Greenlee 1990 User manual

999 8517.9 © 2000 Greenlee Textron SB 226 REV 5 4/00
SERVICE MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
1990
Dieless Hydraulic Crimping Tool
Serial Codes WH and YM

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
1990 Dieless Hydraulic CrimpingTool
KEEPTHIS MANUAL
Table of Contents
Description ................................................................... 2
Safety ........................................................................... 2
Purpose........................................................................ 2
Other Publications........................................................ 2
Important Safety Information........................................ 3
Identification ................................................................. 4
Tools and Supplies....................................................... 5
Pressure Check Procedure .......................................... 5
Pressure Adjustment Procedure .................................. 6
Pressure Calibration Check ......................................... 7
Air Purging and Oil Filling Procedure ........................... 8
Die Replacement.......................................................... 9
Disassembly......................................................... 10–11
Assembly.............................................................. 12–15
Service Tips ............................................................... 15
Retrofit Kits................................................................. 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 is 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)

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1990 Dieless Hydraulic CrimpingTool
IMPORTANT SAFETY INFORMATION
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 can
result in severe injury or death.
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic
system before servicing.
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.
Pinch points:
Keep hands away from closing dies.
• This tool is intended for two-
handed operation. Maintain a firm
grip on both handles during
operation. Using this tool in any
other manner can result in injury
or property damage.
• Do not operate the tool without
dies in place. Damage to the ram
or crimping head may result.
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

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1990 Dieless Hydraulic CrimpingTool
Identification
Serial Code WH
1. The crimping head is slightly tapered.
2. The fixed die is a bolt-on assembly which includes
four bright zinc-plated die plates.
3. The two arms on the cylinder each have two
machined slots for the die assembly to engage.
4. Serial number begins with “WH” prefix.
5. The pump block is covered with a black rubber
coating.
6. The handles are bonded assemblies and include
fiberglass inserts.
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.
•Movable die is yellow.
•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.
Serial Code YM
1. The crimping head is more steeply tapered.
2. The fixed die is one-piece steel casting, colored
black.
3. The two arms on the cylinder are not slotted.
4. Serial number begins with “YM”prefix.
5. The pump block is covered with a green rubber
coating.
6. The handles are one-piece cast aluminum, covered
with green rubber.
7. The handle grips have “motorcycle style”ribs.
The WH series and YM series crimping tools have
several distinguishing characteristics, which are listed
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.
See Retrofit Kits in this manual for an explanation of
interchangeable parts.
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
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3
6
7
3
245
7
6
1
3
6
7
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4
5
7
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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 other 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
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.

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1990 Dieless Hydraulic CrimpingTool
Pressure Adjustment Procedure
1. Fully retract the ram, then pump the handle one
stroke.
2. Remove the RTV (16) and set screw (17) from the
fixed handle assembly (18).
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.
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.
8. Serial Code WH: Remove RTV (101) and screw
(100).
9. Loosen fastener (92).
10. 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
11. Install reservoir (20).
12. 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).
13. Serial Code WH: Tighten the set screw (92). Install
the nylon washer (99) and screw (100).
Serial Code YM: Tighten the jam nut (92).
14. Pump to achieve pressure relief, to ensure that the
adjustment was not disturbed during Step 13.
15. Install the reservoir (20) and O-ring (21).
16. Retract the ram fully.
17. Repeat Step 5 of the Pressure Check Procedure.
18. Remove the gauge and adapter and install the port
plug (97).
19. Add hydraulic oil to the reservoir until it overflows.
20. 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.
21. 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.
22. Install the reservoir plug (19) and wipe off all excess
oil.
23. Serial Code WH: Coat the reservoir lightly with a
dry white lubricant (silicone or talcum).
24. Pump the handle one stroke and install the reservoir
handle (18). Install the set screw (17) and tighten
securely.
25. Clean the following items, then cover them with an
RTV sealant:
•set screw (17)
•pipe plug (97)
•screw (100)
Vise with
Jaw Protectors
RTV and
Set Screw
(16, 17)
Reservoir
Plug (19)

