat several times to purge all of the air from the system 9 With the pump handle vertical and the ram fully retracted fill the reservoir until it overflows 10 Replace the plug 19 and wipe off excess oil Serial Code WH Coat the reservoir with a dry white lubricant silicone or talcum 11 Pump the handle one stroke and install the reservoir Remove handle 18 Replace the set screw 17 and tighten Set Screw securely 12 Cover the set screw with a silicone rubber sealant such as Dow Corning Silastic 7329 Multipurpose Sealant Greenlee Textron Subsidiary of Textron Inc 8 GREENLEE 1990 Dieless Hydraulic Crimping Tool Die Replacement This procedure is divided into two sections one for the fixed die which has some steps that are particular to the serial code and one for the movable die which includes both serial codes Fixed Die 1 Pull the pin 23 Remove one retaining ring 27 pin 24 and fixed die assembly
17. damaged or missing 4 D Replace O ring and backup ring 64 65 5 between pump block and E Loose cylinder 5 E Tighten screws 59 to proper torque cylinder cap F O rings WH or copper washers YM damaged 5 F Replace components 43 44 45 or 60 6 around cylinder near cap Damaged cylinder seal in 6 G Replace O ring and backup ring 40 41 7 movable die H Damaged O rings and backup ring on ram 7 H Replace O ring and backup ring 36 37 Damaged ram 7 Replace ram Check cylinder bore for damage Air in the Hydraulic System A Improper fill and purge procedure A Fill reservoir and purge air B Loose or missing reservoir plug B Replace plug or install plug properly C Damaged O ring on low pressure plunger C Replace O ring and backup ring D Damaged reservoir D Replace reservoir E Damaged or missing O ring on reservoir E Replace O ring F Reservoir is underfilled F Fill reservoir and purge air Greenlee Textron Subsidiary of Textron Inc 17 GREENLEE 1990 Dieless Hydraulic Crimping Illustration Serial Code WH 100 101 i 4 E 98 RTV Greenlee Textron Subsidiary of Textron Inc 18 GREENLEE 1990 Dieless Hydraulic Crimping Greenlee Textron Subsidiary of Textron Inc 19 GREENLEE 1990 Dieless Hydraulic Crimping Parts List Serial Code WH UPC NO KEY 78 3310 PART NO DESCRIPTION QTY Ade d 32532 503 2532
18. dies The distance should be between 56 and 57 1 mm 2 205 and 2 250 If the dimension is outside of this range remove the set screw 25 and movable die 26 to increase the distance remove a spacer 102 to decrease the distance add a spacer 102 Install the movable die 26 and secure with the set screw 25 GREENLEE 1990 Dieless Hydraulic Crimping Tool Disassembly Before performing any repair procedure 1 Refer to the Service Tips and Troubleshooting sections to determine the appropriate service procedure 2 Read through the entire procedure to be sure that you have all of the necessary tools repair parts and supplies When performing any service procedure 1 Check all disassembled parts for wear or damage 2 Visually inspect the ball seats 3 Carefully replace any O rings backup rings and other disposable items 4 Check all items for dirt grit or other contaminants The disassembly procedure is divided into five basic sections in this order 5 1 Cylinder 2 Cylinder Cap 3 Reservoir 4 Pump Block Relief Valves and Pressure Release Mechanism 5 Pump Pistons Cylinder ACAUTION The spring stores at least 310 Newtons 70 pounds of force Follow this procedure exactly as instructed to release the pressure on the spring carefully Failure to observe this precaution will release all of the energy in the spring at once resulting in injury due to flying part
19. eene Hee e e 1 88 32564 503 2564 7 Roller Valve Adjustment 197 x 247 1 89 32559 503 2559 0 Slide MOVING rre rn eee eta ee 2 ev 90 35681 503 5681 0 Plate 22 1 91 51462 905 1462 9 Screw Machine 10 32 1 25 Round Head 2 ev 92 51686 905 1686 9 Nut Hex 410 932 Full heec ii Eet 1 ev 93 53961 905 3961 3 Screw 10 32 Socket Set 1 v 94 35684 503 5684 4 Rod Units DriVihg Ad RE 1 95 32557 503 2557 4 e eie reef 1 96 51245 905 1245 6 Screw Set 1 4 20 x 250 Flat Point 1 wv 97 53960 905 3960 5 Plug O Ring 5 16 24 x 380 1 98 RTV 101 RTV 102 33730 503 3730 0 Spacer 549 997 x 025 Stainless A 103 35462 503 5462 0 Decals ETRA ATE integer E ete EIE 1 4 104 22726 502 2726 2 Filter Oil 35 27 235 Nes Sion MEL AO cae Dh Mec s 1 Quantity of one or two if necessary To determine if this item is necess
