CT06
1650 PSI
HYDRAULIC
CRIMPING TOOL
Safety, OperatiOn and Maintenance
USer ManUaL
© 2010 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
58543 7/2011 Ver. 3
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS..........................................................................................................................................5
TOOL STICKER & TAGS ..........................................................................................................................................6
HOSE TYPES............................................................................................................................................................7
HOSE RECOMMENDATIONS ..................................................................................................................................8
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................8
HTMA REQUIREMENTS...........................................................................................................................................9
OPERATION............................................................................................................................................................10
FIGURE 2. OC/CC SETUP..................................................................................................................................10
TOOL PROTECTION & CARE................................................................................................................................14
TROUBLESHOOTING ............................................................................................................................................15
SPECIFICATIONS...................................................................................................................................................16
CT06 PARTS ILLUSTRATION.................................................................................................................................17
CT06 PARTS LIST...................................................................................................................................................18
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERVICING THE STANLEY HYDRAULIC CRIMPING TOOL. This manual contains safety, operation, and routine
maintenance instructions. Stanley Hydraulic Tools recommends that servicing of hydraulic tools, other than routine
maintenance, must be performed by an authorized and certified dealer. Please read the following warning.
WARNING
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
CT06 User Manual ◄ 3
Download from Www.Somanuals.com. All Manuals Search And Download.
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair ac-
tions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicate an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
DANGER
WARNING
CAUTION
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoid-
ed, may result in property damage.
CAUTION
NOTICE
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in dam-
age to the equipment.
IMPORTANT
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and mainte-
nance personnel.
4 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
•
•
Know the location of buried or covered electrical
services before starting work.
Keep your work area clean and clear of tripping haz-
ards. Oily surfaces and hoses lying around can be
hazardous.
These safety precautions are given for your safety. Re-
view them carefully before operating the tool and before
performing general maintenance or repairs.
•
•
Always operate the tool within its rated capacity.
Do not use the tool for applications for which it was
not designed.
Supervising personnel should develop additional pre-
cautions relating to the specific work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
•
Do not inspect, clean or replace any part(s) if the
hydraulic power source is connected. Do not inspect
or clean the tool while the hydraulic power source is
connected. Accidental engagement of the tool can
cause serious injury.
The model CT06 Hydraulic Crimping Tool will provide
safe and dependable service if operated in accordance
with the instructions given in this manual. Read and un-
derstand this manual and any stickers and tags attached
to the tool and hose before operation. Failure to do so
could result in personal injury or equipment damage.
•
•
•
•
Always connect hoses to the tool hose couplers be-
fore energizing the hydraulic power source. Be sure
all hose connections are tight and are in good condi-
tion.
Always replace hoses, couplings, and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Refer to the parts list at the end of
this manual for part numbers.
Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher temperatures can
cause higher than normal temperatures at the tool
which can result in operator discomfort.
•
•
The operator must start in a work area without by-
standers. Flying debris can cause serious injury.
Make sure all critical tool markings, such as labels
and warning decals, are securely in place and leg-
ible. Replace any that are damaged or missing.
Do not operate a damaged, improperly adjusted, or
incompletely assembled tool. Do not carry tool by
the hoses.
•
•
•
Do not operate the tool unless thoroughly trained
or under the supervision of an instructor. Establish
a training program for all operators to ensure safe
operation.
•
•
Keep the handles dry, clean and free of oil.
Ensure adequate lighting for the area where the tool
is being used.
Always wear personal protection equipment (PPE)
such as goggles, ear and head protection, and safe-
ty shoes at all times when operating the tool. Use
gloves and aprons when necessary.
•
•
Use proper lifting techniques when handling the
tool. Do not overreach. Maintain secure footing and
balance at all times.
Never wear loose clothing or unrestrained long hair
that can get entangled in the working parts of the
tool.
When using tools near energized transmission lines,
be sure to use only hoses labeled and certified non-
conductive.
•
•
•
•
Keep all parts of your body away from the tool and
maintain proper footing and balance at all times.
•
•
Turn off the power unit or move the hydraulic control
valve to neutral before setting the tool down.
Do not rely exclusively upon the safety devices built
into the tool.
To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained per-
sonnel.
Always be well rested and mentally alert before op-
erating the tool.
The operator must be familiar with all prohibited
work areas such as excessive slopes and danger-
ous terrain conditions.
