© Panduit Corp. 2007
Website: www.panduit.com
E-mail: cs@panduit.com
Panduit Corp., Technical Support:
888-506-5400, ext. 3255
Fax: 630-759-7532
CT-2981
PA24830A01
REV: 03 05-2007
UNI-D
IE
HYDRAULIC COMPRESSION TOOL
OPERATION INSTRUCTIONS
Read and understand all of the instructions and safety information
in this manual prior to operating or servicing this tool.
Retain this manual for future reference.
Page: 1 of 10
CT-2981
UNI-DIE HYDRAULIC COMPRESSION TOOL
OPERATION INSTRUCTIONS
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
OPTIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CT-2981 TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS AND GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Compression Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Terminations per Battery Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOOL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crimping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Periodic Pressure Relief Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose of this Manual
This manual is intended to familiarize the user with the safe
operation and maintenance procedures for this tool.
Keep this manual available to all personnel.
Replacement manuals are available upon request.
Page: 2 of 10
CT-2981 OPERATION INSTRUCTIONS
INTRODUCTION
The CT-2981
UNI-D
IE
Hydraulic Compression Tool can crimp #4 AWG thru 750 kcmil
PANDUIT
Copper
Compression Connectors and #6 AWG thru 500 kcmil
PANDUIT
Aluminum Compression Connectors using
only one set of
UNI-D
IE
universal nibs. The Hydraulic Compression Tool develops up to 6.2 tons (5.6 met-
ric tons) of compressive force.
This manual will guide you step-by-step in the set-up, operation, and maintenance of
your CT-2981 Tool. Proper maintenance is vital to the continued trouble-free
operation of the tool. If you have a problem not covered in the manual, call:
(888) 506-5400, Ext. 3255
Ask for one of our Tool Service Technicians
The information contained in this literature is based on our experience to date and is believed to be reliable. It is intended as a
guide for use by persons having technical skill at their own discretion and risk. We do not guarantee favorable results or assume
any liability in connection with its use. Dimensions contained herein are for reference purposes only. For specific dimensional
requirements consult the factory. This publication is not to be taken as a license to operate under, or a recommendation to infringe
any existing patents. This supersedes and voids all previous literature, etc.
Safety
Safety is essential in the use and maintenance of
PANDUIT
tools and equipment. This manual and any
markings on the tool provide information for avoiding hazards and unsafe practices related to the use or
service of this tool. Observe all of the safety information provided.
TOOL SPECIFICA
TIONS
Hydraulic Compression Tool Output: 6.2 tons / (5.6 metric tons)
Applicable Range:
PANDUIT
Connectors - #4 AWG to 750 kcmil
copper compression lugs and splices; and #6
AWG to 500 kcmil aluminum lugs and splices
Motor: 12 V DC motor
Dimensions: 14.87" L x 3.0" H x 12.25" W - with battery
377.7 mm L x 76.2 mm H x 311.2 mm W
Weight: 10.8 lbs. / (4.9 kg) - with battery
Sound Level 75 dB (A) at 1 meter
Vibration <2.5 m/s
2
Motor Type DC permanent field motor
Motor Voltage 12 VDC
Makita Battery Cartridge Battery Type: Nickel Metal Hydride (NiMH)
Part No.: 1234 Output: 12 V DC
Capacity: 2.6 AH
Charging time: 1 hour
Weight: 1.45 lbs. / (.659 kg)
Makita Battery Charger Input: 120 Volt AC 50Hz - 60Hz
Part No.: DC1413 Output: 7.2 V - 14.4 Volt DC
Dimensions: 7-1/8" L x 2-1/16" H x 3-5/8" W
181 mm L x 78 mm H x 92 mm W
Weight: 1.17 lbs. / (.528 kg)
OPTIONAL ACCESSORIES
Makita NiCad 12 Volt replacement battery cartridge Makita Part No.: 1222
Makita NiMH 12 Volt replacement battery cartridge Makita Part No.: 1234
Makita 7.2 Volt - 14.4 Volt DC replacement battery charger Makita Part No.: DC1413
Replacement Makita Batteries and Battery Chargers are available for purchase from local Makita products
distributors.
Test Slug Package (SS-1) and Test Slug Gauge (SS-1Gage) are available for purchase from your local
PANDUIT
distributor.
