CT10
1650 PSI
HYDRAULIC
CRIMPING TOOLS
Safety, OperatiOn and Maintenance
USer’S ManUaL
© 2011 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
58545 3/2014 Ver. 8
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TABLE OF CONTENTS
SAFETY SYMBOLS ........................................................................................................................................................4
SAFETY PRECAUTIONS................................................................................................................................................5
TOOL STICKERS & TAGS..............................................................................................................................................6
TOOL HOSE INFORMATION..........................................................................................................................................7
HTMA REQUIREMENTS.................................................................................................................................................9
OPERATION..................................................................................................................................................................10
STORAGE.....................................................................................................................................................................13
EQUIPMENT PROTECTION & CARE ..........................................................................................................................14
TROUBLESHOOTING ..................................................................................................................................................15
SPECIFICATIONS.........................................................................................................................................................16
ACCESSORIES.............................................................................................................................................................16
CT10016N PARTS ILLUSTRATION..............................................................................................................................17
CT10016N PARTS LIST................................................................................................................................................18
CT10056DN PARTS ILLUSTRATION ...........................................................................................................................19
CT10056DN PARTS LIST .............................................................................................................................................20
CT10056N PARTS ILLUSTRATION..............................................................................................................................21
CT10056N PARTS LIST................................................................................................................................................22
CT10066AN PARTS ILLUSTRATION............................................................................................................................23
CT10066AN PARTS LIST..............................................................................................................................................24
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 CRIMPING TOOL: This manual contains safety, operation, and routine main-
tenance 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.
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.
3
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SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equip-
ment.
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 situa-
tion which, if not avoided, will 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 safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage or damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
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
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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.
These safety precautions are given for your safety. Review them carefully before operating the tool and before performing
general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific work area and local safety regula-
tions. If so, place the added precautions in the space provided on page 4.
The model CT10 Hydraulic Crimping Tool will provide safe and dependable service if operated in accordance with the
instructions given in this manual. Read and understand 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.
• The operator must start in a work area without bystanders. Flying debris can cause serious injury.
• 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.
• Always wear safety equipment such as goggles, ear and head protection, and safety shoes at all times when operating
the tool. Use gloves and aprons when necessary.
• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.
• 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.
• Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose connec-
tions are tight and are in good condition.
• 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.
• Do not operate a damaged, improperly adjusted, or incompletely assembled tool. Do not carry tool by the hoses.
• Never wear loose clothing that can get entangled in the working parts of the tool.
• Keep all parts of your body away from the tool and maintain proper footing and balance at all times.
• Do not rely exclusively upon the safety devices built into the tool.
• Always be well rested and mentally alert before operating the tool.
• Do not allow other persons to be near the tool when in operation. Keep bystanders and animals out of the work area.
• Keep the handles dry, clean and free of oil.
• When using tools near energized transmission lines, be sure to use only hoses labeled and certified non-conductive.
• Turn off the power unit or move the hydraulic control valve to neutral before setting the tool down.
• Know the location of buried or covered electrical services before starting work.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by au-
thorized and properly trained personnel.
5
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TOOL STICKERS & TAGS
Please refer to the Parts List Illustration for location of stickers.
58499
CT10 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 LABELEDAND CERTIFIED
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 HOSESARE PROPERLY CONNECTED
TO THE TOOL BEFORE PRESSURING SYSTEM. SYSTEM
PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL
“IN” PORT. SYSTEM RETURN HOSE MUST ALWAYS BE
CONNECTED TO TOOL “OUT” PORT. REVERSING CONNEC-
TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN
RESULT IN SEVERE PERSONAL INJURY.
REPLACE DECALS IF THEY BECOME
WORN OR DAMAGED. REPLACEMENTS
ARE AVAILABLE FROM YOUR LOCAL
STANLEY DISTRIBUTOR.
BEFORE USING HOSE LABELED AND CERTIFIED AS NON-
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE
SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT
LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART-
MENT INSTRUCTIONS.
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION
INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL
INJURY.
4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-CEN-
TER HYDRAULIC SYSTEMS. THIS MAY RESULT IN LOSS OF
OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME
SYSTEM AND/OR SEVERE PERSONAL INJURY.