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1990 Dieless Hydraulic CrimpingTool
Pressure Calibration Check
To perform this procedure, use Pressure Test Kit 32891.
1. Rotate the swivel head fully counterclockwise.
2. Clamp the tool head gently in a vise with the
handles upward.
3. Remove the RTV (98) and port plug (97).
4. Install the pressure gauge with the gauge adapter
into the port that the plug (97) was removed from.
5. Center a new test slug in the dies and pump the
handle. Note the pressure required to open the relief
valve (which produces an audible click).
6. 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).
7. 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.
“Go” Gauge “No Go” Gauge
Check Point (center depression
of the three depression side)

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1990 Dieless Hydraulic CrimpingTool
Air Purging and Oil Filling Procedure
Fill the reservoir with Exxon Univis®J26 all temperature
hydraulic oil only.
1. Clamp the tool into a vise with jaw protectors so the
handles are upward, as shown.
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).
Vise with Jaw
Protectors
Rubber
Plug (16)
Remove
Set Screw
(17)
Reservoir
Plug (19)
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.
5. Unscrew the reservoir handle from the crimper.
Remove the plug (19) from the reservoir.
6. Retract the ram fully.
7. Add oil until the reservoir overflows.
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
handle (18). Replace the set screw (17) and tighten
securely.
12. Cover the set screw with a silicone rubber sealant,
such as Dow Corning®Silastic®732®Multipurpose
Sealant.

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1990 Dieless Hydraulic CrimpingTool
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.
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.
Outer Die Plate Inner Die Plate
Lower
Radii
Side with
grooves
faces out.
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)
2.250"
2.205"
YM
2.250"
2.205"
WH
5. Install the movable die (26) and secure with the set
screw (25).
Movable Die — Either Serial Code
1. Remove the fixed die. See Step 1 under Fixed Die.
2. Remove set screw (25) and movable die (26).
3. Install new movable die and set screw.
4. Install fixed die.
5. Rotate the cylinder fully counterclockwise and fully
retract the ram. Measure the distance between the
outermost blades of the two 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)
2.250"
2.205"
YM
2.250"
2.205"
WH
6. Install the movable die (26) and secure with the set
screw (25).

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1990 Dieless Hydraulic CrimpingTool
1. Clamp the pump block in a vise with the handles
downward. Fully retract the ram.
2. Loosen the set screw (96) and unscrew the cylinder
(33) from the cylinder cap (42).
Note: Pull the cylinder straight off of the cap to
prevent damaging the driving rod.
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:
1. Cylinder
2. Cylinder Cap
3. Reservoir
4. Pump Block, Relief Valves, and
Pressure Release Mechanism
5. Pump Pistons
Cylinder
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 parts.
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).
YMWH
95
94
95
94
4. If the cylinder does not require service, proceed to
Cylinder Cap.
5. Clamp the cylinder assembly in a vise and support
the back of the ram with a C-clamp or arbor press, if
available.
6. 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.
7. Disassemble the C-clamp or arbor press setup.
8. Remove the set screw (25), movable die (26), ram
(38), spring (39), guide (35) and wiper (34).
9. Replace all available packing (O-rings, backup
rings, springs, balls, wiper, etc.).

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1990 Dieless Hydraulic CrimpingTool
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 damaged.
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 guide (83),
adjusting roller (88), two slides (89), valve spring
cap (86), valve spring (85) and relief valve plunger
(81).
4. Use a 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. Use a 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. Use an Allen wrench to unscrew the high-pressure
plunger (68).
5. Remove the copper washer (67).
6. Use a 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).
Disassembly (cont’d)