20. v 54 51046 905 1046 1 O ring 187 x 312 x 062 Nitrile sess 1 v 55 53469 905 3469 7 Oring 156X 281 X 062 scs er ERI 1 v 56 51215 905 1215 4 O ring 437 x 562 x 062 Nitrile ssssseeeenen 1 vw 57 10761 501 0761 5 Spring Compression 153 x 203 x 440 1 v 58 32590 503 2590 6 Check Ite ere doo heen nadie einer 1 59 50581 905 0581 6 Screw 1 4 20 1 00 Socket Head 4 w 60 32535 503 2535 3 Washer Flat 260 x 390 x 046 4 61 53474 905 3474 3 Screw Jam 1 vv 62 50883 905 0883 1 Backup Ring Spiral 375 485 x 027 Teflon 1 v 63 53689 905 3689 4 Oring 334X475 X070 iie tee Dex eie re cere p Pe 1 v 64 50394 905 0394 5 O ring 750 x 1 00 x 125 70D Nitrile 1 vv 65 51272 905 1272 3 Backup Ring Spiral 750 992 x 027 1 Greenlee Textron Subsidiary of Textron Inc 20 GREENLEE 1990 Dieless Hydraulic Crimping Parts List Serial Code WH cont d UPC NO KEY 78 3310 PART NO DESCRIPTION QTY 66 32503 503 2503 5 Plunger Lo Pressure uero rete egeta ieee 1 Vv 67 53477 905 3477 8 Washer Flat
21. 9 Grip Handle e e eu patto 2 AD 2 03427 500 3427 8 Release Trigger e ea RR HR I REPRE HEURE 1 AP 3 32511 503 2511 6 Rod Pressure Release iiss ferire roa cor cocer taz 1 AP 4 50458 905 0458 5 Pin 125 X975 xac irte ccn recte ze vetat re erp ted DER da 1 AP 5 32495 503 2495 0 Lever Unit 1 AP 6 52482 905 2482 9 Roll Pin 4125 X 1 25 2 dec miS edes 1 AP 7 50420 905 0420 8 Pin Release 125 X 1 00 i eaeoe aa 1 AD 8 32510 503 2510 8 Bal Pressure Releases tese eie riesen Dd ea De Eo Oed 1 AP 9 03334 500 3334 4 Spring Torsion 187 x 280 x 312 1 AP 10 53475 905 3475 1 Pins Foll 15651237 41 ee on here ve other beers 3 AP 11 32690 503 2690 2 Boot Pivot Head ue a Rte eee ie See 1 12 32493 503 2493 4 PiVOEl eVer nito IBN RUE 1 13 51265 905 1265 0 Screw 1 4 20 x 750 Socket Head 2 A 14 03418 500 3418 9 55 EQ ER AGER 2 Av 15 51773 905 1773 3 Ring Retaining 3127 1 coii nee nente tt 2 16 RTV V 17 51241 905 1241 3 Screw Set 10 32 x 187 Flat Point Socket 1 18 32496 503 2496 9 Handle Beservoli tte ep era erste ns odas 1 19 32488 503 2488 8 Plug Bladder Rubber
22. RA NSCA 2 E 35 Vantage Point Drive Rochester NY 14624 Call 1 800 800 5001 SERVICE MANUAL GREENLEE 1990 Dieless Hydraulic Crimping Tool Serial Codes WH and YM GREENLEE 1990 Dieless Hydraulic Crimping Tool Table of Contents Description 2 Safely cie etui e E tet tec vt nad 2 PUDOS Ev niia tee aeree 2 Other Publications see 2 Important Safety Information 3 Identification i icasi aiaa 4 Tools and Supplies sss 5 Pressure Check Procedure 5 Pressure Adjustment Procedure 6 Pressure Calibration Check 7 Air Purging and Oil Filling Procedure 8 Die 9 Disassembly et Rte etes 10 11 Assembly 25 x teh ee edet 12 15 t Red d Attn 15 Retrofit AitS 16 Troubleshooting 17 Illustrations and Parts Lists 18 25 Description The Greenlee 1990 Dieless Hydraulic Crimping Tool is a self contained tool intended to crimp copper and aluminum compression connectors A single set of integral dies provides a wide crimping range The Greenlee 1990 i
23. and assemble Pump piston O rings Remove retaining rings 15 from pins 14 and remove handle unit from pump block 46 Remove the two cap screws 13 and pivot block 12 Pull the low pressure plunger 66 upward and out of the pump block Check O rings and backup rings 62 65 and replace if worn or damaged The pump handle can be disassembled by removing the front pin and pivoting the handle up and beyond the normal stroke GREENLEE 1990 Dieless Hydraulic Crimping Retrofit Kits Many components are interchangeable between the older WH and current YM crimping tools However the replacement of several components at once Use this table to select the appropriate repair kit some components are not interchangeable requiring Crimping Tool Purchase Part Repair Kit explanation Relief valve cap 87 36150 Repair kit includes cap cover nut and screw 87 90 92 93 or cover 90 Crimping head 36149 Failure of either pin will overstress the other components requiring components or complete replacement of the crimping head cylinder 33 Repair kit includes pins YM type fixed die and cylinder 23 24 28 33 This kit is compatible with WH style tools also The pins dies and cylinder are not individually interchangeable between the WH and YM series Whenever the cylinder is serviced replacement of the following is recommended wiper guide O ring and backup ring 34 35 36 37 C
