CT06 User Manual - Stanley Hydraulic Tools
Contents
1. N gt oO D 37 38 39 40 1 fons fji 2 fons ji 3 om 12 4 os 2 5 osso 1 _ 6 mn 1 7 oosso 1 _ s oore 2 9 jo 2 _ 10 os 1 M ossa 12 oros a 3 oros 1 _ 14 fos fji s ossa _ omg az eos 1 te oz fi 9 iesse f1 20 18050 fi 21 2424 fi 2 2 23 so 1 24 399251 1 25 so 1 _ 2 smez 1 2 snes 1 28 52 2 29 seo 1 _ so seo 1 3t ssm fi 32 sss 33 seo 1 _ 34 ss2o 1 35 ses2i 1 ss sss22 1 37 ses 1 se 58525 1 39 sesos 1 40 e72s9 1 18 gt CT06 User Manual STAN LEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com2. REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL IMPORTANT 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 TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 Shown smaller then actual size STANLEY 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 co
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4. IMPORTANT age 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 ALP 4 gt CT06 User Manual STAN LEY 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 Re view them carefully before operating the tool and before performing general maintenance or repairs 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 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 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 D
5. 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 Do not operate a damaged improperly adjusted or incompletely assembled tool Do not carry tool by the hoses Keep the handles dry clean and free of oil Ensure adequate lighting for the area where the tool is being used Use proper lifting techniques when handling the tool Do not overreach Maintain secure footing and balance at all times 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 To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained per sonnel CT06 User Manual 5 Milwaukie OR 97267 11 34 pm6 9 gpm Modai Ne CT06 198 bav2000 psi Stanley Hydraulic Tools STANLEY sss Read owners manual and make sure that you have been properly trained in the correc
6. low the instructions in this section OC CC Adjustment to make the change CHECK POWER SOURCE 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 Ipm within a pressure range of 1650 2000 psi 114 140 bar The hydraulic fluid temperature should be at least 80 F 27 C for this test CONNECT HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections 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 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 CT06 User Manual lt 11 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 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 The crimping tools relief valve is located below the trig ger guard
7. CT06 HYDRAULIC CRIMPING TOOL USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 58543 10 2014 Ver 4 SAFETY SYMBOLS cnn a 4 SAFETY PRECAUTIONS si at A ia dde isaac 5 TOOL STICKER amp TAC Sicuani s 6 HOSE TYPES assets s a a a E RA A AAA TA EE 7 HOSERECOMMENDATIONS ota u la n uqu aqa maaa A a 8 FIGURE 1 TYPICAL HOSE CONNECTIONS 22 2 eating 8 IMA REQUIREMENTS soci uu u ai ai idas 9 OPERATION iii A Ft A da 10 FIGURE 2 OC CE SETUP ast Ma saku asian satu a aayqa aaa aha qa gaa 10 TOOL PROTECTION amp CARB uu uu is 5 A dulu GR iE a EAA a Ea aaa NG 14 TROUBLESHOOTING ISI L u S aca casted castaway een la aay 15 SPECIFICATIONS uu uy u uama u G td A A at 16 CTOGIPARTS ILLUSTRATION sista 17 CTOG PARTS E ST uuu a ee A A aii 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 SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AN
8. CTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY 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 CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS 2 A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE A LEAK OR BURST 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 IMPORTANT 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 TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE DANGER D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE 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
9. D 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 STAN LEY CT06 User Manual lt 3 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 A DANGER 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 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 This signal word indicates a situation which if not avoided will result in damage NOTICE to the equipment This signal word indicates a situation which if not avoided may result in dam
10. F 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 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm m m pm dm nm dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti wear non conductive 20 82 centistokes 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 EHTMA CLASSIFICATION HYDRAULIC SYSTEM kusi A A A A Flow Range 3 5 4 3 gpm 4 7 5 8 gom 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 Ipm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page
11. LU e o inss id yoeq ainssald ul uin i d y 0 papuajul ase suo epu uuuuo5 1 esau uud nuiuu Jed say wud lnuluu sd suojje uo paseq syjBua sou SNONEA 10 si uuelp esoy LUNUUIUIUU p pu wwovs smoys jyBu ey o yeyo SUL SUONEPUSWWOISN 9SOH AN9A19 9NEIP H 0 loo L STANLEY 8 CT06 User Manual HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE II TYPERR TYPEII Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 Ipm 26 34 Ipm 34 40 Ipm 42 49 Ipm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 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 Sufficient heat rejection 140 F 140 F 140 F 140 F capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3hp 5 hp 6 hp 7hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40