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1990 Dieless Hydraulic CrimpingTool
1. Install backup ring (37) and O-ring (36) onto ram
(38).
2. Clamp the cylinder (33) in a vise with the bore
upward. Install wiper and guide (34, 35).
3. Install spring (39) and ram assembly into cylinder
(33). Compress the spring using either an arbor
press or a C-clamp.
4. Slide the ram die (26) into place. Tighten set screw
(25) securely.
5. Set the assembly aside.
Cylinder Cap Assembly
1. Install the seal and backup washer (40, 41) into the
cylinder cap (42).
Serial Code WH: Install backup ring (43), O-ring
(44) and retaining ring (45) onto the cylinder cap.
2. Set the assembly aside.
Assembly
The spring stores at least 310 Newtons (70 pounds)
of force. Follow this procedure exactly as instructed
to contain the spring and its energy.
Failure to contain the spring will release all of its
energy, resulting in injury due to flying parts.
Pump Block Assembly — Serial Code WH
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-ring (50), 3/16" diameter ball (51),
and roll pin (52). Set this assembly aside.
Note: Roll pin must be below the surface of the
check ball insert. A protruding roll pin will damage
the pump block.
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. Loosen jam screw (61). Assemble O-rings (54–56),
bushing (58) and spring (57) to cylinder cap. Torque
the bushing (58) to 4 Newton-meters (3 foot-pounds).
4. Set cylinder cap in place on the pump block and
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
(3 foot-pounds).
4. Assemble the O-ring (44), backup ring (43) and
copper washers (54, 55) to the cylinder cap (42).
5. Set cylinder cap in place on the pump block and
install four copper washers (56) and cap screws
(59). Torque to 27 Newton-meters (20 foot-pounds).
Pump Plunger Assembly
1. Cut 6 mm (1/4") off of backup ring (62) to prevent
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.
Note: Lubricate all O-rings and backup rings before
assembling.
Cylinder

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1990 Dieless Hydraulic CrimpingTool
Pressure Release Assembly
1. Assemble O-ring (69) to pressure release shaft (70).
Assemble O-ring (71) to pressure release body (72).
2. Slide shaft assembly into body assembly.
Serial Code YM: Set washer (30) into recess in
pump block.
3. Install spring (73) and 9/32" ball (74) into the pump
block.
4. Assemble pressure release assembly to pump
block. Torque to 8 to 9.25 Newton-meters
(6 to 7 foot-pounds).
Relief Valve/Pressure Control Assembly
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.
2. 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.
3. 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).
4. Insert the roller guide (83) into the pump block. Slide
the stepped rod (84) into the roller guide.
88
84 83
Flat Side
5. Tilt the tool so that the roller guide is at the bottom
side. Insert the valve spring (85) and spring cap
(86).
6. 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).
7. Install the roller (88) in the notch of the roller guide
(83).
8. 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.
WH
93
92
88
Notch
YM
92
93
88
Notch
8989
9. 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).
Assembly (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 14
1990 Dieless Hydraulic CrimpingTool
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
of 94
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 surface
of the ram.
YMWH
95
94
95
94
6. 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).
2. Assemble the pressure release bar (8) and torsion
spring (9) to the handle with roll pins (10). Glue grip
(11) to handle (5).
3. Mount the lever pivot block (12) to the pump block.
Fasten with two cap screws (13). Torque to
20 Newton-meters (15 foot-pounds).
4. 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).
5. Serial Code WH: Assemble the fixed die head. See
the following illustration and the exploded view.
Outer Die Plate Inner Die Plate
Lower
Radii
Side with
grooves
faces out.
Install the bolts (28) and nuts (29). Torque to
13.5 Newton-meters (10 foot-pounds).
6. Serial Code YM: Assemble the detent (22) to the
die head (28).
7. Install the spacer(s) (102) and movable die (26).
Secure by tightening set screw (25).
8. Fasten the fixed die to cylinder with pins (23, 24).
Secure pin (24) with retaining rings (27).
Assembly (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 15
1990 Dieless Hydraulic CrimpingTool
ServiceTips
•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 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.
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)
2.250"
2.205"
YM
2.250"
2.205"
WH
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 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. 16
1990 Dieless Hydraulic CrimpingTool
Retrofit Kits
CrimpingTool Purchase Explanation
Part Repair Kit
Relief valve cap (87) 36150 Repair kit includes cap, cover, nut and screw (87, 90, 92, 93).
or cover (90)
36149 Failure of either pin will overstress the other components, requiring
complete replacement of the crimping head.
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).
Cylinder 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.
Many components are interchangeable between the
older (WH) and current (YM) crimping tools. However,
some components are not interchangeable, requiring
the replacement of several components at once.
Use this table to select the appropriate repair kit.
Crimping head
components or
cylinder (33)

