CT04 User Manual - Stanley Hydraulic Tools
Contents
1. z lt lt lt MO14 D P E l e u d X NYN L38 x 9 l S G g MOT gt gt gt 2 Hal u x JYNSSIYA a GIL 0092 uny GZ L 0 8 001 92 09 67 91 EL GIL 0052 einsseid 6l pe GIL 0052 unay SL vIe g o dn gz 0 dn 09 67 QL L GIL 0052 eunsseid QL 8 5 GIL 0052 unay 792 L 09 0 002 001 6r 8E L OL GIL 0052 einsseid 6l pe GIL 0052 uInoy EI vie 08 91 OOL LS 6v 8 L OL GIL 0052 einsseid QL 8 9 GIL 0052 yjog QL 8 9 GL 0 dn Og o dn 6v 8 L OL GIL 0052 uInoy SL vIe I 06 0 00 001 Op 6l S OL S GIL 0052 einsseid QL 8 5 GIL 0052 40g QL 8 5 08 91 OOL LS Or 6L GOL S GIL 0052 yjog el ZIL GL 0 dn Og o dn Op 6l SOLS GIL 0052 yjog el ZIL 08 92 001 92 EZ or GIL 0052 yjog OL 8 S ol dn Gz 0 dn CC or SYOLINANOI 1IV9IN LOATS YVAN ISN LON OQ plejg 19014 10 pIe1g M SSOH BAONPUOD SSL 0922 40g OL 8 e o dn OL 0 dn Gel 6 p syon L jang Ann 404 plesg 19014 SOH SAHINPUOI UON Baus uva ISd uunoyjssaud WIN HONI SU3L3N 1334 Wd Nd9 s nssauld BUIYJOM UNA 3sn 19 9Uu1e1q 2pISUI sy 5us7 9soH MOI IO PRESSURE LIST IYS Aq uuoy yas se suoneoyioads p x 10 j9au Jsnw sou 91 ne p y IIV BUNSS anjea jonas wajs s 91ne1pAU uinuu xew ay o enba a nssaud Bulyjom LUNUUIUIUU pajel e jses je aney Jsnw aesoy 2UDEIDAU suonyeo dde Jayjo Aue 10 pasn aq jou pjnoys pue slu uu uinb i Bunesado joo sjoo aneJp H aju2. 400 ssu 82 centistokes 140 F 60 C 140 F 60 C 140 F 60 C 140 F 60 C 3 hp 2 24 kW 40 F 22 C 5 hp 3 73 kW 40 F 22 C 6 hp 5 22 kW 40 F 22 C 7 hp 4 47 kW 40 F 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 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 NOTE 25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm 114 Ipm 114 Ipm 114 Ipm 114 Ipm 100 400 ssu 100 400 ssu 20 82 centistokes 100 400 ssu 100 400 ssu 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 HYDRAULIC SYSTEM REQUIREMENTS Flow Range Nominal Operating Pressure at the power supply outlet System relief valve setting at the power supply outlet CLASSIFICATION 3 5 4 3 gpm 4 7 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22
3. 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 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 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 TO CHANGE THE CURRENT SETTING 1 Remove the hydraulic hose coupling from the return port on the tool if one is installed When making the change from CC to OC hydraulic fluid may be trapped in the tool preventing complete movement of the adapter Remove the return coupling to allow the hydraulic fluid to escape 10 gt CT04 User Manual Cylinder Open Center no gap WITHOUT DIES DO NOT OPERATE Trigger Handle Nae Top View of Tool Loosen the 2 setscrews on the cylinder 3 Turn the adapter until it stops e 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 DIE INSTALLATION Each crimping head has two die holders one station ary and one moved by hydraulic flow when the trigger is squeezed To install dies
4. may result in dam 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 DANGER 2 WARNING Gegen CAUTION NOTICE IMPORTANT 4 gt CT04 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 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 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 a
5. 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 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 POSSIBL
6. 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 a Ifthe 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 b If the indicated value is high adjust the relief valve on the CT to get the correct die load 5 When the value is within the acceptable range turn the hydraulic system control valve OFF and discon nect the hoses from the tool 6 Follow the Die Installation instructions at the begin ning of this section to remove the blank dies and install the proper crimping dies 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 Open Center No gap Closed Center Approximately 1 4 inch 6 4 mm 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 DIE CHECK 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 Using a calibrated flowmeter and pressure gauge check the hydraulic power source at the tool s input port M