A
DO NOT EXCEED SPECIFIED FLOWAND 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 PROTEC-
TION.
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 COUPLERSAND CONNECTORS DAILY
FOR LEAKS. DO NOT FEEL FOR LEAKS WITH YOUR HANDS.
CONTACT WITHALEAK MAY RESULT IN SEVERE PERSONAL
INJURY.
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
I M P O R T A N T
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
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.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE OPERA-
TION MANUAL.
USE ONLY PARTS AND REPAIR
PROCEDURES APPROVED BY
STANLEY AND DESCRIBED IN THE OPERA-
TION 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
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TOOL HOSE INFORMATION
HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic
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 rein-
forcement, 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 reinforcement, 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) - constucted of thermoplastic or synthetic rubber inner 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 MAYRESULT IN DEATH
OR SERIOUS INJURY.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND
ELECTRIC LINES.
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, 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 FITTING
WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE 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 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.
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 LEAKS ABRASIONS, 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
ELECTRIC 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)
7
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HYDRAULIC CIRCUIT
CONTROL PANEL
PRESSURE
RETURN
RETURN
PRESSURE
TOOL
8
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HTMA / EHTMA REQUIREMENTS
HTMA / EHTMA REQUIREMENTS
HTMA
TOOL TYPE
HYDRAULIC SYSTEM REQUIREMENTS
TYPE I
TYPE II
TYPE RR
9-10.5 gpm
(34-40 lpm)
1500 psi
TYPE III
11-13 gpm
(42-49 lpm)
1500 psi
4-6 gpm
7-9 gpm
Flow Range
(15-23 lpm)
1500 psi
(103 bar)
(26-34 lpm)
1500 psi
(103 bar)
Nominal Operating Pressure
(at the power supply outlet)
(103 bar)
(103 bar)
2100-2250 psi
(145-155 bar)
2100-2250 psi
(145-155 bar)
2200-2300 psi
(152-159 bar)
2100-2250 psi
(145-155 bar)
System relief valve setting
(at the power supply outlet)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
250 psi
(17 bar)
Maximum back pressure
(at tool end of the return hose)
400 ssu*
400 ssu*
400 ssu*
400 ssu*
Measured at a max. fluid viscosity of:
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)
(at min. operating temperature)
Temperature: Sufficient heat rejection
capacity to limit max. fluid temperature to:
(at max. expected ambient temperature)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
140° F
(60° C)
Min. cooling capacity at a temperature
3 hp
5 hp
6 hp
7 hp
difference of between ambient and fluid
temps
(2.24 kW)
40° F
(3.73 kW)
40° F
(5.22 kW)
40° F
(4.47 kW)
40° F
NOTE:
(22° C)
(22° C)
(22° C)
(22° C)
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
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
25 microns
30 gpm
(114 lpm)
Min. full-flow filtration
Sized for flow of at least:
(For cold temp. startup and max.
dirt-holding capacity)
Hydraulic fluid Petroleum based
(premium grade, anti-wear, non-conductive)
Viscosity (at min. and max. operating temps)
100-400 ssu*
100-400 ssu*
(20-82 centistokes)
100-400 ssu*
100-400 ssu*
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
CLASSIFICATION
EHTMA
HYDRAULIC SYSTEM
REQUIREMENTS
C
B
D
Flow Range
3.5-4.3 gpm
(13.5-16.5 lpm) (18-22 lpm)
1870 psi
(129 bar)
4.7-5.8 gpm
7.1-8.7 gpm
(27-33 lpm)
1500 psi
9.5-11.6 gpm
(36-44 lpm)
1500 psi
11.8-14.5 gpm
(45-55 lpm)
1500 psi
Nominal Operating Pressure
(at the power supply outlet)
1500 psi
(103 bar)
(103 bar)
(103 bar)
(103 bar)
System relief valve setting
(at the power supply outlet)
2495 psi
(172 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
2000 psi
(138 bar)
NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements
9
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OPERATION
TO CHANGE THE CURRENT SETTING:
PRE-OPERATION
Careful inspection of the tool and hydraulic system before
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. Operating
the tool without dies can deform the crimping heads. Refer to
Die Installation for instructions.