12. NY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY 6 AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES 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 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 DO NOT REMOVE THIS TAG Svl SIHL 3INAOMN3Y LON OG Ce SEE OTHER SIDE h s EEE SEE OTHER SIDE Ww Y SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY CT06 User Manual 7 suono uuoo asoH IB9Id alnBiy E RETURN Tool z lt lt lt MOT x l 5 o NYNLIM x Oo 3 3 G E MOT gt gt gt E E gt _ 7 m x JYNSSIYA a GLL 0092 uny GZ L 0
13. SE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH AGE TO COUPEINGS IE ANY OF THESE CONDITIONS ENST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE SAFETY DEPARTMENT INSTRUCTIONS AFTER EACH USE STORE IN A CLEAN DRY AREA FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND DO NOT REMOVE THIS TAG Svl SIHL JAON3Y LON OG SEE OTHER SIDE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR A
14. The relief valve on the hydraulic system is totally separate and has a different function 1 Perform steps 1 through 5 under Die Load Verifica tion 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 a Turn the hydraulic system control valve OFF b Remove the plug from the end of the relief valve below the trigger guard c Using a hex wrench turn the adjusting screw Clockwise CW to increase pressure or Coun terclockwise CCW to decrease pressure d Replace the plug in the relief valve and retest Repeat the adjustment if necessary 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 CONDUCTOR PREPARATION 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 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 STARTUP 1 Clean the nibs on the t
15. c 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 Make sure hoses are connected properly and the couplers are tight Hydraulic control valve OFF Turn the hydraulic system control valve ON Hydraulic system not functioning Check hydraulic power unit for correct flow and pressure Couplers or hoses blocked Remove obstruction Pressure port check valve is Install pressure port check valve in installed in tool return port pressure port Tool operates in reverse piston Hoses connected to wrong ports on Connect input supply line to IN advances retracts when trigger is tool port Connect output return line to squeezed OUT port Tool under crimps Die load less Hydraulic system pressure too low Check hydraulic power source for than 6 tons 5443 kg 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 Install proper die set connector Tool over crimps Die load more Hydraulic system pressure too high Check hydraulic power source for than 6 tons 5443 kg correct flow and pressure Relief valve set too high Decrease relief valve pre
16. for tool specific requirements STAN LEY CT06 User Manual 9 PRE OPERATION 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 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 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 5 Check the tool and hydraulic system for proper op eration and performance 6 If the equipment does not appear to operate prop erly have it serviced before use 7 Periodically verify the crimping force of the tool Re fer to Die Load Verification SETUP AND TEST Verify the crimping force before operating the tool 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 TO CHANGE THE CURRENT SETTING 1 Remove the hydraulic hose coup
17. ling 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 10 gt CT06 User Manual Cylinder Open Center no gap WITHOUT DIES DO NOT OPERATE New Top View of Tool Trigger Handle Figure 2 OC CC Setup 2 Loosen the 2 setscrews on the cylinder 3 Turn the adapter until it stops Counter clockwise CCW to change to closed center creates gap Clockwise CW to change to open center clos es gap 4 Tighten the two setscrews LATCH NIB REPLACEMENT The CT06 Hydraulic Crimping Tool has two main com ponents in the Anderson compression head The cam yoke assembly forms the base of the com pression head It functions as a movable piston die to provide the crimping force 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 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 STANLEY 1 Ifthe hydraulic hoses are connected Turn the hydraulic
18. n the tool is the inlet coupler 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 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 DIE LOAD VERIFICATION 1 Use Anderson test slugs to verify the crimping force in the tool STANLEY 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 3 Position the test slug within the nibs Actuate the tool to squeeze the test slug 5 Release the test slug and then measure it 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 6 When the value is within the acceptable range turn the hydraulic system control valve OFF and discon nect the hoses from the tool 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 Open Center No gap e Closed Center Approximately 1 4 inch 6 4 mm gap If the setting is not correct for your hydraulic system fol
19. nductors 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 DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY 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 ELECTRIC LINES HANDLE AND ROUTE HO
