CT10 User Manual - Stanley Hydraulic Tools
Contents
1. umasa 22 CT10066AN PARTS ILLUSTRATION tt rnt ttt to tree ett et n needs ea 23 CT10066AN PARTS LIST excors aka RE ap exta ce apes io ee e Ae Ia us deep n ees i eu eR a 24 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 AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER STAN LEY CT10 USER MANUAL 3 Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment IMPORTANT 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 dea2. Trigger difficult to operate Hoses connected to wrong ports on tool Connect input supply line to IN 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 spool in bore Repair or replace trigger assembly STANLEY CT10 USER MANUAL 15 Capacity depending on 500 MCM Copper to 1033 Aluminum Crimping dole 12 tons 1650 psi 10 886 kg 114 bar Pressure RANGE c O 1650 2500 psi 114 172 bar diete 3 9 gpm 11 34 Ipm Optimum uuu 8 30 Ipm Poria 3 8 Hose Whips amp Couplers uuu pn rate SC ERE E AREE NAXOS UN TRY CAE YA No WV GIGI c E 17 Ibs 7 7 kg Overall Lenglhu u u l 22 inches 56 9 cm Overall Vidi uuu Z us E 7 inches 18 cm 16 CT10 USER MANUAL STAN LEY THIS IS A OLDER MODEL CYLINDER HEAD AND C FRAME THE CYLINDER HEAD ITEM 38A HAS A THREAD DIAMETER OF 2 3 16 AND A THREAD LENGTH OF 1 100 CHE
3. CT10 USER MANUAL 11 2 Connect the tool to an appropriate hydraulic power source Follow the Hydraulic Hose Connection safety guidelines and instructions in this section If possible use the hydraulic power Source you plan to use for crimping 3 Place the die load tester between the blank test dies 4 Actuate the tool and read the value shown on the load tes ter indicator The force should be 10 12 tons 9072 10 886 kg depending on the pressure from the hydraulic power Source 5 If the indicated value is low and the system pressure relief valve setting is greater than 1650 psi 114 bar adjust the relief valve on the CT to get the correct die load If the indicated value is high 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 orr and disconnect the hoses from the tool 7 Follow the Die Installation instructions at the beginning 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 inch 6 4 mm gap If the setting is not correct for your hydraulic system follow the instructions in this section OC CC Adjustment to make the change
4. 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 12 CT10 USER MANUAL 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 hdyraulic power source to the tool fittings or quick disconnects It is good practice to connect the return hose first and disconnect it last to minimize or eliminate trapped pressure within the wrench 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 before operating the tool for the first time CONDUCTOR PREPARATION
5. 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 avail able carefully shave the insulation from the cable Be sure not to nick or cut the strands of the conductor 2 Remove any oxide or foreign matter from the exposed conductor A bright shiny surface is required for a good con nection Do not wire brush tin plated copper conductors or tinned connectors STARTUP 1 Move the hydraulic system control valve to the ON position STANLEY 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 retainer die yoke or C frame die on the connector being crimped to ensure the connector is centered between the dies 5 Squeeze the trigger to advance the piston and crimp the connector 6 Release the trigger to retract the piston 7 Slide the tool into position for the next crimp Some sleeves and connectors have special crimping requirements Refer to the fitting manufacturer s requirements 8 Remove the tool by lifting it free of the connector SHUTDOWN 1 Move the hydraulic system control valve to the orr posi tion 2 Disconnect the hydraulic hoses from the tool first th
6. O ON O Plug Kearney Jam Nut Capscrew Spring Back Up Ring Relief Valve N N N N N 0 Capscrew N N Spring Plunger Valve Sleeve N N Compression Spring Valve Handle Trigger Guard O Trigger Setscrew Adapter 9 Retaining Ring O Sleeve Oil Tube Piston O Ring Cylinder 22 CT10 USER MANUAL STAN LEY Ow ON 2 1 1 1 2 1 1 2 1 1 4 1 1 1 1 1 1 1 21 1 2 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 o 3 lt is older model cylinder head c frame The cylinder head item 41A has a threaded diameter of 2 3 8 and a thread length of 1 500 Check these dimensions on your cylinder head before ordering parts to make sure you are ordering correct parts This is a newer model cylinder head and c frame The cylinder head item 41 has a threaded diameter of M60x1 5 metric and a thread length of 1 100 Check these dimensions on your cylinder head before ordering parts to make sure you are order ing correct parts STAN LEY CT10 USER MANUAL 23 Item Part No Description Item Part No Description No No Retaining Ring Piston HSHCS Capscrew HSHCS O Ring O Ring O Ring O Ring Adapter O Ring HSHCS Roll Pin Steel Ball Valve Spool Cylinder O Ring Sticker Cylinder Head Cylinder Head T Seal Die Retainer Button Die Retainer Pin