Trigger Handle
Adapter
2. Connect hoses. Wipe all hose couplers with a clean, lint-
free cloth before making connections. Dirty couplers can
contaminate the hydraulic lines and prevent a good seal at
the connection.
Top View of Tool
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, prevent-
ing complete movement of the adapter. Remove the return
coupling to allow the hydraulic fluid to escape.
3. Check all fasteners for tightness.
4. Check the equipment for oil leaks. If leaks are observed, do
not use the tool; have the equipment serviced before use.
5. Check the tool and hydraulic system for proper operation
and performance.
2. Loosen the 2 setscrews on the cylinder.
3. Turn the adapter until it stops:
6. If the equipment does not appear to operate properly, have
it serviced before use.
• counter clockwise (CCW) to change to closed center
(creates gap)
7. Periodically verify the crimping force of the tool. Refer to
Die Load Verification.
• clockwise (CW) to change to open center (closes gap)
4. Tighten the two setscrews.
SETUP AND TEST
DIE INSTALLATION
Never operate the tool without dies. Operating without dies can
deform the crimping head (retainer die yoke or C-frame).
One die is installed in the crimping head (Retainer Die Yoke
or C-frame) and the other die is installed onto the ram or
die piston assembly, depending on the model. See below to
identify the style of crimping head you have. Refer to the parts
illustrations in this manual for more detailed reference.
If this happens, the dies cannot be installed and the crimping
head must be replaced.
Never install the dies while the hydraulic hoses are connected
to the tool.
Verify the crimping force before operating the tool.
OPEN CENTER/CLOSED CENTER
SETUP
Burndy Y35 & 30 mm Style
Kearney WH3 Style
Retainer Die Yoke
C-Frame
The CT10 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:
Kearney PH2 Style
Stanley Y35 Style
Retainer Die Yoke
C-Frame
10
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OPERATION
To install dies, follow the instructions below for your model
of crimping head.
TO INSTALL DIES ON KEARNEY CRIMPING
HEAD -WH3 STYLE:
1. If the hydraulic hoses are connected:
Install the die to the C-Frame:
• Turn the hydraulic system control valve OFF.
• Disconnect first the hydraulic input (supply) hose, then
the output (return) hose.
1. Loosen the capscrew at the side of the C-frame.
2. Press the stub on the die into the socket.
3. Tighten the capscrew to retain the die .
Install the die to the push rod.
2. Clean the surfaces of the die holder to remove any dirt or
grease.
3. Select the dies for the task:
1. Loosen the capscrew at the side of the push rod.
2. Press the stub on the die into the push rod socket.
3. Tighten the capscrew to retain the die.
• If the die load has not been verified, select blank dies
and verify die load.
• If the die load has been verified, select a set of dies to
match the sleeve or connector to be crimped.
TO INSTALL DIES ON STANLEY OR BURNDY
CRIMPING HEADS - Y35 STYLE
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 couplers and cause
overheating of the hydraulic system.
Install the die to the Retainer Die Yoke:
Before installing the hoses, wipe the fittings and the entire
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.
1. Insert and center the die until it clicks into place.
Install the die to the Die Piston Assembly or Ram:
1. Press the die release pin at the side of the die piston
asembly or ram.
Check the flow indicators (arrows) stamped on the couplers
to ensure oil flows in the proper direction. The female coupler
on the tool is the inlet coupler.
2. Insert and center the die.
3. Release the pin to lock the die in place.
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.
TO INSTALL DIES ON STANLEY OR KEARNEY
CRIMPING HEADS - PH2 STYLE
1. Connect the output hose to the OUT or T port on the tool.
2. Connect the input hose to the IN or P port.
3. Be sure all hose connections are tight.
Install the die to the C-Frame:
1. Loosen the capscrew at the side of the C-frame.
2. Press the stub on the die into the socket.
3. Tighten the capscrew to retain the die.
Install the die to the push rod.