Greenlee Textron / Subsidiary of Textron Inc. 17
1990 Dieless Hydraulic CrimpingTool
Problem ProbableTrouble Area Recommended Service
Ram advance:
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 A. 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 the 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 damaged or missing {4} D. Replace O-ring and backup ring (64, 65).
5. between pump block and E. Loose cylinder cap {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 G. Damaged cylinder seal in cap {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).
I. Damaged ram {7} I. 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.
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).

Greenlee Textron / Subsidiary of Textron Inc. 18
1990 Dieless Hydraulic CrimpingTool
8
10
14
10
66
72
7
6
70
12
5
3
2
4
19
20
18
17 16 RTV
88
89
84
83
46
13
68
64
62
99
100
77
78
79
21
82
85
93
92
91
9
15
80
81
86
69
74
73
71
65
63
67
101 RTV
98 RTV
97
103
1
87
104
90
Illustration — Serial CodeWH

Greenlee Textron / Subsidiary of Textron Inc. 19
1990 Dieless Hydraulic CrimpingTool
11
95
49
29
58
38
31
42
59
32
31
28
24
26
23
22
33
27
27
25
37
60
61
44
43
45
40
41
54
56
57
53
51
52
50
48
47
30 (outer)
30 (inner)
30 (inner)
30 (outer)
94
36
55
96
39
35
34
102