CT06 User Manual ◄ 5
Download from Www.Somanuals.com. All Manuals Search And Download.
TOOL STICKER & TAGS
58500
CT06 1650 PSI Combined Sticker
NOTE:
D A N G E R
D A N G E R
THE INFORMATION LISTED
ON THE STICKERS SHOWN,
MUST BE LEGIBLE AT ALL
TIMES.
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-
TIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
D. DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO
NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR
DAMAGED HOSE.
3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON-
NECTED TO THE TOOL BEFORE PRESSURING SYSTEM.
SYSTEM PRESSURE HOSE MUST ALWAYS BE CON-
NECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE
MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT.
REVERSING CONNECTIONS MAY CAUSE REVERSE
TOOL OPERATION WHICH CAN RESULT IN SEVERE
PERSONAL INJURY.
BEFORE USING HOSE LABELEDAND CERTIFIEDAS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY
DEPARTMENT INSTRUCTIONS.
REPLACE DECALS IF
THEY BECOME WORN OR
DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM
YOUR LOCAL STANLEY
DISTRIBUTOR.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-
TION INTO THE BODY OR CAUSE OTHER SEVERE
PERSONAL INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-
CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN
LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY
THE SAME SYSTEMAND/OR SEVERE PERSONAL INJURY.
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY
CAUSE A LEAK OR BURST.
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
B. DO NOT EXCEED RATED WORKING PRESSURE OF
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS
PRESSURE MAY CAUSE A LEAK OR BURST.
6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PRO-
TECTION.
7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE,
ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST
ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY
TRAINED PERSONNEL.
C. CHECK TOOL HOSE COUPLERS AND CONNECTORS
DAILY FOR LEAKS. DO NOT FEEL FOR LEAKS WITH
YOUR HANDS. CONTACT WITH A LEAK MAY RESULT
IN SEVERE PERSONAL INJURY.
The safety tag (P/N 15875) at right is
attached to the tool when shipped from
the factory. Read and understand the
safety instructions listed on this tag before
removal. We suggest you retain this tag and
attach it to the tool when not in use.
I M P O R T A N T
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
SEE OTHER SIDE
SAFETY TAG P/N 15875 (Shown smaller then actual size)
6 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy-
draulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with
Stanley Hydraulic Tools. They are:
Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforce-
ment, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.
Fabric-braided (not certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber in-
ner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certified non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
D A N G E R
D A N G E R
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN
DEATH OR SERIOUS INJURY.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE
OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.
KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT
CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION
AND SEVERE PERSONAL INJURY.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR
CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT
USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-
TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-
AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE
IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
D A N G E R
D A N G E R
1. DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS
NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR
ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, BULGES, OR DAMAGE TO
COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.
NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-
TRIC LINES.
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.
3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR
HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP HOSE
AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT
DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE
PERSONAL INJURY.
4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT
WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO
PULL OR LIFT TOOLS, POWER UNITS, ETC.
SEE OTHER SIDE
SEE OTHER SIDE
SIDE 1
SIDE 2
(Shown smaller than actual size)
CT06 User Manual ◄ 7
Download from Www.Somanuals.com. All Manuals Search And Download.
HOSE RECOMMENDATIONS
8 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
HTMA REQUIREMENTS
TOOL CATEGORY
HYDRAULIC SYSTEM
REQUIREMENTS
FLOW RATE
TYPE I
4–6 gpm
(15–23 lpm)
TYPE II
TYPE III
TYPE RR
9–10.5 gpm
(34–40 lpm)
7–9 gpm
(26–34 lpm)
11–13 gpm
(42–49 lpm)
TOOL OPERATING PRESSURE
(At the power supply outlet)
2000 psi
(145–155 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
SYSTEM RELIEF VALVE SETTING
(At the power supply outlet)
2100–2250 psi
(145–155 bar)
2100–2250 psi 2100–2250 psi 2200–2300 psi
(145–155 bar)
(145–155 bar)
(145–155 bar)
MAXIMUM BACK PRESSURE
(At tool end of the return hose)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Measured at a max. fluid viscosity of:
400 ssu*
400 ssu*
400 ssu*
400 ssu*
(At min. operating temperature)
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
TEMPERATURE
140 °F
(60 °C)
140 °F
(60 °C)
140 °F
(60 °C)
140 °F
(60 °C)
Sufficient heat rejection capacity
to limit max. fluid temperature to:
(At max. expected ambient temperature)
Min. cooling capacity
3 hp
5 hp
7 hp
6 hp
at a temperature difference of
between ambient and fluid temps
(2.24 kW)
40 °F
(3.73 kW)
40 °F
(4.47 kW)
40 °F
(5.22 kW)
40 °F
(22 °C)
(22 °C)
(22 °C)
(22 °C)
NOTE:
Do not operate the tool at oil temperatures above 140 °F (60 °C). Operation at higher temperatures can cause operator
discomfort at the tool.