DIE LOAD VERIFICATION
With blank (test) dies installed, use a die load tester to verify
the crimping force in the tool before operating a new crimping
tool, before placing the tool in service after storage or repair
or periodically during normal use
1. Loosen the capscrew at the side of the push rod.
2. Press the stub on the die into the push rod socket.
3. Tighten the capscrew to retain the die.
1. Make sure blank (test) dies are installed in the die holder.
If not, follow the Die Installation instructions at the beginning
of this section.
11
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OPERATION
2. Connect the tool to an appropriate hydraulic power source.
The hydraulic fluid temperature should be at least 80°F/27°C
for this test.
Follow the Hydraulic Hose Connection safety guidelines and
instructions in this section. If possible, use the hydraulic power
source you plan to use for crimping.
CONNECT HOSES
3. Place the die load tester between the blank (test) dies.
1. Wipe all hose couplers with a clean, lint-free cloth before
making connections.
4. Actuate the tool and read the value shown on the load tes-
ter indicator. The force should be 10–12 tons (9072–10,886
kg), depending on the pressure from the hydraulic power
source.
2. Connect hoses from the hdyraulic power source to the tool
fittings or quick disconnects. It is good practice to connect the
return hose first and disconnect it last to minimize or eliminate
trapped pressure within the wrench.
5. If the indicated value is low 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.
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.
If the indicated value is high, adjust the relief valve on the CT
to get the correct die load.
Note:
6. When the value is within the acceptable range, turn the
hydraulic system control valve off and disconnect the hoses
from the tool.
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.
7. Follow the Die Installation instructions at the beginning of
this section to remove the blank dies and install the proper
crimping dies.
OPERATION
OC/CC SETTING
Observe all safety precautions when operating the tool. Read
Safety and Hydraulic System Requirements, before operating
the tool for the first time.
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 5-1.
CONDUCTOR PREPARATION
• open center - no gap
• closed center - approximately ¼-inch (6.4-mm) gap
1. If the conductor is insulated, remove the insulation from
the end of the conductor.
If the setting is not correct for your hydraulic system, follow
the instructions in this section, OC/CC Adjustment, to make
the change.
Use an insulation stripping tool. If a stripping tool is not avail-
able, carefully shave the insulation from the cable.
Be sure not to nick or cut the strands of the conductor.
DIE CHECK
2. Remove any oxide or foreign matter from the exposed
conductor. A bright, shiny surface is required for a good con-
nection. Do not wire-brush tin-plated copper conductors or
tinned connectors.
Make sure the dies installed in the tool match the sleeve or
connector to be crimped. If not, follow the instructions in this
section, Die Installation.
CHECK POWER SOURCE
STARTUP
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.
1. Move the hydraulic system control valve to the ON
position.
12
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OPERATION
2. 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.
STORAGE
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.
3. Position the tool to make the crimp.
IMPORTANT
Failure to center the connector between the dies will
damage the dies and/or die holders.
4. Hook the stationary (retainer die yoke or C-frame) die on the
connector being crimped to ensure the connector is centered
between the dies.
5. Squeeze the trigger to advance the piston and crimp the
connector.
6. Release the trigger to retract the piston.
7. Slide the tool into position for the next crimp. Some sleeves
and connectors have special crimping requirements. Refer to
the fitting manufacturer’s requirements.
8. Remove the tool by lifting it free of the connector.
SHUTDOWN
1. Move the hydraulic system control valve to the off posi-
tion.
2. Disconnect the hydraulic hoses from the tool—first the input
(supply) hose, then the output (return) hose.
3. Insert plugs in the hose ends, couplers or tool ports, as
applicable.
4. Wipe the tool thoroughly with a clean dry cloth.
5. Clean any foreign matter or joint compound from the die
holder surfaces.
COLD WEATHER OPERATION
If the tools is to be used during cold weather, preheat the hy-
draulic fluid at low engine speed. When uysing the normally
recommended fluids, fluid temperature should be at or above
50°F/10°C (400 ssu/82 centistokes) before use.
Damage to the hydraulic system or compression tool can
result from use with fluid that is too viscous or too thick.
13
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EQUIPMENT PROTECTION & CARE
NOTICE
In addition to the Safety
Precautions in this manual,
observe the following for
equipment protection and
care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling
hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating
of the hydraulic system.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN” port.