24. and purge air from the tool Add oil until reser voir overflows Wipe off the excess oil 6 Proceed to calibrate the tool See the Pressure Adjustment Procedure Greenlee Textron Subsidiary of Textron Inc Service Tips If the hydraulic system has air in it purge the air and top off the oil as instructed under Air Purging and Oil Filling procedure See Air in the Hydraulic System at the end of the troubleshooting table Check valve service requires removal of the cylinder and cylinder cap Inspect the ball seats in the pump block and check body If performing release mechanism service check for clearance between the ball 74 and release pin 70 Inspect the body seat body seats at the bottom of the hole and Serial Code WH against the block or Serial Code YM against the copper washer 30 Low pressure relief service Serial Code WH Drain and remove reservoir 20 Remove relief cap 87 to allow access to the spring retaining screw Remove screw 79 spring 78 and ball 77 Inspect parts for contaminants and seat for damage Clean and repair Serial Code YM Remove RTV 101 O ring plug 79 spring 78 and ball 77 High pressure relief service Drain and remove reservoir 20 Remove relief cap 87 to allow access to the relief valve and control mechanism Remove slides 89 roller 88 spring cap 86 and spring 85 Remove cone 81 Check torque on the adjusting body Reseat cone clean
25. ary see Die Replacement procedure Decals 32792 503 2792 5 Decal Identification sess nnne 1 35463 503 5463 9 Decal Connector Oha 1 06233 500 6233 6 Decal Safety Hd NeT ideae E De ie ies 1 06243 500 6243 3 Decal Operating list iie incen HE ete pedites 1 Accessory 32791 503 2791 7 Case Carrying ceccecceccecceceeceeeceeceecaeceeceecaesaeeaecaeeaeeseeaeeeteeseateeseeseeteetertaees 1 Repair Kits and Supplies 32891 503 2891 3 Slug Test Kit includes one Go No Go Gauge and 30 test slugs 33013 503 3013 6 Hydraulic Repair Kit 33737 503 3737 8 Relief Valve Repair Kit 35671 503 5671 2 Pump Handle Unit 36149 503 6149 0 Cylinder and Die Head Repair Kit 36150 503 6150 3 Valve Cap and Cover Repair Kit 36151 503 6151 1 Reservoir Handle Repair Kit 36152 503 6152 0 Pump Handle Repair Kit 36153 503 6153 8 Pump Block Repair Kit 4 08 lt Greenlee Textron Subsidiary of Textron Inc 25 35 Vantage Point Drive Rochester NY 14624 Call 1 800 800 5001 GREENLEE Printed in the U S A
26. ble the O ring 44 backup ring 43 and 5 Setthe assembly aside copper washers 54 55 to the cylinder cap 42 5 Setoylinder cap in place on the pump block and Cylinder Cap Assembly install four copper washers 56 and cap screws 1 Install the seal and backup washer 40 41 into the 59 Torque to 27 Newton meters 20 foot pounds cylinder cap 42 Serial Code WH Install backup ring 43 O ring Pump Plunger Assembly 44 and retaining ring 45 onto the cylinder cap 1 Cut 6 mm 1 4 off of backup ring 62 to prevent 2 Setthe assembly aside overlap Assemble O rings and backup rings 63 62 65 64 to the low pressure plunger 66 2 Assemble copper washer 67 and high pressure plunger 68 to the pump block Torque to 24 5 to 27 Newton meters 18 to 20 foot pounds 3 Install low pressure plunger assembly onto the high pressure plunger assembly Greenlee Textron Subsidiary of Textron Inc 12 GREENLEE 1990 Dieless Hydraulic Crimping Tool Assembly cont d Pressure Release Assembly 1 2 Assemble O ring 69 to pressure release shaft 70 Assemble O ring 71 to pressure release body 72 Slide shaft assembly into body assembly Serial Code YM Set washer 30 into recess in pump block Install spring 73 and 9 32 ball 74 into the pump block Assemble pressure release assembly to pump block Torque to 8 to 9 25 Newton meters 6 to 7 foot pounds Relief Valve Pressure Control A