FILTER
Min. full-flow filtration
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
Sized for flow of at least:
(For cold temp. start-up and max. dirt-holding
capacity)
HYDRAULIC FLUID
100–400 ssu*
100–400 ssu*
100–400 ssu*
100–400 ssu*
Petroleum based
(20–82 centistokes)
(Premium grade, anti-wear, non-conductive)
VISCOSITY
(At min. and max. operating temps)
NOTE:
When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine
the most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the
requirements over a wide range of operating temperatures.
*SSU = Saybolt Seconds Universal
CT06 User Manual ◄ 9
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
PRE-OPERATION
Careful inspection of the tool and hydraulic system be-
fore startup is important for safe, reliable operation of the
tool.
Cylinder
Open-Center (no gap)
The following items should be checked daily at the start
and the end of each work shift.
1. Make sure the proper dies are securely in place. Op-
erating the tool without dies can deform the crimping
heads. Refer to Die Installation for instructions.
Trigger
Adapter
Handle
2. Connect hoses. Wipe all hose couplers with a clean,
lint-free cloth before making connections. Dirty cou-
plers can contaminate the hydraulic lines and pre-
vent a good seal at the connection.
Top View of Tool
Figure 2. OC/CC Setup
2. Loosen the 2 setscrews on the cylinder.
3. Turn the adapter until it stops:
3. Check all fasteners for tightness.
4. Check the equipment for oil leaks. If leaks are ob-
served, do not use the tool; have the equipment ser-
viced before use.
•
Counter clockwise (CCW) to change to closed
center (creates gap)
5. Check the tool and hydraulic system for proper op-
eration and performance.
•
Clockwise (CW) to change to open center (clos-
es gap)
6. If the equipment does not appear to operate prop-
erly, have it serviced before use.
4. Tighten the two setscrews.
7. Periodically verify the crimping force of the tool. Re-
LATCH NIB REPLACEMENT
fer to Die Load Verification.
The CT06 Hydraulic Crimping Tool has two main com-
ponents in the Anderson compression head:
SETUP AND TEST
Verify the crimping force before operating the tool.
•
•
The cam yoke assembly forms the base of the com-
pression head. It functions as a movable piston die
to provide the crimping force.
OPEN CENTER/CLOSED CENTER
SETUP
The CT06 Hydraulic Crimping Tool can be configured
for either open-center or closed-center operation. The
current setting is easily determined by looking at the gap
between the adapter and the cylinder:
The latch assembly bridges the cam yoke across
the end of the head. The latch nib in the center of
the assembly is the stationary die.
The following procedure describes how to remove and
replace the latch nibs.
TO CHANGE THE CURRENT SETTING:
1. Remove the hydraulic hose coupling from the return
port on the tool, if one is installed. When making
the change from CC to OC, hydraulic fluid may be
trapped in the tool, preventing complete movement
of the adapter. Remove the return coupling to allow
the hydraulic fluid to escape.
WARNING
Installing dies in the tools with the hydraulic hoses
connected can cause severe personal injury or
equipment damage.
To prevent accidental start-up, always disconnect the
hoses before installing dies.
10 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
1. If the hydraulic hoses are connected:
2. Connect the tool to an appropriate hydraulic power
source. Follow the Hydraulic Hose Connection safe-
ty guidelines and instructions in this section. If pos-
sible, use the hydraulic power source you plan to
use for crimping.
•
•
Turn the hydraulic system control valve OFF.
Disconnect first the hydraulic input (supply)
hose, then the output (return) hose.
2. Clean the surfaces of the die holder to remove any
dirt or grease.
3. Position the test slug within the nibs.
4. Actuate the tool to squeeze the test slug.
5. Release the test slug and then measure it.
3. Pull the pin out to release the latch.
4. Rotate the latch away from the head to provide ac-
cess to the nib/nest die.
