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)

Greenlee Textron / Subsidiary of Textron Inc. 3
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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1990 Dieless Hydraulic CrimpingTool
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.

Greenlee Textron / Subsidiary of Textron Inc. 6
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)

Greenlee Textron / Subsidiary of Textron Inc. 8
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.).