27. crew 17 from the fixed handle assembly 18 Vise with Jaw Protectors RTV and Set Screw 16 17 3 Unscrew the fixed handle assembly 18 from the tool body 4 Pump the handle to fully extend the ram 5 Remove the plug 19 from the reservoir taking care not to spill the oil Reservoir Plug 19 6 Remove the tool from the vise and pour the oil into a waste oil container 7 Clamp to tool head in the vise Remove O ring 21 and reservoir 20 Add oil until the pump block is 3 4 full Greenlee Textron Subsidiary of Textron Inc 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Serial Code WH Remove RTV 101 and screw 100 Loosen fastener 92 Adjust the pressure by turning screw 93 in small increments Each 15 of adjustment makes a difference of approximately 10 Bar 150 psi Adjust as follows clockwise to increase relief pressure counterclockwise to decrease relief pressure Install reservoir 20 Pump the handle to fully extend the ram Note the pressure required to open the relief valve which produces an audible click Repeat the adjustment procedure until the valve consistently relieves between 90 and 103 Bar 1300 to 1500 psi Serial Code WH Tighten the set screw 92 Install the nylon washer 99 and screw 100 Serial Code YM Tighten the jam nut 92 Pump to achieve pressure relief to ensure that the adjustme
28. e of the ram Greenlee Textron Subsidiary of Textron Inc 14 Screw the cylinder assembly 33 into the cylinder cap until it is fully bottomed Back the cylinder out to allow installation of the set screw 96 as follows Do not back the cylinder out more than 180 There are two tapped holes for the set screw Install the set screw in either hole Adjust the set screw in or out until the head rotates 180 freely Do not tighten the set screw Pump Handle Assembly 1 Assemble release trigger 2 to pressure release rod 3 with roll pin 4 Insert into handle 5 and fasten with roll pin 7 Serial Code WH Install trigger stop roll pin 6 Assemble the pressure release bar 8 and torsion spring 9 to the handle with roll pins 10 Glue grip 11 to handle 5 Mount the lever pivot block 12 to the pump block Fasten with two cap screws 13 Torque to 20 Newton meters 15 foot pounds Install the pump handle as follows Serial Code WH Secure the handle to the lever pivot block 12 and low pressure plunger 66 with two pins 14 Secure the pins with retaining rings 15 Serial Code YM One pin is permanently mounted in the handle Install the handle so this pin engages the low pressure plunger 66 Then fasten the handle to the lever pivot block 12 with the pin 14 Secure the pin with retaining rings 15
29. ed 4 Remove the check ball bushing 58 ball 53 and spring 57 Inspect the O ring 56 Cylinder Cap Serial Code YM 1 Unscrew the driving rod 94 from the stepped rod 84 Note To service the check valves 49 58 only proceed to Step 4 2 Remove four cap screws and copper washers 59 60 Remove the cylinder cap 42 Note The cylinder cap must come straight off 3 Inspect various components 43 44 54 55 Replace if worn or damaged 4 Remove the check ball sleeve 58 ball 53 spring 57 O rings 29 56 and backup ring 32 Reservoir 1 Reposition the tool in the vise so that the handles are upward Retract the ram by pulling the release trigger back while pressing down the handle 2 Peel out the RTV 16 and remove the set screw 17 from the reservoir handle 18 3 Unscrew the reservoir handle from the pump block 46 4 Remove the plug 19 from the reservoir 20 5 Remove the tool from the vise and pour the oil into a waste oil container 6 Remove O ring 21 and reservoir 20 from the pump block Pump Block Relief Valves and Pressure Release Mechanism 1 Serial Code WH Remove RTV 101 screw 100 and nylon washer 99 Turn set screw 93 clock wise until it is flush with the relief valve cap 87 2 Remove the two machine screws 91 and relief valve cover 90 3 Slide out the relief valve cap 87 and remove the following parts stepped rod 84 roller
30. eservoir Handle Repair Retrofit Kit Required A 36152 503 6152 0 Pump Handle Repair Retrofit Kit Required v 36153 503 6153 8 Pump Block Repair Retrofit Kit Required Replace worn or broken components with identical WH style components V 33013 503 3013 6 Hydraulic Repair Kit 33015 503 3015 2 Die Replacement Kit includes two inner dies and two outer dies Greenlee Textron Subsidiary of Textron Inc 21 GREENLEE 1990 Dieless Hydraulic Crimping Tool Illustration Serial Code YM Glue grip 11 to handle 5 Greenlee Textron Subsidiary of Textron Inc 22 GREENLEE 1990 Dieless Hydraulic Crimping Greenlee Textron Subsidiary of Textron Inc 23 GREENLEE 1990 Dieless Hydraulic Crimping Parts List Serial Code YM UPC NO KEY 78 3310 PART NO DESCRIPTION QTY 1 35689 503 5689 5 Grp ReservoirtHandle denn ts 1 AD 2 03427 500 3427 8 Release Trigger ne ERRARE 1 AD 3 35698 503 5698 4 Rod Pressure Release un id trem n etie rida crete 1 AP 4 50458 905 0458 5 Roll Pins 125 X 2375 scar iuc tee p eei yere de cds 1 Ab 5 35672 503 5672 0 Handle Pumps s aec ette pen be erat eoe e ie ee 1 AP 7 51048 905 1048 8 RollPin 125 X 625 nde cete teet iod gus e eder per des 1 AD 8 35697 503 5697 6 Bar Pressure 1 9 03334 500 3334 4 Spring Torsion 187 x 280 312