If the indicated value is low or high and the system
pressure relief valve setting is greater than 1650 psi
(114 bar), adjust the relief valve on the CT to get the
correct die load.
5. To release the nib/nest die, drive the roll pin out of
the center of the latch.
6. Remove the nib/nest die by rotating it out and around
the small pivot pin inside the latch.
6. When the value is within the acceptable range, turn
the hydraulic system control valve OFF and discon-
nect the hoses from the tool.
7. Insert the new nib/nest die, rotating it around the
pivot pin as in step 6. Make sure the nib/nest die is
oriented so the notched side faces the pivot pin.
OC/CC SETTING
Check the open-center/closed-center (OC/CC) setting
on the tool. The current setting is easily determined by
looking at the gap between the adapter and the cylinder,
see Figure 2.
8. Press the nib/nest die firmly until it locks into place.
9. Drive the roll pin into the center of the latch to retain
the nib/nest die.
10. Close the latch. Insert the latch pin.
•
•
Open Center: No gap
Closed Center: Approximately 1/4-inch (6.4-mm)
gap
HYDRAULIC HOSE CONNECTION
Make sure the hydraulic system control valve is in the
OFF position when coupling or uncoupling the hoses.
Failure to do so may result in damage to the quick cou-
plers and cause overheating of the hydraulic system.
If the setting is not correct for your hydraulic system, fol-
low the instructions in this section, OC/CC Adjustment,
to make the change.
CHECK POWER SOURCE
Before installing the hoses, wipe the fittings and the en-
tire length of the hoses with a clean, dry lint-free cloth
to remove any dirt or moisture. Dirty connections can
contaminate the hydraulic fluid, causing rapid wear and
early failure of internal pars.
Using a calibrated flowmeter and pressure gauge, check
the hydraulic power source at the tool’s input port. Make
sure the system maintains an operating flow in the range
of 3–9 gpm/11–34 lpm within a pressure range of 1650–
2000 psi /114–140 bar.
Check the flow indicators (arrows) stamped on the cou-
plers to ensure oil flows in the proper direction. The fe-
male coupler on the tool is the inlet coupler.
The hydraulic fluid temperature should be at least 80
°F/27 °C for this test.
It is a good practice to connect the output (return) hose
first and disconnect it last to minimize or avoid trapped
pressure within the tool.
CONNECT HOSES
1. Wipe all hose couplers with a clean, lint-free cloth
before making connections.
1. Connect the output hose to the OUT or T port on
the tool.
2. Connect hoses from the hydraulic power source to
the tool fittings or quick disconnects. It is good prac-
tice to connect the return hose first and disconnect it
last to minimize or eliminate trapped pressure within
the wrench.
2. Connect the input hose to the IN or P port.
3. Be sure all hose connections are tight.
DIE LOAD VERIFICATION
3. Observe the flow indicators stamped on the main
body assembly and the hose couplers to ensure
that the flow is in the proper directions. The female
couple on the tools “IN” port is the inlet (pressure)
coupler.
1. Use Anderson test slugs to verify the crimping force
in the tool.
CT06 User Manual ◄ 11
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
NOTE:
STARTUP
If the uncoupled hoses are left in the sun, pressure
increase within the hoses can make them difficult to
connect. Whenever possible, connect the free ends
of the hoses together.
1. Clean the nibs on the tool. Remove all traces of lu-
brication from each tool nib before crimping.
2. Pull the ringed latch pin out of the latch. Rotate the
latch away from the crimping head and then place
the crimping head over the connector sleeve on the
conductor. Close the latch and reinstall the ringed
latch pin.
TOOL RELIEF VALVE ADJUSTMENT
The relief valve on a universal pressure CT can be ad-
justed to increase or decrease the tool’s crimping force.
Standard CT’s do not have a relief valve.
3. Move the hydraulic system control valve to the ON
position.
The crimping tools relief valve is located below the trig-
ger guard. The relief valve on the hydraulic system is
totally separate and has a different function.
WARNING
1. Perform steps 1 through 5 under Die Load Verifica-
tion.
The crimping force between the dies in the tool head
can cause severe personal injury.
2. If the load tester indication is within the acceptable
range, the tools’ relief valve on the hydraulic system
is set correctly. If it is not, adjust the valve as follows:
Keep hands away from the die area when operating
the tool.
a. Turn the hydraulic system control valve OFF.
b. Remove the plug from the end of the relief valve,
below the trigger guard.