Page: 3 of 10
CT-2981 OPERATION INSTRUCTIONS
CT-2981 TOOL
The CT-2981 Tool includes: 1 - Hydraulic Compression Tool
2 - Makita NiMH Battery Cartridges
1 - Makita Battery Charger
1 - Carrying Case
1 - Crimp Test Slug Gauge
1 - Package Crimp Test Slugs
PRECAUTIONS AND GENERAL GUIDELINES
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards or
unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates
the severity of the hazard. The message after the signal
word provides information for preventing or avoiding the
hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in severe
injury or death.
DANGER
Hazards or unsafe practices which, if not avoided, MAY
result in injury or property damage.
Read and understand all of the instructions and safety information in this
manual before operating or servicing
this tool.
Failure to observe this warning can
result in severe injury or death.
Electric Shock Hazard:
This tool is not insulated. When
using this unit on or near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning can
result in severe injury or death.
Wear eye protection when operating or
servicing this tool.
Failure to wear eye protection can
result in serious eye injury from flying
debris or hydraulic oil.
Skin Injection Hazard:
Oil under pressure easily punctures
skin causing serious injury, gangrene,
or death. If you are injured by escaping oil, seek medical attention immediately.
• Do not use hands to check for leaks.
• Depressurize the hydraulic system
before servicing.
Do not use solvents or flammable
liquids to clean the crimping tool.
Solvents or flammable liquids could
ignite and cause serious injury or
property damage.
DANGER
WARNING
WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING
Page: 4 of 10
CT-2981 OPERATION INSTRUCTIONS
PRECAUTIONS AND GENERAL GUIDELINES (continued)
An incomplete crimp can cause a fire.
• Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
• The relief valve will sound to indicate a completed
crimp. If you do not hear the sound of the relief valve,
the crimp is not complete.
Failure to observe these warnings can result in severe
injury or death.
Do not dispose of batteries in a fire. They will vent
fumes and may explode.
Failure to observe this warning can result in severe
injury from harmful fumes or burns from flying debris.
Inspect tool before use. A worn or damaged tool may
result in breakage striking the operator or nearby
personnel.
Failure to observe this warning can result in severe
injury, death or property damage.
• Do not operate the tool without a connector in
place. Damage to the ram or crimping tool head
can result.
• This tool is not designed for continuous use.
After 30 to 40 crimping cycles, allow the crimping
tool to cool for 15 minutes.
• Do not place the tool in a vise. The crimping tool
is designed for hand-held operation.
• Protect the crimping tool from rain and moisture.
Water will damage the crimping tool and battery.
• Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions can result in
injury or property damage.
• Do not store the battery at more than 60°C
(140°F). Damage to the battery can result.
• Do not use another manufacturer’s charger. Other
manufacturers’ chargers may overcharge and
damage the battery.
• Do not attempt to open the battery. It contains no
user-serviceable parts.
Failure to observe these precautions can result in
injury or property damage.
Do not perform any service or maintenance other than
as described in this manual. Injury or damage to the
tool may result.
Failure to observe this precaution can result in injury and
property damage.
Do not allow anything to contact the battery
terminals.
• Do not immerse the batteries in liquid. Liquid may
create a short circuit and damage the battery. If
batteries are immersed, contact your service center for proper handling.
• Do not place the battery into a pocket, tool pouch,
or tool box with conductive objects.
Conductive objects may create a short circuit and
damage the battery.
• Do not place a battery on moist ground or grass.
Moisture may create a short circuit and damage
the battery.
Failure to observe these precautions can result in
injury or property damage.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning can
result in severe injury or death.
WARNING
WARNING
WARNING
CAUTION
CAUTION
WARNING
CAUTION
CAUTION
Page: 5 of 10
CT-2981 OPERATION INSTRUCTIONS
PRECAUTIONS AND GENERAL GUIDELINES (continued)
HYDRAULIC COMPRESSION TOOL
1. Always verify the proper size connector for the conductor, by checking the color code and the printing
on the connector.
2. Keep the tool head portion clean and free from debris. Excessive dirt and grit can contribute to the premature wear of the tool's internal mechanical parts. Always store the tool in its clean, dry carrying case
when not in use. When using the tool, regularly check that no foreign matter or debris exists in the open
areas between the nibs in the tool head. A tool that is dirty with excessive foreign matter may jam and
become damaged during operation. Soap and a damp cloth should be used to clean the tool body.