The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not
reverse circuit flow. This can cause damage to internal seals.
• Always replace hoses, couplings and other parts with replacement parts recommended by Stanley
Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated flow. Refer to Specifications in this manual for correct flow rate.
Rapid failure of the internal seals may result.
• Always keep critical tool markings, such as warning stickers and tags legible.
• Do not force a small tool to do the job of a large tool.
• Keep tool bit sharp for maximum breaker performance. Make sure that tool bits are not chipped or
rounded on the striking end.
• Never operate a chipper without a tool bit or without holding it against the work surface. This puts
excessive strain on the retainer.
• Tool repair should be performed by experienced personnel only.
• Make certain that the recommended relief valves are installed in the pressure side of the system.
• Do not use the tool for applications for which it was not intended.
14
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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 grinder, 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
Hydraulic hoses not connected
properly.
Make sure hoses are connected and the
couplers are tight.
Tool does not operate.
Turn the hydraulic system control valve
ON.
Hydraulic control valve OFF.
Check hydraulic power unit for correct
flow and pressure.
Hydraulic system not functioning.
Couplers or hoses blocked.
Remove obstruction.
Pressure port check valve is installed in Install pressure port check valve in
tool return port.
pressure port.
Tool operates in reverse.
(piston advances/retracts when trigger
is squeezed.)
Connect input (supply) line to IN port.
Connect output (return) line to OUT
port.
Hoses connected to wrong ports on
tool.
Tool under-crimps. Die load less than
10 tons/9072 kg.
Check hydraulic power source for
correct flow and pressure.
Hydraulic system pressure too low.
Relief valve set too low.
Increase relief valve pressure.
Dirt or obstruction between dies.
Remove obstruction. Clean die area.
Contact an authorized Stanley
distributor.
Piston seal worn or damaged.
Improper die set for wire and
connector.
Install proper die set.
Tool over-crimps. Die load more than 12
tons/10,886 kg.
Check hydraulic power source for
correct flow and pressure.
Hydraulic system pressure too high.
Relief valve set too high.
Decrease relief valve pressure.
Connect input (supply) line to IN port.
Connect output (return) line to OUT
port.
Hoses connected to wrong ports on
tool.
Trigger difficult to operate.
If back-pressure is greater than 250
psi/17 bar, clear the return line
obstruction or restriction.
Excessive back-pressure.
Trigger guard bent and binding on spool
in bore.
Repair or replace trigger assembly.
15
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SPECIFICATIONS
Capacity (depending on model) .........................................................................500 MCM Copper to 1033 MCM Aluminum
Crimping Force.................................................................................................... 12 tons @ 1650 psi / 10,886 kg @ 114 bar
Pressure Range ...........................................................................................................................1650-2500 psi/114-172 bar
Flow Range ..............................................................................................................................................3-9 gpm/11-34 lpm
Optimum Flow ................................................................................................................................................ 8 gpm / 30 lpm
Porting.......................................................................................................................................................................3/8 NPT
Hose Whips & Couplers.....................................................................................................................................................No
Weight ...............................................................................................................................................................17 lbs / 7.7 kg
Overall Length.........................................................................................................................................22 inches / 56.9 cm
Overall Width................................................................................................................................................7 inches / 18 cm
16
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CT10016N PARTS ILLUSTRATION
38A
15A
14
20A
17
19A
THIS IS A OLDER MODEL CYLINDER HEAD AND
C-FRAME. THE CYLINDER HEAD (ITEM 38A) HAS A
THREAD DIAMETER OF 2-3/16 AND A THREAD
LENGTH OF 1.100. CHECK THESE DIMENSIONS ON
YOUR CYLINDER HEAD BEFORE ORDERING PARTS
TO MAKE SURE YOU ARE ORDERING THE CORRECT
PARTS.
39
THIS IS A NEWER MODEL CYLINDER HEAD AND
C-FRAME. THE CYLINDER HEAD (ITEM 38) HAS A
THREAD DIAMETER OF M60X1.5 (METRIC) AND A
THREAD LENGTH OF 1.100. CHECK THESE
DIMENSIONS ON YOUR CYLINDER HEAD BEFORE
ORDERING PARTS TO MAKE SURE YOU ARE
ORDERING THE CORRECT PARTS.
