Stanley CT10056DH, CT10056N, CT10016N, CT10066AN User Manual

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Page 1

CT10

HYDRAULIC

CRIMPING TOOL

USER’S MANUAL

Safety, Operation and Maintenance

New Britain, CT 06053

U.S.A.

58545 5/2017 Ver. 11

Page 2

Page 3

TABLE OF CONTENTS

SAFETY SYMBOLS ........................................................................................................................................................4

SAFETY PRECAUTIONS ................................................................................................................................................5

TOOL STICKERS & TAGS ..............................................................................................................................................6

HOSE TYPES ..................................................................................................................................................................7

HTMA REQUIREMENTS .................................................................................................................................................9

OPERATION ..................................................................................................................................................................10

STORAGE .....................................................................................................................................................................13

EQUIPMENT PROTECTION & CARE ..........................................................................................................................14

TROUBLESHOOTING ..................................................................................................................................................15

SPECIFICATIONS .........................................................................................................................................................16

ACCESSORIES.............................................................................................................................................................16

CT10016N PARTS ILLUSTRATION ..............................................................................................................................18

CT10016N PARTS LIST ................................................................................................................................................19

CT10056DH PARTS ILLUSTRATION ...........................................................................................................................20

CT10056DH PARTS LIST .............................................................................................................................................21

CT10056N PARTS ILLUSTRATION ..............................................................................................................................22

CT10056N PARTS LIST ................................................................................................................................................23

CT10066AN PARTS ILLUSTRATION............................................................................................................................24

CT10066AN PARTS LIST..............................................................................................................................................25

IMPORTANT

To ll 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 certied 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.

CT10 USER MANUAL 3

Page 4

SAFETY SYMBOLS

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 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 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 maintenance personnel.

4 CT10 USER MANUAL

Page 5

SAFETY PRECAUTIONS

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 specic work area and local safety regulations. If so, place the added precautions 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 connections 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 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.

• 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 certied 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 authorized and properly trained personnel.

CT10 USER MANUAL 5

Page 6

TOOL STICKERS & TAGS

Please refer to the Parts List Illustration for location of stickers.

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.

DANGER

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED 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 DEPARTMENT INSTRUCTIONS.

2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY.

A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR

THIS TOOL. EXCESS FLOW OR PRESSURE MAY CAUSE A 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.

C 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 OPERA-

TION MANUAL.

TAG TO BE REMOVED ONLY BY

TOOL OPERATOR.

SEE OTHER SIDE

SAFETY TAG P/N 15875

DANGER

D DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO

NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR DAMAGED HOSE.

3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED 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 CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY.

4. 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.

5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.

6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.

7. 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 OPERA-

(shown smaller then actual size)

TION MANUAL.

TAG TO BE REMOVED ONLY BY

TOOL OPERATOR.

SEE OTHER SIDE

6 CT10 USER MANUAL

Page 7

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:

Certied non-conductive - constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid rein- forcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied 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 reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near electrical

conductors.

Fabric-braided (not certied or labeled non-conductive) - constucted of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This hose is not

certied 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

D A N G E R

1 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.

2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE 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.

DO NOT REMOVE THIS TAG

SIDE 1 SIDE 2

SEE OTHER SIDE

3. 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.

4. 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.

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.

D A N G E R

SEE OTHER SIDE

(shown smaller than actual size)

DO NOT REMOVE THIS TAG

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

D A N G E R

1 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.

2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

4. 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

SIDE 1 SIDE 2

SEE OTHER SIDE

(shown smaller than actual size)

