CT04
HYDRAULIC
CRIMPING TOOL
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
58541 10-2014 Ver. 4
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TABLE OF CONTENTS
WARRANTY (SEE BELOW UNDER “IMPORTANT”) ............................................................................................3
SAFETY SYMBOLS...............................................................................................................................................4
SAFETY PRECAUTIONS ......................................................................................................................................5
TOOL STICKERS AND TAGS................................................................................................................................6
HOSE TYPES ........................................................................................................................................................7
HOSE RECOMMENDATIONS...............................................................................................................................8
HTMA REQUIREMENTS .......................................................................................................................................9
OPERATION ........................................................................................................................................................10
SETUP AND TEST............................................................................................................................................10
OPEN CENTER/CLOSED CENTER SETUP....................................................................................................10
DIE INSTALLATION ..........................................................................................................................................10
TOOL PROTECTION & CARE.............................................................................................................................14
TROUBLESHOOTING.........................................................................................................................................15
SPECIFICATIONS................................................................................................................................................16
CT04 ILLUSTRATION..........................................................................................................................................17
CT04 PARTS LIST ...............................................................................................................................................18
IMPORTANT
To fill out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record must be submitted to validate the warranty).
SERVICING: 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.
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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.
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SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always
•
•
Know the location of buried or covered electrical
services before starting work.
comply with the safety precautions given in this manual
and on the stickers and tags attached to the tool and
hose.
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 CT04 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.
CT04 User Manual ◄ 5
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TOOL STICKERS & TAGS
58501
CT04 1650 psi Combined Sticker
DO NOT OPERATE
WITHOUT DIES
07961
Warning 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
READ OPERATION MANUAL AND
SAFETY INSTRUCTIONS FOR THIS
TOOL BEFORE USING IT.
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)
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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)
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HOSE RECOMMENDATIONS
HYDRAULIC CIRCUIT
PRESSURE RETURN
PRESSURE
RETURN
Tool
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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
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OPERATION
PRE-OPERATION
Cylinder
Open-Center (no gap)
Careful inspection of the tool and hydraulic system be-
fore startup is important for safe, reliable operation of the
tool.
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 Handle
Adapter
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
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)
•
Clockwise (CW) to change to open center (clos-
es gap)
5. Check the tool and hydraulic system for proper op-
eration and performance.
4. Tighten the two setscrews.
6. If the equipment does not appear to operate prop-
erly, have it serviced before use.
DIE INSTALLATION
7. Periodically verify the crimping force of the tool. Re-
Each crimping head has two die holders: one station-
ary and one moved by hydraulic flow when the trigger
is squeezed.
fer to Die Load Verification.
SETUP AND TEST
To install dies, follow the instructions below for your
model of crimping head.
•
Never operate the tool without dies. Operating with-
out dies can deform the crimping head (retainer die
yoke or C-frame).
•
•
•
If this happens, the dies cannot be installed and the
crimping head must be replaced.
WARNING
Never install the dies while the hydraulic hoses are
connected to the tool.
Installing dies in the tools with the hydraulic hoses
connected can cause severe personal injury or
equipment damage.
Verify the crimping force before operating the tool.
To prevent accidental start-up, always disconnect the
hoses before installing dies.
OPEN CENTER/CLOSED CENTER
SETUP
1. If the hydraulic hoses are connected:
The CT04 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:
•
•
Turn the hydraulic system control valve OFF.
Disconnect first the hydraulic input (supply)
hose, then the output (return) hose.
TO CHANGE THE CURRENT SETTING:
2. Clean the surfaces of the die holder to remove any
dirt or grease.
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.
3. Select the dies for the task:
•
If the die load has not been verified, select blank
dies and verify die load.
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OPERATION
•
If the die load has been verified, select a set 1. Make sure blank (test) dies are installed in the die
of dies to match the sleeve or connector to be
crimped.
holder. If not, follow the Die Installation instructions
at the beginning of this section.