37
41
9
15
6
20
14
17
30
35
44
40
18
19
16
13
12
42
7
43
36
3
38
5
27
34
3
26
25
21
32
2
33
22
8
10
23
31
1
4
29
11
28
24
17
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CT10016N PARTS LIST
Item
Part No. Qty Description
Item
Part No. Qty Description
No.
No.
36
37
38
38A
39
40
41
42
43
44
58485
58493
67276
58494
58499
58583
58594
67277
67259
67280
1
1
1
1
1
1
1
1
1
1
O-Ring
1
00118
00144
07626
09330
00294
00360
00936
01259
01521
01534
01608
01809
01812
03014
67281
03870
06324
06326
06332
66588
06333
67279
07438
16556
18050
21424
22147
38622
39925
39939
51182
51183
52534
58439
58440
58441
58442
58480
1
Retaining Ring
Cylinder
2
14 HSHCS
Cylinder Head *
Cylinder Head **
Sticker
3
2
1
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
O-Ring
4
O-Ring
5
O-Ring
T-Seal
6
O-Ring
Retaining Ring
Set Screw *
Check Valve Assy *
Key
7
Adapter
8
O-Ring
9
HSHCS
10
11
12
13
14
15
15A
16
17
18
19
19A
20
20A
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Roll Pin
Steel Ball
58551
1
SEAL KIT
Valve Spool
Valve Spool Screw
Washer †
NOTE 1: Items 38 and 38A differ in several ways and are
not interchangeable. The following information explains the
differences.
Capscrew *
Capscrew **
Die Piston Assy.
Washer †
Item 38A contains 2-3/16-16UN threads and cannot be
used with items 19 that contain M60 metric threads. Like-
wise, items 19 and 38 that contain M60 metric threads can-
not be used with items 19A and 38A that contain 2-3/16-
16UN threads.
O-Ring
C-Frame *
Retainer Die Yoke **
Set Screw Kit *
Key & Capscrew Kit **
Spring
Item 38 and 38A can be identified by measuring the length
of the threads (see figure below). The length of threads for
item 38 is 1.100 inches. For item 38A the length is 1.100
inches. Due to both of these cylinder heads having the
same thread length, you will need to measure the thread
diameter to know wheather you have a M60 metric thread
or a 2-3/16 16UN thread.
Back-Up Ring
Relief Valve
Capscrew
Valve Sleeve
Compression Spring
Valve Handle
Trigger Guard
Trigger
Setscrew
Adapter
Retaining Ring
Sleeve
To determine which model you have, measure the thread
length and diameter on the cylinder head.
Oil Tube
Piston
CT10016N
Cyl Head P/N
Thread Length
1.100
Thread Diameter
M60x1.5
67276 (item 38)
58494 (item-38A)
1.100
2-3/16
18
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CT10056DN & DH PARTS ILLUSTRATION
üüüüüüüüüüüüüüüüüüüü
C-FRAME. THE CYLINDER HEAD (ITEM 38A) HAS A
THREAD DIAMETER OF 2-1/8 AND A THREAD
LENGTH OF 1.650. CHECK THESE DIMENSIONS ON
üüüüüüüüüüüüüüüüüüüü
TO MAKE SURE YOU ARE ORDERING THE CORRECT
PARTS.
16
22A
24A
23A
38A
25A
üüüüüüüüüüüüüüüüüüüü
38
C-FRAME. THE CYLINDER HEAD (ITEM 38) HAS A
THREAD DIAMETER OF M60X1.5 (METRIC) AND A
THREAD LENGTH OF 1.100. CHECK THESE
DIMENSIONS ON YOUR CYLINDER HEAD BEFORE
ORDERING PARTS TO MAKE SURE YOU ARE
ORDERING THE CORRECT PARTS.
