Greenlee 1990 Bedienungsanleitung

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

Greenlee Textron / Subsidiary of Textron Inc. 4

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

245

Greenlee Textron / Subsidiary of Textron Inc. 5

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)

Greenlee Textron / Subsidiary of Textron Inc. 7

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.

Greenlee Textron / Subsidiary of Textron Inc. 9

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"

2.250"

2.205"

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"

2.250"

2.205"

6. Install the movable die (26) and secure with the set

screw (25).

Greenlee Textron / Subsidiary of Textron Inc. 10

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

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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