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.
TO INSTALL DIES ON KEARNEY “O”
STYLE HEAD
1. Loosen the two die retainer screws (items ___ on
the parts illustration).
2. Insert and center the dies.
3. Place the die load tester between the blank (test)
dies.
3. Tighten the die retainer screws to lock the dies in
place.
4. Actuate the tool and read the value shown on the
load tester indicator. The force should be 4.4–5 tons
(4000-4540 kg), depending on the pressure from the
hydraulic power source.
TO INSTALL DIES ON BURNDY “W” STYLE
HEAD
1. Squeeze the release buttons on the side of the C-
head.
a. If the indicated value is low and the system pres-
sure relief valve setting is greater than 1650 psi
(114 bar), adjust the relief valve on the CT to get
the correct die load.
2. Insert and center the die.
3. Release the buttons to hold the die in place
b. If the indicated value is high, adjust the relief
valve on the CT to get the correct die load.
4. Repeat above steps 1 through 3 above using the
release buttons on the piston die holder.
5. When the value is within the acceptable range, turn
the hydraulic system control valve OFF and discon-
nect the hoses from the tool.
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.
6. Follow the Die Installation instructions at the begin-
ning of this section to remove the blank dies and
install the proper crimping dies.
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.
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 5-1.
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.
•
•
Open Center: No gap
Closed Center: Approximately 1/4-inch (6.4-mm)
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.
gap
If the setting is not correct for your hydraulic system, fol-
low the instructions in this section, OC/CC Adjustment,
to make the change.
1. Connect the output hose to the OUT or T port on
the tool.
DIE CHECK
2. Connect the input hose to the IN or P port.
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.
3. Be sure all hose connections are tight.
DIE LOAD VERIFICATION
With blank (test) dies installed, use a die load tester to CHECK POWER SOURCE
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
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.
CT04 User Manual ◄ 11
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OPERATION
The hydraulic fluid temperature should be at least
80 °F/27 °C for this test.
OPERATION
Observe all safety precautions when operating the tool.
Read Safety and Hydraulic System Requirements, be-
fore operating the tool for the first time.
CONNECT HOSES
1. Wipe all hose couplers with a clean, lint-free cloth
before making connections.
CONDUCTOR PREPARATION
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.
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.
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
Be sure not to nick or cut the strands of the conduc-
tor.
couple on the tools “IN” port is the inlet (pressure) 2. Remove any oxide or foreign matter from the ex-
coupler.
posed conductor. A bright, shiny surface is required
for a good connection. Do not wire-brush tin-plated
copper conductors or tinned connectors.
NOTE:
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.
STARTUP
1. Move the hydraulic system control valve to the ON
position.
TOOL RELIEF VALVE ADJUSTMENT
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.
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. Position the tool to make the crimp.
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.
IMPORTANT
1. Perform steps 1 through 5 under Die Load Verifica-
tion.
Failure to center the connector between the dies will
damage the dies and/or die holders.
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:
4. Hook the stationary (C-Head) die on the connector
being crimped to ensure the connector is centered
between the dies.
a. Turn the hydraulic system control valve OFF.
b. Remove the plug from the end of the relief valve,
below the trigger guard.
5. Squeeze the trigger to advance the piston and crimp
the connector.
c. Using a hex wrench, turn the adjusting screw.
Clockwise (CW) to increase pressure or Coun-
terclockwise (CCW) to decrease pressure.
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 re-
quirements. Refer to the fitting manufacturer’s re-
quirements.
d. Replace the plug in the relief valve and retest.
Repeat the adjustment if necessary.
8. Remove the tool by lifting it free of the connector.
12 ► CT04 User Manual
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OPERATION
SHUTDOWN
1. Move the hydraulic system control valve to the OFF
position.
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
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.
Damage to the hydraulic system or compression tool
can result from use with fluid that is too viscous or too
thick.
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.
CT04 User Manual ◄ 13
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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.