SEE NOTE #1
IN PARTS LIST
22
24
46
45
44
23
25
40
üüüüüüüüüüüüüüüüüüüü
C-FRAME. THE CYLINDER HEAD (ITEM 48) HAS A
THREAD DIAMETER OF M60X1.5 (METRIC) AND A
THREAD LENGTH OF 1.750. CHECK THESE
DIMENSIONS ON YOUR CYLINDER HEAD BEFORE
ORDERING PARTS TO MAKE SURE YOU ARE
ORDERING THE CORRECT PARTS.
37
46
45
22 44
24
9
42
6
23
25
36
31
41
14
21
13
25
12
7
39
43
48
3
SEE NOTE #1
IN PARTS LIST
5
35
47
15
27
28
3
26
33
17
34
18
8
10
2
32
19
1
4
30
11
29
20
19
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CT10056DN & DH PARTS LIST
Item
No.
Part No.
Qty
Description
Cylinder
Item
No.
Part No.
Qty
Description
37
38
58481
67276
1
1
1
00118
00144
07626
09330
00294
00360
00936
01259
01521
01534
01608
01809
01812
06332
08337
09906
16556
18050
21424
22147
24446
67264
25513
67278
25833
68272
25834
67282
25837
38622
39925
39939
51182
51183
52534
58439
58440
58441
58442
58480
1
14
2
1
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
Retaining Ring
HSHCS
Cylinder Head *
(See Note 1)
2
3
O-Ring
38A
39
40
41
42
43
44
45
46
47
48
58482
58485
58499
58583
58594
67259
06326
03014
67281
68318
68317
58551
1
1
1
1
1
1
1
1
1
1
1
1
Cylinder Head **
O-Ring
4
O-Ring
5
O-Ring
Sticker
6
O-Ring
T-Seal
7
Adapter
Retaining Ring
Check Valve Assy *
Washer *
8
O-Ring
9
HSHCS
10
11
12
13
14
15
16
17
18
19
20
21
22
22A
23
23A
24
24A
25
25A
26
27
28
29
30
31
32
33
34
35
36
Roll Pin
Washer *
Steel Ball
Capscrew *
Valve Spool
Valve Spool Screw
O-Ring
Jam Nut * (See Note 1)
Cylinder Head * (See Note 1)
SEAL KIT
Ball Detent
Jam Nut
NOTE 1: Items 38, 38A and 48 differ in several ways and
are not interchangeable. The following information explains
the differences.
Spring
Back-Up Ring
Relief Valve
Capscrew
Push Rod
C-Frame *
C-Frame **
Ball Plunger *
Ball Plunger **
Setscrew *
Setscrew **
Slotted Capscrew *
Slotted Capscrew **
Valve Sleeve
Compression Spring
Valve Handle
Trigger Guard
Trigger
Item 38A contains 2-1/8-16UN threads and cannot be used
with items 22 and 48/47 that contain M60 metric threads.
Likewise, items 22, 38 and 48 that contain M60 metric
threads cannot be used with items 16, 22A and 38A that
contain 2-1/8-16UN threads.
Item 48 is used with a jam nut (item 47) whereas item 38
does not use a jam nut. Item 38 and 48 can be identified
by measuring the length of the threads (see figure below).
The length of threads for item 38 is 1.100 inches. For item
48 the length is 1.750 inches.
Setscrew
To determine which model you have, measure the thread
length and diameter on the cylinder head.
Adapter
Retaining Ring
Sleeve
CT10016N
Cyl Head P/N
Thread Length
1.100
Thread Diameter
M60x1.5 (metric)
2-1/8 in.
Oil Tube
67276 (item 38)
58482 (item-38A)
68317 (item 48)
Piston
1.650
1.750
M60x1.5 (metric)
20
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CT10056N PARTS ILLUSTRATION
21
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CT10056N PARTS LIST
Item
No.
Part
No.
Qty Description
Item
No.
Part
No.