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

D A N G E R

SEE OTHER SIDE

DO NOT REMOVE THIS TAG

CT10 USER MANUAL 7

Page 8

Operating Pressure

Hose Spec

HOSE RECOMMENDATIONS

HYDRAULIC CIRCUIT

CONTROL PANEL

PRESSURE

MALE PIPE HOSE END

RETURN

Working Pressure Fiber Braid

Wire Braid

Hose Spec

USE

Tool To Circuit Hose Recommendations

5/8 16 Pressure SAE 100R2-10 2750 190 SAE 100R8-10 2750 190

3/4 19 Return SAE 100R1-12 1250 86 SAE 100R7-12 1250 86

5/8 16 Pressure SAE 100R2-10 2750 190 SAE 100R8-10 2750 190

3/4 19 Return SAE 100R1-16 1000 69 SAE 100R7-12 1250 86

3/4 19 Pressure SAE 100R17-12 3000 230 NA NA NA

1 25.4 Return SAE 100R1-16 1000 69 NA NA NA

5/8 16 Pressure SAE 100R2-10 2750 190 SAE 100R8-10 2750 190

3/4 19 Return SAE 100R1-12 1250 86 SAE 100R7-12 1250 86

3/4 19 Pressure SAE 100R17-12 3000 230 NA NA NA

1 25.4 Return SAE 100R1-16 1000 69 NA NA NA

PRESSURE

<<<FLOW

H.T.M.A. FEMALE QUICK

DISCONNECT COUPLER

ADAPTER OR HOSE WHIPS, 3/8

FLOW>>>

RETURN

MALE PIPE HOSE END

Typical Hose Connections

H.T.M.A. MALE QUICK

DISCONNECT COUPLER

INCH MALE PIPE x -8 SAE O-RING

Oil Flow Each Hose Length Inside Diameter

5-8 19-30 up to 50 up to 15 1/2 13 Both SAE 100R17-8 3000 230 SAE 100R7-8 2000 140

5-8 19-30 51-100 15-30 5/8 16 Both SAE 100R17-10 3000 230 SAE 100R8-10 2750 190

5-8 19-30 100-300 30-90

GPM LPM FEET METERS INCH MM PSI BAR PSI BAR

9-12 34-45 up to 50 up to 15 5/8 16 Both SAE 100R17-10 3000 230 SAE 100R8-10 2750 190

8 CT10 USER MANUAL

9-12 34-45 51-100 15-30

9-12 34-45 100-200 30-60

13-16 49-60 up to 25 up to 8

PRESSURE

RETURN

TOOL

13-16 49-60 26-100 8-30

NOTE: SAE 100R16 may be used in place of SAE100R2

Page 9

HTMA / EHTMA REQUIREMENTS

HTMA HYDRAULIC SYSTEM REQUIREMENTS

Flow Range

Nominal Operating Pressure (at the power supply outlet)

System relief valve setting (at the power supply outlet)

Maximum back pressure (at tool end of the return hose)

Measured at a max. uid viscosity of:

(at min. operating temperature)

Temperature: Sufcient heat rejection capacity to limit max. uid temperature to:

(at max. expected ambient temperature)

Min. cooling capacity at a temperature

difference of between ambient and uid

temps NOTE: 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-ow ltration Sized for ow of at least:

(For cold temp. startup and max. dirt-holding capacity)

4-6 gpm 7-9 gpm 9-10.5 gpm 11-13 gpm (15-23 lpm) (26-34 lpm) (34-40 lpm) (42-49 lpm) 1500 psi 1500 psi 1500 psi 1500 psi (103 bar) (103 bar) (103 bar) (103 bar)

2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi (145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

250 psi 250 psi 250 psi 250 psi (17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu* (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F (60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 6 hp 7 hp (2.24 kW) (3.73 kW) (5.22 kW) (4.47 kW) 40° F 40° F 40° F 40° F (22° C) (22° C) (22° C) (22° C)

25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm (114 lpm) (114 lpm) (114 lpm) (114 lpm)

TYPE I TYPE II

TOOL TYPE

TYPE RR

TYPE III

Hydraulic uid Petroleum based

(premium grade, anti-wear, non-conductive) Viscosity (at min. and max. operating temps)

NOTE:

When choosing hydraulic uid, the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics. Hydraulic uids with a viscosity index over 140 will meet the requirements

over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

EHTMA

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu* (20-82 centistokes)

CLASSIFICATION HYDRAULIC SYSTEM REQUIREMENTS

Flow Range

Nominal Operating Pressure (at the power supply outlet)

System relief valve setting (at the power supply outlet)

NOTE: These are general hydraulic system requirements. See tool specication page for tool specic requirements

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 lpm) (18-22 lpm) (27-33 lpm) (36-44 lpm) (45-55 lpm) 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)

CT10 USER MANUAL 9

Page 10

OPERATION

PRE-OPERATION

Careful inspection of the tool and hydraulic system 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, lintfree 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.

7. Periodically verify the crimping force of the tool. Refer to

Die Load Verication.

TO CHANGE THE CURRENT SETTING:

Cylinder

Top View of Tool

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 uid may be trapped in the tool, preventing complete movement of the adapter. Remove the return

coupling to allow the hydraulic uid 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)

Open-Center (no gap)

Adapter

Trigger Handle

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 congured 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 CT10 USER MANUAL

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 & 30 mm Style

Retainer Die Yoke

Stanley Y35 Style Retainer Die Yoke

Kearney WH3 Style

C-Frame

Kearney PH2 Style

C-Frame

Page 11

OPERATION

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 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:

• If the die load has not been veried, select blank dies and verify die load.

• If the die load has been veried, 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:

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 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.

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.