7. Naef Road Read owners manual and make sure that you have been property trained in the correct 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 result in death or serious injury ocicc For use on open center and closed center hydraulic systems Use open center tool on open center systems Use closed center tool an closed center systems Set tool for proper system before use Do not exceed specified flow or pressure Correctly connect hoses to tool IN and OUT Improper handling use or maintenance can result in a leak or burst Contact at a leak or burst can cause oll injection to the body Failure to observe the precautions can result in serious personal injury CAUTION Stay clear of dies and tool heads Failure to observe the precautions can result in serious personal injury 58501 CT04 1650 psi Combined Sticker DO NOT OPERATE WITHOUT DIES 07961 Warning 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 reta
8. 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 STAN LEY CT04 User Manual 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
9. follow the instructions below for your model of crimping head 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 1 If the hydraulic hoses are connected Turn the hydraulic system control valve OFF Disconnect first the hydraulic input supply hose then the output return hose 2 Clean the surfaces of the die holder to remove any dirt or grease 3 Select the dies for the task Ifthe die load has not been verified select blank dies and verify die load STANLEY Ifthe die load has been verified select a set of dies to match the sleeve or connector to be crimped TO INSTALL DIES ON KEARNEY O STYLE HEAD 1 Loosen the two die retainer screws items on the parts illustration Insert and center the dies 3 Tighten the die retainer screws to lock the dies in place TO INSTALL DIES ON BURNDY W STYLE HEAD 1 Squeeze the release buttons on the side of the C head Insert and center the die Release the buttons to hold the die in place Repeat above steps 1 through 3 above using the release buttons on the piston die holder 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
10. 83 ram 2 3 _ Be 5 i z _ EX _ 10 CN 12 KE 4 KE i 17 HE EES 2 21 _ 2 _ 2 _ 24 2 2 2 _ 28 2 _ 3 3 32 33 18 gt CT04 User Manual NEN KARI QTY DESCRIPTION a fasor seess Em ES es SR ER 58549 1 SEAL KIT m INDICATES PART IN SEAL KIT STANLEY STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
11. CT04 HYDRAULIC CRIMPING TOOL USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 58541 10 2014 Ver 4 WARRANTY SEE BELOW UNDER IMPORTANT isis aia a aid a 3 SAFETY SYMBOLS aa a Seege ed SNE SEENEN dee 4 SAFETY PR CAUTIONS coord a geseet 5 TOOL STICKERS AND TAGS u a ee EES 6 HOSE TYPES cui dos 7 HOSE RECOMMENDATIONS A quqawa qapiq RAEE EA EANA EAE AAAA aiad 8 HTMAREQUIREMENISu N u n aa A aD aa na a A nanas tee 9 OPERATION uu en in ishu A ged 10 SETUP AND TEST esas t ae A 10 OPEN CENTER CLOSED CENTER SETUP a it js a SA aaia adasa 10 DIE INSTALLATION aaa aa RA a a eege 10 TOOL PROTECTION CARE aid a a a dat tra 14 TROUBLESHOOTING erinan a a a 15 SPECIFICATIONS EE 16 CTO ILLUS TRATION ss aaa ai A a 17 CTOF PARTS LIST sea ee a a ta 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
12. E 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 HOSE 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 Ovl 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 USI
13. NG 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 ANY 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 9OVIL SIHL SAOWSY LON OG Ce SEE OTHER SIDE h s TEE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY CT04 User Manual 7 suono uuoo SSOH e01d an4 RETURN STANLEY Tool
14. ONAL 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 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
15. ake 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 CT04 User Manual 11 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 Itis 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 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 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 r
16. an dry place STAN LEY CT04 User Manual lt 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 uncoupling hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic 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 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 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 syste
17. ange 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 12 gt CT04 User Manual 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 STARTUP 1 Move the hydraulic system control valve to the ON position 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 3 Position the tool to make the crimp IMPORTANT Failure to center the connector between t