Qty Description
1
00118
00144
07626
09330
00294
00360
00936
01259
01397
01521
01534
01607
01608
01809
01812
04795
08330
08334
08335
08336
09906
12430
16556
18050
21424
22147
34133
38622
39925
39939
51182
51183
52534
58439
58440
58441
58442
58480
58485
58493
1
Retaining Ring
41
42
43
44
45
58499
58513
58583
58594
67259
1
1
1
1
1
Sticker
2
14 HSHCS
Cylinder Head
T-Seal
3
2
1
1
1
2
1
1
2
1
1
4
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
O-Ring
4
O-Ring
Retaining Ring
Check Valve Assy*
5
O-Ring
6
O-Ring
7
Adapter
58551
1
SEAL KIT
8
O-Ring
9
Setscrew
HSHCS
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
Roll Pin
Setscrew
Steel Ball
Valve Spool
Valve Spool Screw
O-Ring
Push Rod
C-Frame
Pin - Kearney
Plug - Kearney
Jam Nut
Capscrew
Spring
Back-Up Ring
Relief Valve
Capscrew
Spring Plunger
Valve Sleeve
Compression Spring
Valve Handle
Trigger Guard
Trigger
Setscrew
Adapter
Retaining Ring
Sleeve
Oil Tube
Piston
O-Ring
Cylinder
22
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CT10066AN PARTS ILLUSTRATION
17
20A
41A
3A
15
18
43
45
This is an older model cylinder head and
c-frame. The cylinder head (item 41A) has
a threaded diameter of 2-3/8 and a thread
length of 1.500. Check these dimensions on
your cylinder head before ordering parts to
make sure you are ordering correct parts.
44
46
47
40
This is a newer model cylinder head and
c-frame. The cylinder head (item 41) has
a threaded diameter of M60x1.5 (metric)
and a thread length of 1.100. Check these
dimensions on your cylinder head before
ordering parts to make sure you are order-
ing correct parts.
41
38
48
10
7
37
49
42
50
3
20
15
18
1
6
21
14
2
51
13
22
8
4
6
36
52
23
28
4
29
11
27
19
34
39
35
24
9
25
33
31
1
5
12
30
26
23
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CT10066AN PARTS LIST
Item Part No.
No.
Qty
Description
Item Part No.
No.
Qty
Description
37
38
39
40
41
41A
42
43
44
45
46
47
48
49
50
51
52
58480
58481
58485
48499
67276
58515
58583
19504
19505
19509
19510
19511
58594
67279
67280
67277
67259
1
1
1
1
1
1
1
1
1
1
1
1
1
Piston
1
2
00118
00144
67281
00154
07626
09330
00294
00360
00936
01259
01521
01534
01608
01809
01812
04420
06332
07438
10123
16556
66591
17589
17678
17680
17681
18050
21424
22147
38622
39925
39939
51182
51183
52534
58439
58440
58441
58442
1
14
1
1
2
1
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
Retaining Ring
HSHCS
Cylinder
O-Ring
3
Capscrew *
HSHCS **
Sticker
3A
4
Cylinder Head *
Cylinder Head **
T-Seal
O-Ring
5
O-Ring
6
O-Ring
Die Retainer Button **
Die Retainer Pin **
Grooved Pin Type B **
Compresion Coil Spring **
Setscrew **
7
O-Ring
8
Adapter
9
O-Ring
10
11
12
13
14
15
16
17
18
19
20
20A
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
HSHCS
Roll Pin
Retaining Ring
Setscrew *
Steel Ball
1
1
1
1
Valve Spool
Valve Spool Screw
Lockwasher †
O-Ring
Guide Plate *
Setscrew *
Check Valve Assy *
Key & Capscrew Kit **
Stopper †
58551
1
SEAL KIT
Spring
C-Frame *
Retainer Die Yoke Assy. **
Push Rod
Before ordering parts for the cylinder head or c-frame parts,
contact a Stanley hydraulic tools customer service represen-
tative to ensure the correct parts are being ordered.
Modified Ram Assy.
Spring Pin
Back-Up Ring
Relief Valve
Capscrew
To determine which model you have, measure the thread
length and diameter on the cylinder head.
Valve Sleeve
Compression Spring
Valve Handle
Trigger Guard
Trigger
CT10066AN
Cyl Head P/N
Thread Length
1.100
Thread Diameter
M60x1.5
67276 (item 41)
58515 (item-41A)
1.500
2-3/8 in.
Setscrew
Adapter
Retaining Ring
Sleeve
Oil Tube
24
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Stanely Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon
503-659-5660 / Fax 503-652-1780
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