CT15 User Manual - Stanley Hydraulic Tools
Contents
1. 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 7 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 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 low the instructions in this section OC CC Adjustment to make the change STANLEY 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 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 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 d2. 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 IF ANT 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 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 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 CORR
3. STANLEY CT15 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 Never operate the tool without dies Operating without 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 con nected to the tool Verify the crimping force before operating the tool OPEN CENTER CLOSED CENTER SETUP The CT1
4. cuit flow This can cause damage to internal seals e 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 Always keep critical tool markings such as warning stickers and tags legible STAN LEY CT15 User Manual lt 13 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 Tool operates in reverse piston advances retracts when trigger is squeezed Tool under crimps Die load less than 10 tons 9072 kg Tool over crimps Die load more than 16 tons 13 600 kg Trigger difficult to operate 14 CT15 User Manual 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 fo
5. 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 STANLEY 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 Do not force a small tool to do the job of a large tool nection Tool repair should be performed by experienced e The hydraulic circuit control valve must be in the personnel only 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 e o draulic system e Do not use the tool for applications for which it was not intended 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 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
6. 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 a Ifthe die load has not been verified select blank dies and verify die load STANLEY b Ifthe die load has been verified select a set of dies to match the sleeve or connector to be crimped DIE LOAD VERIFICATION With blank test dies installed use a die load tester to verify the crimping force in the tool before operating a new crimping tool before placing the tool in service after storage or repair or periodically during normal use 1 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 4 Actuate the tool and read the value shown on the load tester indicator The force should be 15 tons 13 600 kg depending on the pressure from the hy draulic power source 5 Ifthe indicated value is low and the system pressure relief valve setting is greater than 1650 psi 114 bar adjust the relief valve on the CT to get the correct die load If the indicated value is high
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8. 5 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 10 CT15 User Manual TO CHANGE THE CURRENT SETTING Cylinder Open Center no gap N N N a oe Top View of Tool U lt D w a O b e 2 WITHOUT DIES DO Trigger Handle Figure 2 OC CC 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 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 e 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 Tooling manufacturers have different names for their corresponding parts For simplicity the generic term die holder will be used in the following instruc tions To install dies follow the instructions below 1 If the hydraulic hoses are connected a Turn the hydraulic system control valve OFF b Disconnect
9. 97 9soH MO UO SOH UDO o1jneipAH 0 JOOL STANLEY 8 CT15 User Manual HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE TYPE II TYPERR TYPE III 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 lpm 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 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 3 hp 2 24 kW 40 F 22 C 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 5 hp 3 73 kW 40 F 22 C 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 C 6 hp 5 22 kW 40 F 22 C 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu 82 centistokes 140 F 60 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 h
10. CT15 HYDRAULIC CRIMPING TOOL USER MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 USA 58547 10 2014 Ver 6 SAFETY SYMBOLS EE 4 SAFETY PRECAUTIONS undertekst beseire dene 5 TOOL STICKERS amp TAGS uge ikea a 6 HOSE TYPES TTT 7 HOSE RECOMMENDATIONS TTT 8 FIGURE 1 TYPICAL HOSE CONNECTIONS T 8 ATMA REQUIREMENTS a eege ea ES 9 OPERATION EE 10 FIGURE 2 OG CG SETTING Langestrand alain 10 TOOL PROTECTION amp CARE uud ish 13 TROUBLESHOOTING caian 14 e Eelere 15 ERIMPING DATA EE 15 REENEN 16 CT150366N PARTS LIS Tocando da 17 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 au thorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and
11. DRAULIC 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 conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant syntheti
12. ECT 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 SY L SIHL SAOWSY LON OG Ce SEE OTHER SIDE ma TEE SEE OTHER SIDE SIDE 1 SIDE 2 Shown smaller than actual size STAN LEY CT15 User Manual 7 suo 99UUOJ SSOH JESIdAL an4 lt lt lt MOT3 O lt lt mm NYn13Y RETURN RETURN MOT gt gt gt Er El 3YNSSTYUA HYDRAULIC CIRCUIT PRESSURE PRESSURE GLL 0092 unay 797 L 0 8 001 92 09 67 9L EL GLL 0092 ainssald 6l vIe SLL 0092 unay SL vie 8