3. Avoid dropping the tool. Extreme shock may damage the hydraulic circuit and result in malfunction of
the tool.
Identification - CT-2981 Tool:
1. Flip Top
2. 360° Rotatable Crimp Head
3. Body
4. Ram Retract Button
5. Battery
6. Trigger
7. Battery Condition Light
Before crimping a connection, verify that the flip top on
the tool head is locked in the closed position. The
lockout pin must be engaged completely through the
tool head and both surfaces of the tool flip top.
Failure to lock the tool flip top in the closed position
may result in damage to the tool and personal injury.
NOTE:
CONNECTIONS UTILIZING THIS TOOL ARE
U.L. LISTED AND C.S.A. CERTIFIED ONLY
WHEN
PANDUIT
COPPER COMPRESSION
CONNECTORS ARE USED. USE OF ANY
OTHER BRAND OF COMPRESSION CONNECTORS IS NOT RECOMMENDED.
CAUTION
2
1
3
7
6
4
5
Page: 6 of 10
CT-2981 OPERATION INSTRUCTIONS
PRECAUTIONS AND GENERAL GUIDELINES (continued)
BATTERY CHARGER
Read the instructions supplied with the battery charger.
TERMINATIONS PER BATTERY CHARGE
The estimated number of terminations before the battery will need to be recharged is dependent on variables such as the connector size and type being terminated, ambient temperature, and time lapsed
between termination cycles as well as other variables. It is recommended that the spare battery be kept at
full charge for uninterrupted tool use.
BATTERY CONDITION
Battery Load Display Battery Condition
Momentary illumination at beginning of crimp Normal
Flickering at end of crimp Normal
Flickering during entire crimp Low charge
Constant illumination during entire crimp Low charge
TOOL OPERATION
Electric Shock Hazard:
This tool is not insulated. When using
this unit on or near energized electrical
lines, use proper personal protective
equipment.
Failure to observe this warning can
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from flying
debris or hydraulic oil.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning can
result in severe injury or death.
An incomplete crimp can cause a fire.
• Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
• The relief valve will sound to indicate a completed
crimp. If you do not hear the sound of the relief valve,
the crimp is not complete.
Failure to observe these warnings can result in severe
injury or death.
Inspect tool before use. A worn or damaged tool
may result in breakage striking the operator or nearby personnel.
Failure to observe this warning can result in severe
injury, death or property damage.
WARNING
WARNING
WARNING
WARNING
WARNING
Page: 7 of 10
CT-2981 OPERATION INSTRUCTIONS
1. Verify the proper size connector for the conductor, by checking the color code and the printing on the
connector. Also, consult the connector installation instructions to verify the correct number of crimps to
apply to the connector being used.
2. Verify that the hinged tool flip top is locked in the closed position with the lock pin. Center the connector against the stationary nib.
4. Depress the trigger to advance the nibs toward the connector. Release the trigger once the connector
is held by the nibs.
CAUTION: DO NOT crimp the connector at this time.
5. Insert the prepared conductor completely into the connector barrel (see connector installation instructions for conductor preparation requirements).
6. Depress the trigger until the crimp is completed; the ram will automatically retract when crimp cycle is
complete.
NOTE: Pressure relief occurs at approximately 690 bar (10,000 psi) and is indicated by an audible
“pop”.
CAUTION: DO NOT release the trigger or interrupt the crimping cycle until the crimp is
completed. The tool ram will automatically retract upon completion of the crimping
cycle.
NOTE: If the tool stalls during the crimping operation, the battery may need recharging, or an
improper connector or wire was used. Replace the battery to verify battery power status;
also verify that correct connector and conductor are being crimped. Complete the crimping
cycle until the release pressure is attained.
Should the crimp cycle need to be interrupted prior to termination completion, the operator
can release the tool trigger - stopping the ram advancement, then depress the ram retract
button to retract the tool ram.
WARNING: Interruption of the crimp cycle may result in an incomplete termination between the con-
nector and conductor. It is the responsibility of the operator to complete the termination or
remove and replace the connector.
7. Complete the number of crimps required per the connector installation instructions.
IIMMPPOORRTTAANNTT
Small connectors may become
wedged between the nibs of the tool.
Center the connector between the
four nibs before crimping.
Failure to observe this precaution can
cause property damage.