Before installing the hoses, wipe the ttings 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 uid, causing rapid wear and early failure of internal

pars.

Check the ow indicators (arrows) stamped on the couplers to ensure oil ows 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 rst

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.

CT10 USER MANUAL 11

Page 12

OPERATION

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 tester 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 off 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 ¼-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.

DIE CHECK

The hydraulic uid 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

ttings or quick disconnects. It is good practice to connect the return hose rst and disconnect it last to minimize or eliminate

trapped pressure within the wrench.

3. Observe the ow indicators stamped on the main body assembly and the hose couplers to ensure that the ow 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 difcult 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 rst 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 conductor.

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 owmeter and pressure gauge, check the

hydraulic power source at the tool’s input port. Make sure the system maintains an operating ow 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

2. Remove any oxide or foreign matter from the exposed 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.

Page 13

OPERATION

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 tting manufacturer’s requirements.

8. Remove the tool by lifting it free of the connector.

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.

SHUTDOWN

1. Move the hydraulic system control valve to the off position.

2. Disconnect the hydraulic hoses from the tool—rst 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

If the tools is to be used during cold weather, preheat the hy-

draulic uid at low engine speed. When uysing the normally recommended uids, uid 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 uid that is too viscous or too thick.

CT10 USER MANUAL 13

Page 14

NOTICE

EQUIPMENT PROTECTION & CARE

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 disconnect) is connected to the opposite port. Do not

reverse circuit ow. 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 ow. Refer to Specications in this manual for correct ow 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

Page 15

TROUBLESHOOTING

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 ow and pressure to the grinder as listed in the table. Use a owmeter known to be accurate. Check the ow

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 12 tons/10,886 kg.

Trigger difcult to operate.

Hydraulic hoses not connected properly.

Hydraulic control valve OFF.

Hydraulic system not functioning.

Couplers or hoses blocked. Remove obstruction.

Pressure port check valve is installed in tool return port.

Hoses connected to wrong ports on tool.

Hydraulic system pressure too low.

Relief valve set too low. Increase relief valve pressure.

Dirt or obstruction between dies. Remove obstruction. Clean die area.

Piston seal worn or damaged.

Improper die set for wire and connector.

Hydraulic system pressure too high.

Relief valve set too high. Decrease relief valve pressure.

Hoses connected to wrong ports on tool.

Excessive back-pressure.

Trigger guard bent and binding on spool in bore.

Make sure hoses are connected and the couplers are tight.

Turn the hydraulic system control valve ON.

Check hydraulic power unit for correct

ow and pressure.

Install pressure port check valve in pressure port.

Connect input (supply) line to IN port. Connect output (return) line to OUT port.

Check hydraulic power source for

correct ow and pressure.

Contact an authorized Stanley distributor.

Install proper die set.

Check hydraulic power source for

correct ow and pressure.

Connect input (supply) line to IN port. Connect output (return) line to OUT port.

If back-pressure is greater than 250 psi/17 bar, clear the return line obstruction or restriction.

Repair or replace trigger assembly.

CT10 USER MANUAL 15

Page 16

SPECIFICATIONS

Capacity (depending on model) .........................................................................500 MCM Copper to 1033 MCM Aluminum

Crimping Force .................................................................................................... 12 tons @ 1650 psi / 10,886 kg @ 114 bar

Pressure Range ...........................................................................................................................1650-2500 psi/114-172 bar

Flow Range ..............................................................................................................................................3-9 gpm/11-34 lpm

Optimum Flow ................................................................................................................................................ 8 gpm / 30 lpm

Porting ....................................................................................................................................................................... 3/8 NPT

Hose Whips & Couplers .....................................................................................................................................................No

Weight ...............................................................................................................................................................17 lbs / 7.7 kg

Overall Length .........................................................................................................................................22 inches / 56.9 cm

Overall Width ................................................................................................................................................ 7 inches / 18 cm

16 CT10 USER MANUAL

Page 17

NOTES

CT10 USER MANUAL 17

Page 18

THIS IS A NEWER MODEL CYLINDER HEAD AND

C-FRAME. THE CYLINDER HEAD (ITEM 38) HAS A THREAD 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 ORDERING THE CORRECT PARTS.

CT10016N PARTS ILLUSTRATION

D D

18 CT10 USER MANUAL

Page 19

CT10016N PARTS LIST

Item

No.

10 01534 1 Roll Pin

11 01608 4 Steel Ball

12 01809 1 Valve Spool

13 01812 1 Valve Spool Screw

14 03014 1 Washer

15 67281 1 Capscrew

16 06324 1 Die Piston Assy.