4. Remove any trapped air from the tool by squeezing
the trigger 4 or 5 times to advance and retract the
piston nearly a full stroke.
c. Using a hex wrench, turn the adjusting screw.
Clockwise (CW) to increase pressure or Coun-
terclockwise (CCW) to decrease pressure.
5. Position the tool as follows:
a. Connector sleeves
d. Replace the plug in the relief valve and retest.
Repeat the adjustment if necessary.
Center the sleeve between all four nibs in the
compression head. Place the sleeve so the nibs
make the first crimp adjacent to the center-band
mark.
TOOL OPERATION
Observe all safety precautions when operating the tool.
Read Safety and Hydraulic System Requirements, be-
fore operating the tool for the first time.
Make sure the connector sleeve is carefully
centered between all four nibs in the tool.
b. H-Frame Connectors:
CONDUCTOR PREPARATION
Place the connector in the tool so the main
groove is positioned between the top nib and ei-
ther side nib. Make sure the positioning grooves
mate with two of the nibs.
1. If the conductor is insulated, remove the insulation
from the end of the conductor.
Use an insulation stripping tool. If a stripping tool is
not available, carefully shave the insulation from the
cable.
6. Squeeze the trigger to crimp the connector.
Be sure not to nick or cut the strands of the conduc-
tor.
2. Remove any oxide or foreign matter from the ex-
posed conductor. A bright, shiny surface is required
for a good connection. Do not wire-brush tin-plated
copper conductors or tinned connectors.
3. Install the connector sleeve onto the conductor.
12 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION
7. Release the trigger to retract the nibs.
8. Repeat the crimp as required.
COLD WEATHER OPERATION
9. After the last crimp, make sure the nibs in the crimp-
ing head are fully retracted
IMPORTANT
10. Pull out the latch pin and rotate the latch away from
the crimping head.
Use an oil with the recommended specification from
the HTMA Requirement table. Using oil that is too
viscous (thick) can damage the hydraulic system.
11. Remove the tool by lifting it clear of the cable.
SHUTDOWN
1. Move the hydraulic system control valve to the OFF
position.
If the tools is to be used during cold weather, preheat the
hydraulic fluid at low engine speed. When using the nor-
mally recommended fluids, fluid temperature should be
at or above 50°F/10°C (400 ssu/82 centistokes) before
use.
2. Disconnect the hydraulic hoses from the tool: first
the input (supply) hose, then the output (return)
hose.
Damage to the hydraulic system or compression tool
can result from use with fluid that is too viscous or too
thick.
3. Insert plugs in the hose ends, couplers or tool ports,
as applicable.
4. Wipe the tool thoroughly with a clean dry cloth.
STORAGE
5. Clean any foreign matter or joint compound from the
die holder surfaces.
Replace any damaged or missing safety labels and tags
before storing the tool. Clean, dry and lubricate moving
parts before storage. Store in a clean, dry place.
CT06 User Manual ◄ 13
Download from Www.Somanuals.com. All Manuals Search And Download.
TOOL PROTECTION & CARE
NOTICE
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
•
•
Make sure all couplers are wiped clean before con-
nection.
•
•
Do not exceed the rated flow. Refer to Specifications
in this manual for correct flow rate. Rapid failure of
the internal seals may result.
The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling
hy-
Always keep critical tool markings, such as warning
stickers and tags legible.
draulic tools. Failure to do so may result in damage
to the quick couplers and cause overheating of the
hydraulic system.
•
•
Do not force a small tool to do the job of a large tool.
Tool repair should be performed by experienced
personnel only.
•
•
Always store the tool in a clean dry space, safe from
damage or pilferage.
•
•
Make certain that the recommended relief valves
are installed in the pressure side of the system.
Make sure the circuit PRESSURE hose (with male
quick disconnect) is connected to the “IN” port. The
circuit RETURN hose (with female quick discon-
nect) is connected to the opposite port. Do not re-
verse circuit flow. This can cause damage to internal
seals.
Do not use the tool for applications for which it was
not intended.
•
Always replace hoses, couplings and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a mini-
mum working pressure rating of 2500 psi/172 bar.
14 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
TROUBLESHOOTING
If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem.
When diagnosing faults in operation of the crimping tool, always check that the hydraulic power source is supplying
the correct hydraulic flow and pressure to the grinder as listed in the table. Use a flowmeter known to be accurate.
Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.
PROBLEM
CAUSE
SOLUTION
Tool does not operate.