31. guide 83 adjusting roller 88 two slides 89 valve spring cap 86 valve spring 85 and relief valve plunger 81 Greenlee Textron Subsidiary of Textron Inc 4 Usea spanner wrench to remove the pressure adjusting valve body 80 and copper washer 82 5 Disassemble the low pressure relief Serial Code WH Remove the jam screw spring and ball 79 78 77 Serial Code YM Remove RTV plug spring and ball 101 79 78 77 6 Remove one retaining ring 15 and pin 14 from handle 5 Remove handle assembly 7 Unscrew the pressure release body 72 Remove the ball 74 and spring 73 Remove the shaft 70 from the body 72 Inspect the O rings 69 71 and replace if worn or damaged Serial Code YM Also remove copper washer 30 8 Usea T handle Allen wrench or similar tool to push the check ball insert 49 out Remove ball and spring 47 48 from the pump block 46 Serial Code WH Remove roll pin and ball 52 51 from the insert 49 Serial Code YM Remove roll pin and ball 52 51 from the body 49 Inspect the O ring 50 Pump Piston 1 Remove one retaining ring 15 and pin 14 from handle 5 Remove handle assembly 2 Remove cap screws 13 and pivot block 12 3 Pull the low pressure plunger 66 upward and out of the pump block Check O rings quad ring Serial Code YM only and backup rings 62 65 and replace if worn or damaged 4 Usean Allen wre
32. he Hydraulic System at the end of this troubleshooting table C Internal parts bind C Check stepped rod and driving rod for a bind point 84 94 D Dies bind D Replace dies Pressure setting 1 does not change as ram advances A Pressure adjusting screw is loose 1 3 A Adjust pressure and tighten screw 92 93 2 does not change when adjusting B Improper assembly 1 2 B Check the assembly of stepped rod and Screw setting is changed roller slides 84 89 3 does not hold adjustment C Stepped rod turned 1 C Turn to position Adjust pressure D Spring cap missing 1 2 D Replace cap 86 and adjust pressure E Valve cap not tight 1 2 3 E Tighten cap 87 and adjust pressure F Driving rod disconnected 1 3 F Assemble Fasten with threadlocking compound Internal leak at 1 low pressure relief A Ball cone seat damage 1 2 A Reseat or replace 2 high pressure relief B Dirt or grit in the hydraulic system 1 2 B Drain oil clean parts Fill with fresh oil 3 stepped rod seals C Missing or damaged components C Rebuild tool D Damaged O ring 3 D Replace O ring and backup ring External leak at 1 base of reservoir handle A Damaged reservoir 1 2 3 A Replace reservoir 20 2 grip B Damaged or missing O ring at reservoir 1 2 3 B Replace O ring 21 3 inside reservoir handle C Reservoir plug damaged or missing 1 2 3 C Replace reservoir plug 19 4 around release plunger D O ring on plunger
33. itrile 1 72 35696 503 5696 8 Body Pressure Release sse retener 1 v 73 32534 503 2534 5 Spring Compression 164 x 240 x 750 1 74 50436 905 0436 4 Ball Steel 281 Diameter Grade 25 1 Vv 77 50452 905 0452 6 Ball Steel 218 Diameter Grade 25 1 78 53959 905 3959 1 Spring Compression 188 x 240 x 625 same as item 57 1 v 79 53960 905 3960 5 Plug O Ring 5 16 24 x 380 1 80 32523 503 2523 0 Body Pressure Adjusting Valve 1 81 32789 503 2789 5 ecards ds eee 1 82 03421 500 3421 9 Washer Flat 440 687 x 064 1 83 35699 503 5699 2 Roller 35 euet Mie HEB 1 84 32562 503 2562 0 Rod Stepped 1 RV 85 32572 503 2572 8 Spring Compression 178 x 322 x 875 1 86 35695 503 5695 0 Cap Valve Spring 343 x 432 x 435 1 ev 87 35682 503 5682 8 Cap Relief Valve ia