18. ejs uo paseq juo suoneoidde 100 olnespAy 10 pasn aq 0 papuajul s yeyo SIUL soueuoJed joo WINWIXEW Insua 0 9 A 2192148998 WWNWIUILU e o aeunssad q49eq nss d ul Luna daa 0 papuajul ase suo epuauwuosal s u ud a nulw Jed say wud amu 49d suojje uo paseq syjBua sou SNONEA JO SISJOWUEIP esoy LUNUUIUIUU papuauwuuogal smoys ju ey o yeyo SUL SUONEPUSWWOISN 9SOH HD 9NEIP H 0 loo L 8 CT04 User Manual HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE II TYPERR TYPE Ii 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 at the power supply outlet Maximum back pressure at tool end of the return hose Measured at a max fluid viscosity of at min operating temperature Temperature Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity at a temperature difference of between ambient and fluid temps NOTE 2100 2250 psi 145 155 bar 2100 2250 psi 145 155 bar 2200 2300 psi 152 159 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 250 psi 17 bar 250 psi 17 bar 250 psi 17 bar 400 ssu 400 ssu 82 centistokes 82 centistokes 400 ssu 82 centistokes
19. he dies will damage the dies and or die holders 4 Hook the stationary C Head 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 Release the trigger to retract the piston 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 8 Remove the tool by lifting it free of the connector STANLEY 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 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 cle
20. in this tag and attach it to the tool when not in use 6 gt CT04 User Manual DANGER DANGER 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 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 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 REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERS
21. lpm 27 33 lpm 36 44 lpm 45 55 Ipm 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi 129 bar 103 bar 103 bar 103 bar 103 bar 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi 172 bar 138 bar 138 bar 138 bar 138 bar NOTE These are general hydraulic system requirements See tool specification page for tool specific requirements STANLEY CT04 User Manual lt 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 Never operate the tool without dies
22. m 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 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 Make sure hoses are connected and properly 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 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 Remove obstruction Clean die area Piston
23. ol can cause serious injury 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 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 CT04 User Manual 5 Milwaukie OR 97267 1194 19m0 9 gpm Modai No CT04 138 ba 2000 psi Stanley Hydraulic Tools STANLEY 3810 SE
24. 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 on 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 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 STANLEY 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 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 Place the die load tester between the blank test dies
25. re securely in place and leg ible Replace any that are damaged or missing 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 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 Do not rely 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 to
26. 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 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 Repair or replace trigger assembly spool in bore STAN LEY CT04 User Manual lt 15 Capacidad 6 4 0 Conductor Crimpindg FOCE iii 4 4 tons 1650 psi 4000 kg 114 bar Pressure Range ii in 1650 psi 114 bar Flow Range aan 3 9 gpm 11 34 Ipm Optiuni FOW a u LS A A annee A A a a 8 gpm 30 Ipm A een E 3 8 NPT Hose Whips amp Couplers Luna u nn Ai a Eee a lg a No Welghl u ana ara sine 12 lbs 5 4 kg Overall Len EE 20 inches 50 8 cm Overall Width corista 3 75 inches 9 5 cm 16 CT04 User Manual STAN LEY STAN LEY CT04 User Manual 17 ITEM L NO QTY 00144 12 07626 2 09330 00294 00360 DESCRIPTION 01534 01608 01809 01812 07736 16556 18050 20428 20430 20747 21255 2 21424 1 zur 38622 39925 39939 52534 2 58439 58440 58442 584
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