•
Always keep critical tool markings, such as warning
stickers and tags legible.
The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling hydrau-
lic tools. Failure to do so may result in damage to
the quick couplers and cause overheating of the hy-
draulic system.
•
•
Do not force a small tool to do the job of a large tool.
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.
•
•
Always store the tool in a clean dry space, safe from
damage or pilferage.
Do not use the tool for applications for which it was
not intended.
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 cir-
cuit 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 mini-
mum 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.
14 ► CT04 User Manual
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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
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
Hoses connected to wrong ports on Connect input (supply) line to IN port.
advances/retracts when trigger is tool.
Connect output (return) line to OUT
squeezed).
port.
Tool under-crimps. Die load less Hydraulic system pressure too low.
Check hydraulic power source for
than 4.4 tons/4000 kg.
correct flow and pressure.
Relief valve set too low.
Increase relief valve pressure.
Dirt or obstruction between dies.
Piston seal worn or damaged.
Remove obstruction. Clean die area.
Contact an authorized Stanley
distributor.
Improper die set for wire and
connector.
Install proper die set.
Tool over-crimps. Die load more Hydraulic system pressure too high. Check hydraulic power source for
than 5 tons/4540 kg.
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 port.
tool.
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.
CT04 User Manual ◄ 15
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SPECIFICATIONS
Capacity ........................................................................................................................................#6 - 4/0 Conductor
Crimping Force.......................................................................................... 4.4 tons @ 1650 psi / 4000 kg @ 114 bar
Pressure Range................................................................................................................................ 1650 psi/114 bar
Flow Range .................................................................................................................................3-9 gpm / 11-34 lpm
Optimum Flow .....................................................................................................................................8 gpm / 30 lpm
Porting............................................................................................................................................................3/8 NPT
Hose Whips & Couplers ......................................................................................................................................... No
Weight ...................................................................................................................................................12 lbs / 5.4 kg
Overall Length..............................................................................................................................20 inches / 50.8 cm
Overall Width...............................................................................................................................3.75 inches / 9.5 cm
16 ► CT04 User Manual
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CT04 ILLUSTRATION
CT04 User Manual ◄ 17
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CT04 PARTS LIST
ITEM
NO.
PART
NO.
ITEM
NO.
PART
NO.
QTY DESCRIPTION
QTY DESCRIPTION
1
00118
00144
07626
09330
00294
00360
00831
00936
01259
01534
01608
01809
01812
07736
16556
18050
20428
20430
20747
21255
21424
22147
38622
39925
39939
51182
51183
52534
58439
58440
58441
58442
58483
1
12
2
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
2
1
1
1
1
1
RETAINING RING
HSHCS
34
35
36
37
38
39
40
41
42
58501
58533
58534
58535
58536
58538
350850
58594
67259
1
1
1
1
1
1
1
1
1
CT04 1650 PSI COMBINED STICKER
2
T-SEAL ■
3
O-RING ■
CYLINDER
4
O-RING ■
PISTON
5
O-RING ■
CYLINDER HEAD
PUSH ROD
6
O-RING ■
7
ROD WIPER■
ADAPTER
O-RING ■
8
RETAINING RING EXTERNAL
CHECK VALVE ASSY
9
O-RING ■
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
ROLL PIN
STEEL BALL
VALVE SPOOL
VALVE SPOOL SCREW
SETSCREW
58549
1
SEAL KIT
(■ INDICATES PART IN SEAL KIT)
SPRING
BACK-UP RING ■
O-RING ■
RETAINING RING EXTERNAL
C FRAME – BROCK
SETSCREW
RELIEF VALVE
CAPSCREW
VALVE SLEEVE
COMPRESSION SPRING
VALVE HANDLE
TRIGGER GUARD
TRIGGER
SETSCREW
ADAPTER
RETAINING RING
SLEEVE
OIL TUBE
O-RING ■
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon
503-659-5660 / Fax 503-652-1780
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