Greenlee Textron / Subsidiary of Textron Inc. 20
1990 Dieless Hydraulic CrimpingTool
Parts List — Serial Code WH
UPC NO.
KEY 78-3310- PART NO. DESCRIPTION QTY.
▲ ◗ ◆ 1* 32532 503 2532.9 Grip, Handle................................................................................................ 2
▲ ◗ 2 03427 500 3427.8 Release Trigger .......................................................................................... 1
▲ ◗ 3 32511 503 2511.6 Rod, Pressure Release............................................................................... 1
▲ ◗ 4 50458 905 0458.5 Roll Pin, .125 x .375" .................................................................................. 1
▲ ◗ 5* 32495 503 2495.0 Lever Unit, Handle ...................................................................................... 1
▲ ◗ 6 52482 905 2482.9 Roll Pin, .125 x 1.25" .................................................................................. 1
▲ ◗ 7 50420 905 0420.8 Pin, Release, .125 x 1.00" .......................................................................... 1
▲ ◗ 8 32510 503 2510.8 Bar, Pressure Release................................................................................ 1
▲ ◗ ✓ 9 03334 500 3334.4 Spring, Torsion, .187 x .280 x .312" ........................................................... 1
▲ ◗ 10 53475 905 3475.1 Pin, Roll, .156 x 1.37" ................................................................................. 3
▲ ◗ 11 32690 503 2690.2 Boot, Pivot Head......................................................................................... 1
12 32493 503 2493.4 Pivot, Lever................................................................................................. 1
13 51265 905 1265.0 Screw, Cap, 1/4–20 x .750" Socket Head .................................................. 2
▲14 03418 500 3418.9 Pin, Fulcrum................................................................................................ 2
▲ ✓ 15 51773 905 1773.3 Ring, Retaining, .312"................................................................................. 2
16 RTV
✓17 51241 905 1241.3 Screw, Set, #10–32 x .187" Flat Point Socket ............................................ 1
◆18* 32496 503 2496.9 Handle, Reservoir ....................................................................................... 1
19 32488 503 2488.8 Plug, Bladder, Rubber, Black...................................................................... 1
20 32530 503 2530.2 Reservoir .................................................................................................... 1
✓21 53814 905 3814.5 O-ring, 1.47 x 1.71 x .118"–90D ................................................................. 1
22 53599 905 3599.5 Stud, Grooved............................................................................................. 1
23 32518 503 2518.3 Pin Unit, Removable ................................................................................... 1
24 32517 503 2517.5 Pin, Pivot.....................................................................................................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" .................................................................................. 2
28 32515 503 2515.9 Bolt, Die Plate ............................................................................................. 2
29 53478 905 3478.6 Nut, Jam, 7/16–20 ...................................................................................... 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....................................................................................... 2
32* 32516 503 2516.7 Spacer ........................................................................................................2
33* 32491 503 2491.8 Cylinder....................................................................................................... 1
✓34 53464 905 3464.6 Wiper, Ram................................................................................................. 1
35 35651 503 5651.8 Guide, Ram................................................................................................. 1
✓36 50888 905 0888.2 O-ring, 1.62 x 2.00 x .187" Nitrile................................................................ 1
✓37 50889 905 0889.0 Backup Ring, Spiral, 1.62 x 1.99 x .033" .................................................... 1
38 32509 503 2509.4 Ram ............................................................................................................1
39 32519 503 2519.1 Spring, Compression, 1.49 x 1.82 x 6.06" .................................................. 1
▼ ✓ 40 53473 905 3473.5 O-ring, 2.37 x 2.56 x .093".......................................................................... 1
▼ ✓ 41 53470 905 3470.0 Backup Ring, Single Turn, 2.37 x 2.55 x .050" Teflon ................................ 1
▼42 32508 503 2508.6 Cap, Cylinder .............................................................................................. 1
▼ ✓ 43 53480 905 3480.8 Backup Ring, Spiral, .125 x .250 x .049" Teflon ......................................... 1
▼ ✓ 44 50722 905 0722.3 O-ring, .114 x .250 x .068"–70D Nitrile (same as item 69) ......................... 1
▼ ✓ 45 51382 905 1382.7 Retaining Ring, .312" .................................................................................. 1
▼46* 32691 503 2691.0 Block, Pump................................................................................................ 1
▼ ✓ 47 50678 905 0678.2 Ball, Steel, .187" Diameter, Grade #25 (same as item 51) ......................... 1
▼ ✓ 48 16141 501 6141.5 Spring, Compression, .194 x .214 x .500" .................................................. 1
▼49 32529 503 2529.9 Check Ball Insert......................................................................................... 1
▼ ✓ 50 53688 905 3688.6 O-Ring ........................................................................................................ 1
▼ ✓ 51 50678 905 0678.2 Ball, Steel, .187" Diameter, Grade #25 (same as item 47)........................ 1
▼ ✓ 52 51204 905 1204.9 Pin, Roll, .062 x .375" ................................................................................. 1
▼ ✓ 53 50679 905 0679.0 Ball, Steel, .250" Diameter, Grade #25....................................................... 1
▼ ✓ 54 51046 905 1046.1 O-ring, .187 x .312 x .062" Nitrile................................................................ 1
▼ ✓ 55 53469 905 3469.7 O-ring, .156 x .281 x .062".......................................................................... 1
▼ ✓ 56 51215 905 1215.4 O-ring, .437 x .562 x .062" Nitrile................................................................ 1
▼ ✓ 57 10761 501 0761.5 Spring, Compression, .153 x .203 x .440 ................................................... 1
▼58 32590 503 2590.6 Check Ball Bushing..................................................................................... 1
59 50581 905 0581.6 Screw, Cap, 1/4–20 x 1.00" Socket Head. ................................................. 4
▼ ✓ 60 32535 503 2535.3 Washer, Flat, .260 x .390 x .046" Copper................................................... 4
▼ ✓ 61 53474 905 3474.3 Screw, Jam Socket ..................................................................................... 1
▼ ✓ 62 50883 905 0883.1 Backup Ring, Spiral, .375 x .485 x .027" Teflon ......................................... 1
▼ ✓ 63 53689 905 3689.4 O-ring, .334 x .475 x .070".......................................................................... 1
▼ ✓ 64 50394 905 0394.5 O-ring, .750 x 1.00 x .125"–70D Nitrile ....................................................... 1
▼ ✓ 65 51272 905 1272.3 Backup Ring, Spiral, .750 x .992 x .027" .................................................... 1