34. nch to unscrew the high pressure plunger 68 5 Remove the copper washer 67 6 Usea T handle Allen wrench or similar tool to push the check ball insert 49 out Remove ball and spring 47 48 from the pump block 46 Remove roll pin and ball 52 51 from the insert 49 Inspect the O rings 31 50 GREENLEE 1990 Dieless Hydraulic Crimping Assembly Note Lubricate all O rings and backup rings before Pump Block Assembly Serial Code WH Perform this procedure with the pump block 46 secured in the vise with the threaded end downward Cylinder 1 Assemble the check ball insert assembly 49 as follows Install O ring 50 3 16 diameter ball 51 and roll pin 52 Set this assembly aside ACAUTION The spring stores at least 310 Newtons 70 pounds Note Roll pin must be below the surface of the of force Follow this procedure exactly as instructed check ball insert A protruding roll pin will damage to contain the spring and its energy the pump block Failure to contain the spring will release all of its 2 Assemble 3 16 diameter ball 47 and spring energy resulting in injury due to flying parts 48 with small end toward ball into the pump block 46 Install check ball insert assembly 49 into pump block Insert 1 4 diameter ball 53 into 1 Install backup ring 37 and O ring 36 onto ram the check ball insert assembly Seat each ball in its 38
35. nt was not disturbed during Step 13 Install the reservoir 20 and O ring 21 Retract the ram fully Repeat Step 5 of the Pressure Check Procedure Remove the gauge and adapter and install the port plug 97 Add hydraulic oil to the reservoir until it overflows Cover the reservoir with a clean shop cloth Pump the handle 10 to 12 times then retract the ram fully Repeat several times to eliminate any air in the system With the pump handle vertical and the ram fully retracted fill the reservoir until it overflows Note The pump handle must be all the way up and the ram must be fully retracted Otherwise you may overfill the reservoir which will cause it to leak Install the reservoir plug 19 and wipe off all excess oil Serial Code WH Coat the reservoir lightly with a dry white lubricant silicone or talcum Pump the handle one stroke and install the reservoir handle 18 Install the set screw 17 and tighten securely Clean the following items then cover them with an RTV sealant set screw 17 pipe plug 97 screw 100 e Pressure Calibration Check To perform this procedure use Pressure Test Kit 32891 1 2 3 Rotate the swivel head fully counterclockwise Clamp the tool head gently in a vise with the handles upward Remove the RTV 98 and port plug 97 Install the pressure gauge with the gauge adapter into the port that the plug 97 was removed from Center a new test
36. oil seek medical attention immediately 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 Do not use hands to check for indicates the severity of the hazard The message leaks after the signal word provides information for Depressurize the hydraulic preventing or avoiding the hazard system before servicing A DANGER Immediate hazards which if not avoided WILL result A WARNING UL Severe IU Orne Wear eye protection when operating or servicing this tool AWARNING Failure to wear eye protection can result in serious eye injury from Hazards which if not avoided COULD result in severe flying debris or hydraulic oil injury or death ACAUTION Hazards or unsafe practices which if not avoided MAY result in injury or property damage Pinch points Keep hands away from closing dies A WARNING ACAUTION Electric shock hazard This tool is intended for two handed operation Maintain a firm grip on both handles during This tool is not insulated When using this unit near energized electrical lines use proper personal operation Using this tool in any protective equipment other manner can result in injury Failure to observe this warning can or property damage result in severe injury or death Do not operate the tool without dies in place Damage to the ram or crimping head may result
37. reen rubber fiberglass inserts 7 The handle grips have motorcycle style ribs 7 The handle grips are lobed Note The Greenlee 44999 is similar in appearance to these tools with some major differences Serial Code is not WH or YM e Movable die is yellow e Decal on the handle identifies it as a utility tool 44999 is molded into the rubber covering on the block For repair instructions for this tool see Service Bulletin SB 243 Greenlee Textron Subsidiary of Textron Inc 4 GREENLEE 1990 Dieless Hydraulic Crimping Tools and Supplies Before beginning any repair procedure in this manual read the entire section to be sure all of the necessary tools and supplies are available Tools and supplies for most procedures include Bench vise with jaw protectors to secure the tool Quality pressure gauge with 1 2 accuracy and a range of 0 to 700 Bar 0 to 10 000 psi Gauge adapter Serial Code WH 1 16 NPT male pipe adapter Serial Code YM 1 8 SAE straight thread adapter Greenlee 36246 32 mm 1 1 4 diameter aluminum rod at least 76 mm 3 long RTV room temperature vulcanizing silicone rubber adhesive sealant such as Dow Corning Silastic 732 Multipurpose Sealant Pressure Test Kit Greenlee 32891 Exxon Univis J26 hydraulic oil Serial Code WH only dry white lubricant silicone or talcum Tools and supplies for some specific procedures include C clamp arbor press or o