13. INES 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 07961 Warning Decal 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 REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HY
14. RERSTERLCHEVEERURFEFPEEFEREURBRTESBCBEUPEERETREHFEFENSERGPEEERETFERFLEREFORN 8 gpm 30 Ipm PONG MT 3 8 NPT PEER E No Ke rra A A AAA AA EIA 29 Ibs 13 2 kg Overall Lenin 29 in 74 cm Overall Widih E 7 in 18 cm CRIMPING DATA Crimping Capacity Burndy Y46 P dies Burndy U dies requires P UADP Adaptor 750 MCM Thousand Circular Mils CT15036GN Burndy Y46 Crimping Force 15 tons 13 6 tonne STAN LEY CT15 User Manual 15 16 CT15 User Manual STAN LEY z O PE le EE a o QTY DESCRIPTION QTY DESCRIPTION 626 e lies fi form SE 1 mE 2 A 8689 E ee ar pee 2 per wi E 52 37735 D DieRetainer ER Notem o o O gt Noitem JI 5sss2 Team SEAL KIT 58552 Die Yoke Burndy Y 46 a AUE asja jo a7 2 26 1 Ji 94 11 22 1 VaveSleeve 25 1 Compression Spring 39 1 B2 1 tr 83 1 Tri 3412 SS 39 1 0 EN CO bh gt IS N Kal ow EN co N G LO lO LG OJOJ AJO e N N al co u _ O1 O1 N h gt DIN Sib amp CO CH co 5 gt 5 ojlo CO O a Gn N ojo gt N R se 50x02 1 Tube N A Oe it EA EE Y on Bi oo rp O LOGO lJ LO AIR oO nN O 58441 STAN LEY CT15 User Manual 17 STANLEY Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
15. ask for a Customer Service Representative STAN LEY CT15 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 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 instruct
16. ating the tool 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 the dies will damage the dies and or die holders 4 Hook the stationary die on the connector being crimped to ensure the connector is centered be tween 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 SHUTDOWN 1 Move the hydraulic system control valve to the OFF position 12 CT15 User Manual 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 IMPORTANT Use an oil with the recommended specification from the HTMA Requirement table Using oil that is too viscous thick can damage the hydraulic system If the tools is to be used during cold weather preheat the hydraulic fluid at low
17. c 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 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
18. igher temperatures can cause operator discomfort at the tool Filter BER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 Ipm 114 Ipm 114 Ipm 114 Ipm 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 100 400 ssu 20 82 centistokes 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 EHTMA CLASSIFICATION HYDRAULIC SYSTEM aa A A A A Flow Range 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 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 for tool specific requirements
19. ions in an area accessible to the operator and mainte nance personnel PTA a WARNING Gegen CAUTION NOTICE IMPORTANT 4 gt CT15 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 CT15 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 e 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 the tool unless thoroughly trained or under the supervision of an instructor Establish a training program for all operators to ensure safe operation e Alway
20. isconnects 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 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 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 a Use an insulation stripping tool If a stripping tool is not available carefully shave the insula tion from the cable b Be sure not to nick or cut the strands of the con ductor 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 CT15 User Manual lt 11 STARTUP 1 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 oper
21. nt 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 CT15 User Manual 5 Milwaukie OR 97267 134 pm2 0 gpm oo Stanley Hydraulic Tools STANLEY 3810 SE 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 resul
22. r 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 Hoses connected to wrong ports Connect input supply line to IN port on tool Connect output return line to OUT port Hydraulic system pressure too Check hydraulic power source for low 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 Hydraulic system pressure too Check hydraulic power source for high Relief valve set too high Decrease relief valve pressure Hoses connected to wrong ports Connect input supply line to IN port on tool Connect output return line to OUT port Improper die set for wire and Install proper die set connector correct flow and pressure 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 STANLEY Capacity EE 500 MCM Copper to 1500 MCM Aluminum 795 MCM ACSR CHIMPING eier 15 tons 1650 psi 13 600 kg 114 bar Pressure Range etica 1650 2500 psi 114 172 bar FIOW R ngen ir ee ee 3 9 gpm 11 34 Ipm Optimum FIOW ESPPERASPERAE ER EEE ODE ERBFE a EEE POBREE TE
23. s 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 e 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 e Do not rely exclusively upon the safety devices built into the tool Always be well rested and mentally alert before op erating the tool e 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 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 replaceme
24. t 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 all injection to the body Fallure 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 58498 CT15 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 CT15 User Manual 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 L
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