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)
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:
Certied non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid
reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certied non-
conductive is the only hose authorized for use near electrical conductors.
Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforce-
ment, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near
electrical conductors.
Fabric-braided (not certied or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic ber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This
hose is not certied non-conductive and must never be used near electrical conductors.
HOSE SAFETY TAGS
To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic
Tools. DO NOT REMOVE THESE TAGS.
If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be
obtained from your Stanley Distributor.
THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE
DANGER
1. 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.
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 MOISTURE AND
TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH
SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT REMOVE THIS TAG
SEE OTHER SIDE
SIDE 1
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 DAM-
AGE 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.
(Shown smaller than actual size)
DANGER
DANGER
SEE OTHER SIDE
SIDE 2
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.
DANGER
DANGER
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.
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, 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
SEE OTHER SIDE
SIDE 1
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.
(Shown smaller than actual size)
DANGER
SEE OTHER SIDE
SIDE 2
DO NOT REMOVE THIS TAG
DO NOT REMOVE THIS TAG
CT04 User Manual ◄ 7
HOSE RECOMMENDATIONS
HYDRAULIC CIRCUIT
Min. Working Pressure
USE
(Press/Return)
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
5/8 16 Pressure 2500 175
3/4 19 Return 2500 175
3/4 19 Pressure 2500 175
1 25.4 Return 2500 175
PRESSURE
RETURN
Certied Non-Conductive Hose - Fiber Braid - for Utility Bucket Trucks
Oil Flow Hose Lengths Inside Diameter
GPM LPM FEET METERS INCH MM PSI BAR
4-9 15-34 up to 10 up to 3 3/8 10 Both 2250 155
Conductive Hose - Wire Braid or Fiber Braid -DO NOT USE NEAR ELECTRICAL CONDUCTORS
4-6 15-23 up to 25 up to 7.5 3/8 10 Both 2500 175
4-6 15-23 26-100 7.5-30 1/2 13 Both 2500 175
5-10.5 19-40 up to 50 up to 15 1/2 13 Both 2500 175
5-10.5 19-40 51-100 15-30 5/8 16 Both 2500 175
5-10.5 19-40 100-300 30-90
10-13 38-49 up to 50 up to 15 5/8 16 Both 2500 175
10-13 38-49 51-100 15-30
10-13 38-49 100-200 30-60
13-16 49-60 up to 25 up to 8
13-16 49-60 26-100 8-30
PRESSURE
PRESSURE
<<< FLOW
Tool
RETURN
RETURN
FLOW >>>
Figure 1. Typical Hose Connections
Tool to Hydraulic Circuit Hose
Recommendations
The chart to the right shows recommended
minimum hose diameters for various hose
lengths based on gallons per minute (gpm)/
liters per minute (lpm). These recommenda-
tions are intended to keep return line pressure
(back pressure) to a minimum acceptable lev-
el to ensure maximum tool performance.
8 ► CT04 User Manual
This chart is intended to be used for hydraulic
tool applications only based on Stanley Hy-
draulic Tools tool operating requirements and
should not be used for any other applications.
All hydraulic hose must have at least a rated
minimum working pressure equal to the maxi-
mum hydraulic system relief valve setting.
All hydraulic hose must meet or exceed
specications as set forth by SAE J517.
HTMA / EHTMA REQUIREMENTS
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: Sufcient 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)
TOOL TYPE
TYPE I TYPE II
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 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 specication page for tool specic requirements
B
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)
C
D
CT04 User Manual ◄ 9
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,
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.
7. Periodically verify the crimping force of the tool. Re-
fer to Die Load Verication.
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 CT04 Hydraulic Crimping Tool can be congured
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:
TO CHANGE THE CURRENT SETTING:
1. Remove the hydraulic hose coupling from the return
port on the tool, if one is installed. When making
the change from CC to OC, hydraulic uid may be
trapped in the tool, preventing complete movement
of the adapter. Remove the return coupling to allow
the hydraulic uid to escape.
Cylinder
Top View of Tool
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.