17 06326 1 Washer

18 06332 1 O-Ring

19 66588 1 C-Frame, Head Unit 26mm

20 67279 1 Set Screw

21 16556 1 Spring

22 18050 1 Back-Up Ring

23 21424 1 Relief Valve

24 22147 2 Capscrew

25 38622 1 Valve Sleeve

26 39925 1 Compression Spring

27 39939 1 Valve Handle

28 51182 1 Trigger Guard

29 51183 1 Trigger

30 52534 2 Setscrew

31 58439 1 Adapter

32 58440 1 Retaining Ring

33 58441 1 Sleeve

34 58442 1 Oil Tube

35 58480 1 Piston

36 58485 1 O-Ring

37 58493 1 Cylinder

38 67276 1 Cylinder Head (See Note 1)

Part No. Qty Description

1 00118 1 Retaining Ring

2 00144 14 Capscrew

3 07626 2 O-Ring

4 09330 1 O-Ring

5 00294 1 O-Ring

6 00360 1 O-Ring

7 00936 2 Adapter

8 01259 1 O-Ring

9 01521 2 Capscrew

Assembly (Includes Items 20, 42 & 44)

Item

No.

39 58499 1 Sticker

40 58583 1 T-Seal

41 58594 1 Retaining Ring

42 67277 1 Set Screw

43 67259 1 Check Valve Assembly

44 67280 1 Key

SK1 58551 1 Seal Kit (Includes Items 3-6,

NOTE 1: Item 38 can be identied by measuring the length of the threads (see gure below). The length of

threads for item 38 is 1.100 inches and the thread diameter is M60x1.5. For older models consult the factory.

To determine which model you have, measure the thread length and diameter on the cylinder head. Older models have different cylinder head dimensions.

CT10016N

Cyl Head P/N Thread Length Thread Diameter

67276 (item 38) 1.100 M60x1.5

Part No. Qty Description

8, 18, 22, 36 & 40)

CT10 USER MANUAL 19

Page 20

CT10056DH PARTS ILLUSTRATION

THIS IS AN NEWER MODEL CYLINDER HEAD AND

C-FRAME. THE CYLINDER HEAD (ITEM 38) HAS A THREAD 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 ORDERING THE CORRECT PARTS.

EAD

HRE

ENG

SEE

PAR

LIST

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.

SEE

ARTS

IST

20 CT10 USER MANUAL

Page 21

CT10056DH PARTS LIST

Item

Part No. Qty Description

No.

1 00118 1 Retaining Ring

2 00144 14 Capscrew

3 07626 2 O-Ring

4 09330 1 O-Ring

5 00294 1 O-Ring

6 00360 1 O-Ring

7 00936 2 Adapter

8 01259 1 O-Ring

9 01521 2 Capscrew

10 01534 1 Roll Pin

11 01608 4 Steel Ball

12 01809 1 Valve Spool

13 01812 1 Valve Spool Screw

14 06332 1 O-Ring

15 08337 1 Ball Detent

17 16556 1 Spring

18 18050 1 Back-Up Ring

19 21424 1 Relief Valve

20 22147 2 Capscrew

21 24446 1 Push Rod

22 67264 1 C-Frame (Includes Items 23-

25 & 46)

23 67278 1 Ball Plunger

24 68272 1 Setscrew

25 67282 1 Capscrew

26 38622 1 Valve Sleeve

27 39925 1 Compression Spring

28 39939 1 Valve Handle

29 51182 1 Trigger Guard

30 51183 1 Trigger

31 52534 2 Setscrew

32 58439 1 Adapter

33 58440 1 Retaining Ring

34 58441 1 Sleeve

35 58442 1 Oil Tube

36 58480 1 Piston

37 58481 1 Cylinder

38 67276 1 Cylinder Head

(See Note 1)

39 58485 1 O-Ring

Item

Part No. Qty Description

No.

40 58499 1 Sticker

41 58583 1 T-Seal

42 58594 1 Retaining Ring

43 67259 1 Check Valve Assy

44 06326 1 Washer

45 03014 1 Washer

46 67281 1 Capscrew

47 68318 1 Jam Nut (See Note 1)

48 68317 1 Cylinder Head (See Note 1)

49 25837 1 Slotted Mod. Capscrew

SK 58551 1 Seal Kit (Includes Items 3-6,

8, 14, 18, 39 & 41)

NOTE 1: Item 48 is used with a jam nut (item 47) whereas item 38 does not use a jam nut. Item 38 and 48 can be

identied by measuring the length of the threads (see gure below). The length of threads for item 38 is 1.100

inches. For item 48 the length is 1.750 inches. For older models consult the factory.

To determine which model you have, measure the thread length and diameter on the cylinder head.