38. s 1 Clamp the pump block in a vise with the handles 6 downward Fully retract the ram 2 Loosen the set screw 96 and unscrew the cylinder 33 from the cylinder cap 42 7 Note Pull the cylinder straight off of the cap to 8 prevent damaging the driving rod Greenlee Textron Subsidiary of Textron Inc 10 3 Pull the cylinder away from the cylinder cap 40 mm 1 1 2 and remove the rod retaining screw 95 Remove the driving rod 94 If the cylinder does not require service proceed to Oylinder Cap Clamp the cylinder assembly in a vise and support the back of the ram with a C clamp or arbor press if available Loosen the set screw 25 that secures the movable die 26 Allow the ram to move far enough to release the tension in the spring Disassemble the C clamp or arbor press setup Remove the set screw 25 movable die 26 ram 38 spring 39 guide 35 and wiper 34 Replace all available packing O rings backup rings springs balls wiper etc GREENLEE 1990 Dieless Hydraulic Crimping Tool Disassembly cont d Cylinder Cap Serial Code WH 1 Unscrew the driving rod 94 from the stepped rod 84 2 Remove four cap screws and copper washers 59 60 Remove the cylinder cap 42 3 Inspect various components 43 45 54 55 Replace if worn or damag
39. s protected by U S Patent No 4 796 461 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 and maintenance of this tool Observe all of the safety information provided Purpose This manual is intended to familiarize authorized Greenlee service center personnel with the safe operation and maintenance procedures for the following Greenlee tools 1990 Serial Code WH 1990 Serial Code YM Keep this manual available to all personnel Replacement manuals are available upon request at no charge Greenlee and are registered trademarks of Greenlee Textron Dow Corning Silastic and 732 are registered trade marks of Dow Corning Corporation Loctite is a registered trademark of Loctite Corporation Univis is a registered trademark of Exxon Corporation Other Publications Instruction Manuals Serial Code WH Publication 999 8425 3 IM 1006 Serial Code YM Publication 999 9994 3 IM 1093 KEEP THIS MANUAL Greenlee Textron Subsidiary of Textron Inc 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE 1990 Dieless Hydraulic Crimping Tool IMPORTANT SAFETY INFORMATION SAFETY AWARNING ALERT Skin injection hazard Oil under pressure easily punctures SYMBOL skin causing serious injury gan grene or death If you are injured by escaping
40. slug in the dies and pump the handle Note the pressure required to open the relief valve which produces an audible click Repeat Step 5 twice for a total of three slugs The relief pressure for every slug should be 214 to 289 Bar 3100 to 4200 psi Evaluate every test slug with the Go No Go gauge as shown If the test slug checkpoint does not fit into GO slot the pressure relief valve is set too low If the test slug checkpoint fits into the NO GO slot the pressure relief valve is set too high If the test slug checkpoint fits into the GO slot and does not fit into the NO GO slot the pressure relief valve is set correctly Greenlee Textron Subsidiary of Textron Inc GREENLEE 1990 Dieless Hydraulic Crimping Tool Check Point center depression of the three depression side Go Gauge No Go Gauge GREENLEE 1990 Dieless Hydraulic Crimping Tool Air Purging and Oil Filling Procedure Fill the reservoir with Exxon Univis J26 all temperature 5 Unscrew the reservoir handle from the crimper hydraulic oil only Remove the plug 19 from the reservoir IMPORTANT Do not fill the hydraulic reservoir with any other type of fluid such as brake fluid glycerin castor oil etc Filling the reservoir with anything other than hydraulic fluid will damage the tool and void the warranty Reservoir Plug 19 1 Clamp the tool into a vise with jaw protectors so the handles are upward as shown