7. 24 7 24 22 p 46 INPARTSLIST i ORDERING PARTS TO MAKE SURE YOU ARE N E ORDERING THE CORRECT PARTS THIS IS AN NEWER MODEL CYLINDER HEAD AND C FRAME THE CYLINDER HEAD ITEM 48 HAS A THREAD DIAMETER OF M60X1 5 METRIC AND A THREAD LENGTH OF 1 750 CHECK THESE DIMENSIONS ON YOUR CYLINDER HEAD BEFORE ORDERING PARTS TO MAKE SURE YOU ARE ORDERING THE CORRECT PARTS 45 22 44 24 SEE NOTE 1 IN PARTS LIST STAN LEY CT10 USER MANUAL 19 Item Part No Description Item Part No Description No No Retaining Ring Cylinder HSHCS Cylinder Head O Ring See Note 1 O Ring COURS Head O Ring Cening O Ring Sticker Adapter Tasal O Ring HSHCS Roll Pin Steel Ball Valve Spool P Retaining Ring Check Valve Assy Washer Washer Capscrew Jam Nut See Note 1 Cylinder Head See Note 1 SEAL KIT OMAN O 0 N gt k XS uA O N O Valve Spool Screw O Ring Ball Detent Jam Nut NOTE 1 Items 38 38A and 48 differ in several ways and Spring are not interchangeable The following information explains the differences Back Up Ring Relief Valve Item 38A contains 2 1 8 16UN threads and cannot be used with items 22 and 48 47 that contain M60 metric threads Likewise items 22 38 and 48 that contain M60 metric Push Rod threads cannot be used with items 16 22A and 38A that C Frame contain 2 1 8 16UN threads oa 2 2 OMAN O
8. AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS SEE OTHER SIDE SIDE 1 DANGER 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 ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE SIDE 2 SIHL JAOWSY LON OG shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT REMOVE THIS TAG DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN COR
9. Capscrew N N N C Frame Item 48 is used with a jam nut item 47 whereas item 38 Ball Plunger does not use a jam nut Item 38 and 48 can be identified re by measuring the length of the threads see figure below Ball Plunger The length of threads for item 38 is 1 100 inches For item Setscrew 48 the length is 1 750 inches Setscrew Slotted Capscrew Slotted Capscrew Valve Sleeve Compression Spring Valve Handle Trigger Guard Trigger Setscrew Adapter Retaining Ring Sleeve To determine which model you have measure the thread length and diameter on the cylinder head CT10016N Cyl Head P N Thread Length Thread Diameter Oil Tube Piston N e 828 482 2 j k c Bw PH ow om BR c PO 67276 item 38 1 100 60 1 5 metric 58482 item 38A 1 650 2 1 8 in 68317 item 48 1 750 60 1 5 metric 20 CT10 USER MANUAL STAN LEY E A AY S SY T TE 59 E a A x e lt N e ANIE CT10 USER MANUAL 21 No No No No Retaining Ring Sticker HSHCS Cylinder Head O Ring T Seal O Ring Retaining Ring O Ring Check Valve Assy O Ring Adapter SEAL KIT O Ring Setscrew HSHCS Roll Pin Setscrew Steel Ball Valve Spool P O Q N eX A k lA a Q N Valve Spool Screw O Ring Push Rod C Frame Pin Kearney N gt
10. P Grooved Pin Type B Compresion Coil Spring Setscrew Retaining Ring Setscrew Guide Plate Setscrew Check Valve Assy Valve Spool Screw Lockwasher T O Ring Key amp Capscrew Kit Stopper t SEAL KIT Spring C Frame Retainer Die Yoke Assy X o X X Before ordering parts for the cylinder head or c frame parts contact a Stanley hydraulic tools customer service represen Push Rod tative to ensure the correct parts are being ordered Modified Ram Assy Spring Pin Back Up Ring Relief Valve To determine which model you have measure the thread Capscrew length and diameter on the cylinder head Valve Sleeve CT10066AN Cyl Head P N Thread Length Thread Diameter 67276 item 41 M60x1 5 58515 item 41A 2 3 8 in Compression Spring Valve Handle Trigger Guard Trigger Setscrew Adapter Retaining Ring Sleeve Oil Tube o o o X X IX X o X I c PE c MN gt 24 CT10 USER MANUAL STAN L EY STANLEY Stanely Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanleyhydraulics com
11. before 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 Operating 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 couplers can contaminate the hydraulic lines and prevent a good seal at the connection 3 Check all fasteners for tightness 4 Check the equipment for oil leaks If leaks are observed do not use the tool have the equipment serviced before use 5 Check the tool and hydraulic system for proper operation and performance 6 If the equipment does not appear to operate properly have it serviced before use 7T Periodically verify the crimping force of the tool Refer 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 connected to the tool Verify the crimping force before operating the tool OPEN CENTER CLOSED CENTER SETUP The CT10 Hydraulic Crimping Tool can be configured for either open center or closed center operation The current setting is easily