CRIMPING
To simplify operation, the tool head may be rotated,
by hand, 360° relative to the tool body. Also, the tool
flip top may be opened to accommodate splices and
large connectors. To open the tool flip top, pull the
lock pin allowing the tool flip top to swing open.
Before crimping, lock the tool flip top in the closed
position by lowering the tool flip top, and sliding the
lock pin completely through the tool head and both
surfaces of the tool flip top.
RIGHT
WRONG
Page: 8 of 10
CT-2981 OPERATION INSTRUCTIONS
MAINTENANCE
PERIODIC MAINTENANCE
1. Daily maintenance is important to keep the tool in
good working condition. Keep the tool head portion clean and free from debris. Excessive dirt
and grit can contribute to the premature wear of
the tool's internal mechanical parts. Wipe the
tool surfaces with a damp cloth and mild detergent.
Check the nibs for wear and damage such as
cracks, gouges, or chips. Inspect the tool for
damage or oil leaks Return a damaged tool to
PANDUIT
for repair by contacting
PANDUIT
Tool
Service at (888) 506-5400, Ext. 3255.
Fully retract the ram and store the tool in its
clean, dry carrying case when not in use.
Charge the battery before storage.
Skin Injection Hazard:
Oil under pressure easily punctures
skin causing serious injury, gangrene, or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.
Do not use solvents or flammable
liquids to clean the crimping tool.
Solvents or flammable liquids could
ignite and cause serious injury or
property damage.
2. Avoid humidity wherever possible for efficient operation and the prevention of corrosion.
3. The hydraulic tool has been calibrated and sealed at the factory. Contact
PANDUIT
Tool Service at
(888) 506-5400, Ext. 3255; or your distributor if hydraulic problems are experienced. The hydraulic fluid
should be changed annually or every 10,000 cycles.
CLEANING AND LUBRICATION OF TOOL HEAD
Thorough cleaning and lubrication of the tool head is recommended annually, or every 10,000 cycles. It is
recommended that the CT-2981 Tool be returned to Panduit Corporation for proper maintenance by our
trained service staff.
PERIODIC PRESSURE RELIEF VALVE CHECK
Test the compression force of the CT-2981 tool, monthly, whenever possible damage has occurred, or as
often as operating conditions warrant. Follow the test instructions below (Testing the Crimping Tool).
PANDUIT
’s trained Tool Service staff provides tool Inspection and Calibration service. Contact
PANDUIT
Tool Service at: (888) 506-5400, ext. 3255.
Testing the Crimping Tool
1. Center a test slug between the nibs.
2. Pull the trigger to advance the nibs. Hold the trigger down until the
pressure relief valve activates.
3. After achieving pressure relief, the ram automatically returns to the
start position and the nibs retract.
4. Evaluate the test slug as follows:
• If any part of the test slug does not fit into GO slot, the pressure
relief valve is set too high. Contact
PANDUIT
Tool Service.
• If the test slug fits into the GO slot, the pressure relief valve is set
correctly.
• If the test slug fits into the NO GO slot, the pressure relief valve
is set too low. Contact
PANDUIT
Tool Service.
WARNING
WARNING
GO
NO GO
Page: 9 of 10
CT-2981 OPERATION INSTRUCTIONS
TROUBLESHOOTING
Before you begin, make sure that the battery is charged.
Problem Probable Cause Probable Remedy
Tool is inoperative Dirt, contaminants, etc., in ram
area of tool.
Clean tool.
Tool battery contacts damaged. Reform contacts.
Tool battery contacts corroded. Clean contacts with pencil eraser
or contact cleaner.
Tool components worn or
damaged.
Contact
PANDUIT
Tool Service.
Ram does not advance
completely.
Oil level is low. Contact
PANDUIT
Tool Service.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately 10 seconds.
Battery load display flashes
constantly.
Battery charge low. Charge or replace battery.
Tool loses oil. Damaged internal seal. Contact
PANDUIT
Tool Service.
Page: 10 of 10
CT-2981 OPERATION INSTRUCTIONS
PARTS LIST - CT-2981 Tool:
Key
Part Number Qty.
31 Latch Mounting Pin 1
33 Lock Pin 1
37 Snap Ring 2
26
35
29
30
42
38
33
37
39
31
43
28
37
41
40
30
29
36
34
35
28
32
27
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