41. ssembly 1 Assemble low pressure relief components Serial Code WH Clamp the pump block in the vise with the threaded end upward Install ball 77 spring 78 and jam screw 79 Turn jam screw clockwise until it is flush with the surface Serial Code YM Install ball 77 spring 78 and plug 79 to the side of the pump block Set the pressure adjusting valve body 80 on a hard surface Insert the valve plunger 81 into the body Using a punch and hammer tap the plunger with a moderate amount of force to seat it in the body Note Using excessive force will damage the body Install the copper washer 82 and relief valve body 80 to the pump block Torque to 27 25 to 32 5 Newton meters 20 to 24 foot pounds Insert the roller guide 83 into the pump block Slide the stepped rod 84 into the roller guide Flat Side Greenlee Textron Subsidiary of Textron Inc Tilt the tool so that the roller guide is at the bottom side Insert the valve spring 85 and spring cap 86 Install relief valve cap 87 Serial Code WH Screw the set screw 93 into valve cap until three or four threads are showing above the surface Secure it with the jam screw 92 Install the roller 88 in the notch of the roller guide 83 Insert the two slides 89 into the slot against the roller and spring cap See the illustration for proper orientation Use care so that the roller remains in its slot
42. ther means of retaining the ram spring when disassembling and assembling the cylinder Spanner wrench for removing the pressure adjusting valve body from the pump block Greenlee Textron Subsidiary of Textron Inc Pressure Check Procedure 1 Clamp the tool head gently in a vise with the handles upward Fully retract the ram 2 Remove the RTV 98 and port plug 97 3 Install the pressure gauge with the gauge adapter into the port that the plug 97 was removed from 4 Pump the handle to fully extend the ram Note the pressure required to open the relief valve which produces an audible click The relief pressure should be 90 to 103 Bar 1300 to 1500 psi 5 Retract the ram and place the 32 mm 1 1 4 diameter aluminum rod between the dies Pump the handle until the relief valve opens Note the pressure required to open the relief valve The relief pressure should be 566 to 675 Bar 8200 to 9800 psi 6 If the crimping tool s relief pressure is within the ranges stated in Step 4 or Step 5 remove the gauge and adapter replace the plug 97 and reseal with RTV 98 Add hydraulic oil see Air Purging and Oil Filling Procedure not within the ranges stated in Step 4 or Step 5 proceed to the Pressure Adjustment Procedure GREENLEE 1990 Dieless Hydraulic Crimping Tool Pressure Adjustment Procedure 1 Fully retract the ram then pump the handle one stroke 2 Remove the RTV 16 and set s
43. ylinder cap 42 or 36153 Requires complete rebuild Repair kit includes a YM style pump pump block 46 block and all related components as follows 29 32 40 55 57 58 60 62 64 65 67 69 70 77 79 82 87 90 92 94 Pump handle 36152 Repair kit includes the following assembly with grip 2 5 7 11 14 15 103 This kit includes a pressure release rod 3 and pressure release bar 8 When installing this YM type kit onto a WH type tool you must retain the WH type pressure release rod 3 and pressure release bar 8 They are not interchangeable The grips are not interchangeable When replacing either handle assembly you might consider replacing both of them so that two grips are similar in appearance Reservoir handle 36151 Repair kit includes grip and handle 1 18 assembly with grip The grips are not interchangeable When replacing either handle assembly you might consider replacing both of them so that two grips are similar in appearance Greenlee Textron Subsidiary of Textron Inc 16 GREENLEE 1990 Dieless Hydraulic Crimping Troubleshooting This table lists some of the most common problems first column The probable trouble areas second column contain numbers in brackets relating to the problems listed in the first column Recommended service procedures are provided third column Problem Probable Trouble Area Recommended Service Ram advance
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