12. capscrew at the side of the push rod 2 Press the stub on the die into the push rod socket 3 Tighten the capscrew to retain the die Make sure the hydraulic system control valve is in the OFF position when coupling or uncoupling the hoses Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Before installing the hoses wipe the fittings and the entire length of the hoses with a clean dry lint free cloth to remove any dirt or moisture Dirty connections can contaminate the hydraulic fluid causing rapid wear and early failure of internal pars Check the flow indicators arrows stamped on the couplers to ensure oil flows in the proper direction The female coupler on the tool is the inlet coupler 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 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
13. hydraulic oil temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION Tool does not operate Hydraulic hoses not connected properly Make sure hoses are connected and the couplers are tight Hydraulic control valve OFF 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 installed in tool return port Install pressure port check valve in pressure port Tool operates in reverse piston advances retracts when trigger is squeezed Hoses connected to wrong ports on tool Connect input supply line to IN port Connect output return line to OUT port Tool under crimps Die load less than 10 tons 9072 kg Hydraulic system pressure too low Check hydraulic power source for 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 connector Install proper die set Tool over crimps Die load more than 12 tons 10 886 kg Hydraulic system pressure too high Check hydraulic power source for correct flow and pressure Relief valve set too high Decrease relief valve pressure
14. 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 CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPART MENT INSTRUCTIONS A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE LEAK OR BURST B 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 FORLEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH ALEAK 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 OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE DANGER MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CEN BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP WEAR HEARING EYE FOOT HAND AND HEAD PROTEC TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOS
15. CK THESE DIMENSIONS ON YOUR CYLINDER HEAD BEFORE ORDERING PARTS TO MAKE SURE YOU ARE ORDERING THE CORRECT PARTS 1 l 1 I I I l l I 1 I I l I l THIS IS A NEWER MODEL CYLINDER HEAD AND C FRAME THE CYLINDER HEAD ITEM 38 HAS THREAD DIAMETER OF M60X1 5 METRIC ANDA THREAD LENGTH OF 1 100 CHECK THESE DIMENSIONS YOUR CYLINDER HEAD BEFORE ORDERING PARTS TO MAKE SURE YOU ARE J ORDERING THE CORRECT PARTS gt 15 2 N STAN LEY CT10 USER MANUAL 17 No Retaining Ring HSHCS O Ring O Ring O Ring O Ring Adapter O Ring HSHCS Roll Pin Steel Ball Valve Spool Valve Spool Screw Washer T Capscrew Capscrew Die Piston Assy Washer T O Ring C Frame N Retainer Die Yoke Set Screw Kit Key amp Capscrew Kit Spring Back Up Ring Relief Valve Capscrew Valve Sleeve Compression Spring Valve Handle Trigger Guard Trigger Setscrew Adapter Retaining Ring No O Ring Cylinder Cylinder Head Cylinder Head Sticker T Seal Retaining Ring Set Screw Check Valve Assy Key Q SEAL KIT NOTE 1 Items 38 and 384A differ in several ways and are not interchangeable The following information explains the differences Item 38A contains 2 3 16 16UN threads and cannot be used with items 19 that contain M60 metric threads Like wise items 19 an
16. CT10 HYDRAULIC CRIMPING TOOL USER S MANUAL Safety Operation and Maintenance 2014 Stanley Black amp Decker Inc New Britain CT 06053 U S A 58545 10 2014 Ver 9 SAFETY SYMBOLS uu TTE 4 usd dese 5 TOOL STICKERS amp TAGS cha ene tco enar stes 6 HOSE TYPES v Lugu maaataq a aa 7 HIMAREQUIREMENITS nte 9 Sus cdde HH 10 ORANG E 13 EQUIPMENT PROTECTION amp CARE irren det det cru tr e de eee de ERR tty duree return 14 TROUBLESHOOQTING I TUUM UTE 15 Suseleugecc 16 ACCESSORIE Sparone e te edictis 16 CT10016N PARTS IELUS e ca nette Een tnra dea van eaten d edle cu dd eren dd 17 CT10016N PARTS EIS t tubes qayaspa e ecco e nue 18 CT10056DN PARTS IEEUSTRAT IGN com te ex nen te de erdt er nt vee etd 19 CT10056DN PARTS E ce cce a e eoe eaaet da ee na eiue aen An EAE ue 20 CT10056N PARTS IELUS TRATIONS 21 CT190056N PARTS a tenute
17. E TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNEC TIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY TER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS CLEAR OF YOUR WORK AREA TION 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 OPERA TION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 shown smaller then actual size STANLEY HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid rein forcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conduct