Cyl Head P/N Thread Length Thread Diameter

67276 (item 38) 1.100 M60x1.5 (metric)

68317 (item 48) 1.750 M60x1.5 (metric)

CT10 USER MANUAL 21

Page 22

CT10056N PARTS ILLUSTRATION

22 CT10 USER MANUAL

Page 23

CT10056N PARTS LIST

Item

No.

1 00118 1 Retaining Ring

2 00144 14 Capscrew

3 07626 2 O-Ring

4 09330 1 O-Ring

5 00294 1 O-Ring

6 00360 1 O-Ring

7 00936 2 Adapter

8 01259 1 O-Ring

9 01397 1 Setscrew

10 01521 2 Capscrew

11 01534 1 Roll Pin

12 01607 1 Setscrew

13 01608 4 Steel Ball

14 01809 1 Valve Spool

15 01812 1 Valve Spool Screw

16 04795 1 O-Ring

17 08330 1 Push Rod

18 08334 1 C-Frame

19 08335 1 Pin - Kearney

20 08336 1 Plug - Kearney

21 09906 1 Jam Nut

22 12430 2 Capscrew

23 16556 1 Spring

24 18050 1 Back-Up Ring

25 21424 1 Relief Valve

26 22147 2 Capscrew

27 34133 1 Spring Plunger

28 38622 1 Valve Sleeve

29 39925 1 Compression Spring

30 39939 1 Valve Handle

31 51182 1 Trigger Guard

32 51183 1 Trigger

33 52534 2 Setscrew

34 58439 1 Adapter

35 58440 1 Retaining Ring

36 58441 1 Sleeve

37 58442 1 Oil Tube

38 58480 1 Piston

39 58485 1 O-Ring

40 58493 1 Cylinder

Part

No.

Qty Description

Item

No.

41 58499 1 Sticker

42 58513 1 Cylinder Head

43 58583 1 T-Seal

44 58594 1 Retaining Ring

45 67259 1 Check Valve Assembly*

46 08337 1 Spring Plunger

SK1 58551 1 Seal Kit (Includes Items 3-6, 8,

Part

No.

Qty Description

16, 24, 39, & 43)

CT10 USER MANUAL 23

Page 24

CT10066AN PARTS ILLUSTRATION

24 CT10 USER MANUAL

Page 25

CT10066AN PARTS LIST

Item

No.

Part No. Qty Description

1 00118 1 Retaining Ring

2 00144 14 Capscrew

3 67281 1 Capscrew

4 07626 2 O-Ring

5 09330 1 O-Ring

6 00294 1 O-Ring

7 00360 1 O-Ring

8 00936 2 Adapter

9 01259 1 O-Ring

10 01521 2 Capscrew

11 01534 1 Roll Pin

12 01608 4 Steel Ball

13 01809 1 Valve Spool

14 01812 1 Valve Spool Screw

15 03014 1 Washer

16 06332 1 O-Ring

18 06326 1 Washer

19 16556 1 Spring

20 79298 1 C-Frame (Includes Items 3,

& 49-51)

21 17678 1 Push Rod

22 67248 1 Ram Assembly

23 17681 1 Spring Pin

24 18050 1 Back-Up Ring

25 21424 1 Relief Valve

26 22147 2 Capscrew

27 38622 1 Valve Sleeve

28 39925 1 Compression Spring

29 39939 1 Valve Handle

30 51182 1 Trigger Guard

31 51183 1 Trigger

32 52534 2 Setscrew

33 58439 1 Adapter

34 58440 1 Retaining Ring

35 58441 1 Sleeve

36 58442 1 Oil Tube

37 58480 1 Piston

38 58481 1 Cylinder

39 58485 1 O-Ring

Item

No.

SK1 58551 1 Seal Kit (Includes Items 4-7,

If you have an older CT10066AN, Before ordering parts for the cylinder head or C-frame parts, contact a Stanley hydraulic tools customer service representative to ensure the correct parts are being ordered. Older models could have different size cylinder head and C-frame.

To determine which model you have, measure the thread length and diameter on the cylinder head.

CT10066AN

Cyl Head P/N Thread Length Thread Diameter

67276 (item 41) 1.100 M60x1.5

Part No. Qty Description

40 58499 1 Sticker

41 67276 1 Cylinder Head

42 58583 1 T-Seal

48 58594

49 67279 1 Setscrew

50 67280 1 Key

51 67277 1 Setscrew

52 67259 1 Check Valve Assembly

Retaining Ring

9, 16, 24, 39 & 42)

CT10 USER MANUAL 25

Page 26

Stanely Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon

503-659-5660 / Fax 503-652-1780

www.stanleyhydraulics.com