20. o 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 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 Never wear loose clothing or unrestrained long hair 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 Donotrely exclusively upon the safety devices built into the tool 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 STANLEY 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 Always operate the tool within its rated capacity Do not use the tool for applications for which it was not designed 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 be
21. ool 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 3 Move the hydraulic system control valve to the ON position The crimping force between the dies in the tool head can cause severe personal injury Keep hands away from the die area when operating the tool 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 5 Position the tool as follows a Connector sleeves 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 Make sure the connector sleeve is carefully centered between all four nibs in the tool b H Frame Connectors 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 6 Squeeze the trigger to crimp the connector STANLEY COLD WEATHER OPERATION IMPORTANT Release the trigger to retract the nibs Repeat the crimp as required After the last crimp make sure the nibs in the crimp ing head are fully retracted 10 Pull out the latch pin and rotate the latch away from
22. ssure 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 Repair or replace trigger assembly spool in bore STAN LEY CT06 User Manual 15 Capacidad 10 750 MCM Aluminum and 10 500 MCM Copper CrIMPpINgQUFOICE sonas n En a a 6 tons 1650 psi 5443 kg 114 bar Pressure Range uu u A a A Eee 1650 psi 114 bar FIOW Bange yb A er ai AS ac 3 9 gpm 11 34 Ipm Optimum FIOW cis 8 gpm 30 Ipm PONN 2 sa A EA I O 8 SAE Hose Whips amp Couplers Ra RN A AR RN A AR GR No WeB csn n a S nern 13 Ibs 5 9 kg Overall Len sica 20 inches 50 8 cm Overall Widih NN 7 25 inches 18 cm 16 gt CT06 User Manual STAN LEY STAN LEY CT06 User Manual 17 ITEM NO 1 PART NO 00114 00118 00144 07626 09330 00294 00360 00769 00936 01259 01534 12 01608 13 01809 14 01812 15 04054 16 04794 17 67013 18 07427 19 16556 0 18050 1 21424 2 22147 23 38622 24 39925 1 25 39939 26 51182 27 51183 8 52534 29 58439 58440 58441 58442 58500 58520 58521 58522 58523 58525 58594 67259 ITEM PART QTY DESCRIPTION NO NO QTY DESCRIPTION ROLL PIN 58550 1 SEAL KIT RETAINING RING m INDICATES PART IN SEAL KIT 2 s 2 forna SQ 11 N I N N
23. system control valve OFF e 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 Pull the pin out to release the latch Rotate the latch away from the head to provide ac cess to the nib nest die 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 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 Press the nib nest die firmly until it locks into place Drive the roll pin into the center of the latch to retain the nib nest die 10 Close the latch Insert the latch pin 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 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 Check the flow indicators arrows stamped on the cou plers to ensure oil flows in the proper direction The fe male coupler o
24. t procedures required for work On or around electric lines Failure to use hydraulic hose labeled and certified as non conductive when using hydraulic tools on or near electric lines may resultin death or serious injury oc cc Use closed center tool on closed center systems Set tool for proper system before use For use on open center and closed center hydraulic systems Do not exceed specified flow or pressure Correctly connect hoses to tool IN and OUT Improper handling use or Use open center tool on open center systems maintenance can result in a leak or burst Contact at a leak or burst can cause oil injection to the body Failure to JA gt gt gt 1e oran can resu in serious personal nuy CAUTION Stay clear of dies and tool heads Failure to observe the precautions can result in serious personal injury 58500 CT06 1650 PSI Combined Sticker NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT ALL TIMES REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR 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 6 gt CT06 User Manual DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER TIFIED AS NON CONDU
25. the crimping head 11 Remove the tool by lifting it clear of the cable 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 Insertplugs 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 STANLEY Use an oil with the recommended specification from the HTMA Requirement table Using oil that is too viscous thick can damage the hydraulic system Ifthe 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 CT06 User Manual 13 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 The hydraulic circuit control valve must be in the OFF position when coupling or unco
26. upling hy draulic tools Failure to do so may result in damage to the quick couplers and cause overheating ofthe 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 discon nect is connected to the opposite port Do not re verse 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 mini mum working pressure rating of 2500 psi 172 bar 14 CT06 User Manual 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 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 STANLEY 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 hydrauli
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