Hydraulic hoses not connected
properly.
Make sure hoses are connected
and the couplers are tight.
Hydraulic control valve OFF.
Hydraulic system not functioning.
Couplers or hoses blocked.
Turn the hydraulic system control
valve ON.
Check hydraulic power unit for
correct flow and pressure.
Remove obstruction.
Pressure port check valve is
installed in tool return port.
Install pressure port check valve in
pressure port.
Tool operates in reverse (piston
advances/retracts when trigger is
squeezed).
Hoses connected to wrong ports on Connect input (supply) line to IN
tool.
port. Connect output (return) line to
OUT port.
Tool under-crimps. Die load less
than 6 tons/5443 kg.
Hydraulic system pressure too low. Check hydraulic power source for
correct flow and pressure.
Relief valve set too low.
Increase relief valve pressure.
Dirt or obstruction between dies.
Remove obstruction. Clean die
area.
Piston seal worn or damaged.
Contact an authorized Stanley
distributor.
Improper die set for wire and
connector.
Install proper die set.
Tool over-crimps. Die load more
than 6 tons/5443 kg.
Hydraulic system pressure too high. Check hydraulic power source for
correct flow and pressure.
Relief valve set too high.
Decrease relief valve pressure.
Trigger difficult to operate.
Hoses connected to wrong ports on Connect input (supply) line to IN
tool.
port. Connect output (return) line to
OUT port.
Excessive back-pressure.
If back-pressure is greater than
250 psi/17 bar, clear the return line
obstruction or restriction.
Trigger guard bent and binding on
spool in bore.
Repair or replace trigger assembly.
CT06 User Manual ◄ 15
Download from Www.Somanuals.com. All Manuals Search And Download.
SPECIFICATIONS
Capacity ...................................................................................#10-750 MCM Aluminum and #10-500 MCM Copper
Crimping Force............................................................................................. 6 tons @ 1650 psi / 5443 kg @ 114 bar
Pressure Range................................................................................................................................ 1650 psi/114 bar
Flow Range .................................................................................................................................3-9 gpm / 11-34 lpm
Optimum Flow .....................................................................................................................................8 gpm / 30 lpm
Porting..............................................................................................................................................................-8 SAE
Hose Whips & Couplers ......................................................................................................................................... No
Weight ...................................................................................................................................................13 lbs / 5.9 kg
Overall Length..............................................................................................................................20 inches / 50.8 cm
Overall Width................................................................................................................................7.25 inches / 18 cm
16 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
CT06 PARTS ILLUSTRATION
CT06 User Manual ◄ 17
Download from Www.Somanuals.com. All Manuals Search And Download.
CT06 PARTS LIST
ITEM PART
ITEM PART
NO.
NO.
QTY DESCRIPTION
NO.
NO.
QTY DESCRIPTION
1
00114
00118
00144
07626
09330
00294
00360
00769
00936
01259
01534
01608
01809
01812
04054
04794
67013
07427
16556
18050
21424
22147
38622
39925-1
39939
51182
51183
52534
58439
58440
58441
58442
58500
58520
58521
58522
58523
58525
58594
67259
1
1
12
2
1
1
1
2
2
1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
ROLL PIN
58550
1
SEAL KIT
(■ INDICATES PART IN SEAL KIT)
2
RETAINING RING
HSHCS
3
4
O-RING ■
5
O-RING ■
6
O-RING ■
7
O-RING ■
8
HSHCS
9
ADAPTER
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
O-RING ■
ROLL PIN
STEEL BALL
VALVE SPOOL
VALVE SPOOL SCREW
O-RING ■
O-RING ■
FLIP-TOP CRIMPING HEAD
CAUTION STICKER
SPRING
BACK-UP RING ■
RELIEF VALVE
CAPSCREW
VALVE SLEEVE
COMPRESSION SPRING
VALVE HANDLE
TRIGGER GUARD
TRIGGER
SETSCREW
ADAPTER
RETAINING RING
SLEEVE
OIL TUBE
COMBINED CT06 1650 PSI STICKER
CYLINDER
PISTON
CYLINDER HEAD
T-SEAL ■
PUSH ROD
RETAINER RING
CHECK VALVE ASSY
18 ► CT06 User Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon
503-659-5660 / Fax 503-652-1780
IMPORTANT
To fill out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
Download from Www.Somanuals.com. All Manuals Search And Download.
|