Stanley Black & Decker CT04 User Manual
CT04
HYDRAULIC
CRIMPING TOOL
USER MANUAL
Safety, Operation and Maintenance
© 2014 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
58541 10-2014 Ver. 4
WARNING
TABLE OF CONTENTS
WARRANTY (SEE BELOW UNDER “IMPORTANT”) ............................................................................................3
SAFETY SYMBOLS ............................................................................................................................................... 4
SAFETY PRECAUTIONS ......................................................................................................................................5
TOOL STICKERS AND TAGS ................................................................................................................................6
HOSE TYPES ........................................................................................................................................................7
HOSE RECOMMENDATIONS ............................................................................................................................... 8
HTMA REQUIREMENTS .......................................................................................................................................9
OPERATION ........................................................................................................................................................10
SETUP AND TEST ............................................................................................................................................10
OPEN CENTER/CLOSED CENTER SETUP .................................................................................................... 10
DIE INSTALLATION ..........................................................................................................................................10
TOOL PROTECTION & CARE .............................................................................................................................14
TROUBLESHOOTING .........................................................................................................................................15
SPECIFICATIONS ................................................................................................................................................16
CT04 ILLUSTRATION .......................................................................................................................................... 17
CT04 PARTS LIST ...............................................................................................................................................18
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 certied dealer. Please read the following warning.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
CT04 User Manual ◄ 3
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT
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, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in 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 ► CT04 User Manual
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 pre-
cautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
The model CT04 Hydraulic Crimping Tool will provide
safe and dependable service if operated in accordance
with the instructions given in this manual. Read and 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 by-
standers. Flying debris can cause serious injury.
• Make sure all critical tool markings, such as labels
and warning decals, are securely in place and legible. Replace any that are damaged or missing.
• Do not operate the tool unless thoroughly trained
or under the supervision of an instructor. Establish
a training program for all operators to ensure safe
operation.
• Always wear personal protection equipment (PPE)
such as goggles, ear and head protection, and safety shoes at all times when operating the tool. Use
gloves and aprons when necessary.
• Never wear loose clothing or unrestrained long hair
that can get entangled in the working parts of the
tool.
• Keep all parts of your body away from the tool and
maintain proper footing and balance at all times.
• Do not rely exclusively upon the safety devices built
into the tool.
• Always be well rested and mentally alert before op-
erating the tool.
• The operator must be familiar with all prohibited
work areas such as excessive slopes and dangerous terrain conditions.
• Know the location of buried or covered electrical
services before starting work.
• Keep your work area clean and clear of tripping haz-
ards. Oily surfaces and hoses lying around can be
hazardous.
• Always operate the tool within its rated capacity.
• Do not use the tool for applications for which it was
not designed.
• Do not inspect, clean or replace any part(s) if the
hydraulic power source is connected. Do not inspect
or clean the tool while the hydraulic power source is
connected. Accidental engagement of the tool can
cause serious injury.
• Always connect hoses to the tool hose couplers be-
fore energizing the hydraulic power source. Be sure
all hose connections are tight and are in good condition.
• Always replace hoses, couplings, and other parts
with replacement parts recommended by Stanley
Hydraulic Tools. Refer to the parts list at the end of
this manual for part numbers.
• Do not operate the tool at oil temperatures above
140 °F/60 °C. Operation at higher temperatures can
cause higher than normal temperatures at the tool
which can result in operator discomfort.
• Do not operate a damaged, improperly adjusted, or
incompletely assembled tool. Do not carry tool by
the hoses.
• Keep the handles dry, clean and free of oil.
• Ensure adequate lighting for the area where the tool
is being used.
• Use proper lifting techniques when handling the
tool. Do not overreach. Maintain secure footing and
balance at all times.
• When using tools near energized transmission lines,
be sure to use only hoses labeled and certied non-
conductive.
• Turn off the power unit or move the hydraulic control
valve to neutral before setting the tool down.
• To avoid personal injury or equipment damage, all
tool repair, maintenance and service must only be
performed by authorized and properly trained personnel.
CT04 User Manual ◄ 5
58501
CT04 1650 psi Combined Sticker
DO NOT OPERATE
WITHOUT DIES
07961
Warning Sticker
TOOL STICKERS & TAGS
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.
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
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
DANGERDANGER
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 CON-
NECTED 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 PRO-
TECTION.
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
OPERATION MANUAL.
TAG TO BE REMOVED ONLY BY
TOOL OPERATOR.
SEE OTHER SIDE
6 ► CT04 User Manual
SAFETY TAG P/N 15875 (Shown smaller then actual size)
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