18. 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 OC CC Use closed center tool on closed center systems Set tool for proper system before use observe the precautions can result in serious personal injury 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 ata leak or burst can cause all injection to the body Failure to CAUTION Stay clear of dies and tool heads Failure tn observe the precautions can result in serious personal injury 58499 CT10 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 CT10 USER MANUAL DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED 2 A DONOTEXCEED SPECIFIED FLOW AND PRESSURE FOR
19. RECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC 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 SEE OTHER SIDE KW SIDE 1 DANGER 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA SEE OTHER SIDE SED SIDE 2 SIHL JAOWSY LON OG shown smaller than actual size STANLEY CT10 USER MANUAL 7 Suonooeuuo esoH eoidA Wa dnoo LOANNOOSIC AJNO AWW MO 13 RETURN RETURN 1 3SOH 3dld 3 TVB SNIN O AVS 8 X 3dld HONI 8 SdIHM ISOH HO 1 NO 14 gt gt gt W lt a E 4 E z
20. d 38 that contain M60 metric threads can not be used with items 19A and 38A that contain 2 3 16 16UN threads Item 38 and 38A can be identified by measuring the length of the threads see figure below The length of threads for item 38 is 1 100 inches For item 38A the length is 1 100 inches Due to both of these cylinder heads having the same thread length you will need to measure the thread diameter to know wheather you have a M60 metric thread or a 2 3 16 16UN thread To determine which model you have measure the thread length and diameter on the cylinder head Sleeve Oil Tube IX A 2X a L 2X 2X OX NO X x x PO Piston CT10016N Cyl Head P N Thread Length Thread Diameter 67276 item 38 1 100 M60x1 5 58494 item 38A 1 100 2 3 16 18 CT10 USER MANUAL STANLEY THIS IS AN OLDER MODEL CYLINDER HEAD AND THE CYLINDER HEAD ITEM 38A HAS A THREAD DIAMETER OF 2 1 8 AND A THREAD LENGTH OF 1 650 CHECK THESE DIMENSIONS ON YOUR CYLINDER HEAD BEFORE ORDERING PARTS ij l 1 TO SURE YOU ARE ORDERING THE CORRECT PARTS gt 23A 25A THIS IS AN NEWER MODEL CYLINDER HEAD AND i C FRAME THE CYLINDER HEAD ITEM 38 HAS A k THREAD DIAMETER OF M60X1 5 METRIC AND A i THREAD LENGTH OF 1 100 CHECK THESE WELLE 5 SEE NOTE fH DIMENSIONS YOUR CYLINDER HEAD BEFORE
21. determined by looking at the gap between the adapter and the cylinder 10 CT10 USER MANUAL TO CHANGE THE CURRENT SETTING Open Center gap WITHOUT DIES DO NOT OPERATE Dv Top View of Tool Trigger Handle 1 Remove the hydraulic hose coupling from the return port on the tool if one is installed When making the change from CC to OC hydraulic fluid may be trapped in the tool prevent ing complete movement of the adapter Remove the return coupling to allow the hydraulic fluid to escape 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 closes gap 4 Tighten the two setscrews DIE INSTALLATION One die is installed in the crimping head Retainer Die Yoke or C frame and the other die is installed onto the ram or die piston assembly depending on the model See below to identify the style of crimping head you have Refer to the parts illustrations in this manual for more detailed reference Burndy Y35 amp 30 mm Style Retainer Die Yoke pean C Frame Kearney PH2 Style C Frame Stanley Y35 Style Retainer Die Yoke To install dies follow the instructions below for your model of crimping head 1 If the hydraulic hoses are connected Turn the hydraulic system control valve OFF Disconnect fi
22. disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow Refer to Specifications in this manual for correct flow rate Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Do not force a small tool to do the job of a large tool Keep tool bit sharp for maximum breaker performance Make sure that tool bits are not chipped or rounded on the striking end Never operate a chipper without a tool bit or without holding it against the work surface This puts excessive strain on the retainer Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended 14 CT10 USER MANUAL STAN LEY 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
23. e input supply hose then the output return hose 3 Insert plugs in the hose ends couplers or tool ports as applicable 4 Wipe the tool thoroughly with a clean dry cloth 5 Clean any foreign matter or joint compound from the die holder surfaces COLD WEATHER OPERATION If the tools is to be used during cold weather preheat the hy draulic fluid at low engine speed When uysing the normally recommended fluids fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes before use Damage to the hydraulic system or compression tool can result from use with fluid that is too viscous or too thick STANLEY 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 CT10 USER MANUAL 13 In addition to the Safety Precautions in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick
24. er 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 im m Wb 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 mE 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 STAN LEY CT10 USER MANUAL 9 PRE OPERATION Careful inspection of the tool and hydraulic system
25. g pieJg oepisu y 6ue7 u e3 MO 4 SOH OL 001 8 CT10 USER MANUAL HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE I TYPE Il 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 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 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 73 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 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 high
26. he tool which can result in operator discomfort Do not operate a damaged improperly adjusted or incompletely assembled tool Do not carry tool by the hoses Never wear loose clothing that can get entangled in the working parts of the tool Keep all parts of your body away from the tool and maintain proper footing and balance at all times Do not rely exclusively upon the safety devices built into the tool Always be well rested and mentally alert before operating the tool Do not allow other persons to be near the tool when in operation Keep bystanders and animals out of the work area Keep the handles dry clean and free of oil When using tools near energized transmission lines be sure to use only hoses labeled and certified non conductive Turn off the power unit or move the hydraulic control valve to neutral before setting the tool down Know the location of buried or covered electrical services before starting work To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by au thorized and properly trained personnel STAN LEY CT10 USER MANUAL 5 Please refer to the Parts List Illustration for location of stickers Milwaukie OR 97267 Modol No 11 34 pm amp 0 gpm cro 138 bav 2000 psi Stanley Hydraulic Tools CENA 5 Read owners manual and make sure that you have been property trained in the correct procedures required for work
27. ors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforcement and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constucted of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE 9 lt 2 gt c z a DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE
28. recautions in the space provided on page 4 The model CT10 Hydraulic Crimping Tool will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the tool and hose before operation Failure to do so could result in personal injury or equipment damage The operator must start in a work area without bystanders Flying debris can cause serious injury Do not operate the tool unless thoroughly trained or under the supervision of an instructor Establish a training program for all operators to ensure safe operation Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the tool Use gloves and aprons when necessary The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions Do not inspect clean or replace any part s if the hydraulic power source is connected Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Always connect hoses to the tool hose couplers before energizing the hydraulic power source Be sure all hose connec tions are tight and are in good condition Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause higher than normal temperatures at t
29. rst 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 f the die load has not been verified select blank dies and verify die load If the die load has been verified select a set of dies to match the sleeve or connector to be crimped TO INSTALL DIES ON STANLEY OR BURNDY CRIMPING HEADS Y35 STYLE Install the die to the Retainer Die Yoke 1 Insert and center the die until it clicks into place Install the die to the Die Piston Assembly or Ram 1 Press the die release pin at the side of the die piston asembly or ram 2 Insert and center the die 3 Release the pin to lock the die in place TO INSTALL DIES ON STANLEY OR KEARNEY CRIMPING HEADS PH2 STYLE Install the die to the C Frame 1 Loosen the capscrew at the side of the C frame 2 Press the stub on the die into the socket 3 Tighten the capscrew to retain the die Install the die to the push rod 1 Loosen the capscrew at the side of the push rod 2 Press the stub on the die into the push rod socket 3 Tighten the capscrew to retain the die STANLEY TO INSTALL DIES ON KEARNEY CRIMPING HEAD WH3 STYLE Install the die to the C Frame 1 Loosen the capscrew at the side of the C frame 2 Press the stub on the die into the socket 3 Tighten the capscrew to retain the die Install the die to the push rod 1 Loosen the
30. th This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage or damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 CT10 USER MANUAL STANLEY Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regula tions If so place the added p
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