Open-Center (no gap)
Adapter
Trigger Handle
DIE INSTALLATION
Each crimping head has two die holders: one station-
ary and one moved by hydraulic ow when the trigger
is squeezed.
To install dies, follow the instructions below for your
model of crimping head.
WARNING
Installing dies in the tools with the hydraulic hoses
connected can cause severe personal injury or
equipment damage.
To prevent accidental start-up, always disconnect the
hoses before installing dies.
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 veried, select blank
dies and verify die load.
10 ► CT04 User Manual
OPERATION
• If the die load has been veried, select a set
of dies to match the sleeve or connector to be
crimped.
TO INSTALL DIES ON KEARNEY “O”
STYLE HEAD
1. Loosen the two die retainer screws (items ___ on
the parts illustration).
2. Insert and center the dies.
3. Tighten the die retainer screws to lock the dies in
place.
TO INSTALL DIES ON BURNDY “W” STYLE
HEAD
1. Squeeze the release buttons on the side of the Chead.
2. Insert and center the die.
3. Release the buttons to hold the die in place
4. Repeat above steps 1 through 3 above using the
release buttons on the piston die holder.
HYDRAULIC HOSE CONNECTION
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 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 fe-
male 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.
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 4.4–5 tons
(4000-4540 kg), depending on the pressure from the
hydraulic power source.
a. If the indicated value is low and the system pres-
sure relief valve setting is greater than 1650 psi
(114 bar), adjust the relief valve on the CT to get
the correct die load.
b. If the indicated value is high, adjust the relief
valve on the CT to get the correct die load.
5. When the value is within the acceptable range, turn
the hydraulic system control valve OFF and disconnect the hoses from the tool.
6. 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 1/4-inch (6.4-mm)
gap
If the setting is not correct for your hydraulic system, fol-
low the instructions in this section, OC/CC Adjustment,
to make the change.
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 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.
CT04 User Manual ◄ 11
IMPORTANT
OPERATION
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 hydraulic 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 difcult to
connect. Whenever possible, connect the free ends
of the hoses together.
TOOL RELIEF VALVE ADJUSTMENT
The relief valve on a universal pressure CT can be adjusted to increase or decrease the tool’s crimping force.
Standard CT’s do not have a relief valve.
The crimping tools relief valve is located below the trigger guard. The relief valve on the hydraulic system is
totally separate and has a different function.
1. Perform steps 1 through 5 under Die Load Verication.
2. If the load tester indication is within the acceptable
range, the tools’ relief valve on the hydraulic system
is set correctly. If it is not, adjust the valve as follows:
a. Turn the hydraulic system control valve OFF.
b. Remove the plug from the end of the relief valve,
below the trigger guard.
c. Using a hex wrench, turn the adjusting screw.
Clockwise (CW) to increase pressure or Counterclockwise (CCW) to decrease pressure.
d. Replace the plug in the relief valve and retest.
Repeat the adjustment if necessary.
OPERATION
Observe all safety precautions when operating the tool.
Read Safety and Hydraulic System Requirements, be-
fore 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.
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.
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.
Failure to center the connector between the dies will
damage the dies and/or die holders.
4.
Hook the stationary (C-Head) 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.
12 ► CT04 User Manual
OPERATION
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
hydraulic uid at low engine speed. When using 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.
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.
CT04 User Manual ◄ 13
NOTICE
TOOL PROTECTION & CARE
In addition to the Safety Precautions found in
this manual, observe the following for equipment
protection and care.
• Make sure all couplers are wiped clean before connection.
• The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling hydrau-
lic tools. Failure to do so may result in damage to
the quick couplers and cause overheating of the 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 cir-
cuit 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 mini-
mum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated ow. Refer to Specications
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.
• 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 ► CT04 User Manual
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. Hydraulic hoses not connected
properly.
Hydraulic control valve OFF. Turn the hydraulic system control
Hydraulic system not functioning. Check hydraulic power unit for correct
Couplers or hoses blocked. Remove obstruction.
Pressure port check valve is
installed in tool return port.
Tool operates in reverse (piston
advances/retracts when trigger is
squeezed).
Tool under-crimps. Die load less
than 4.4 tons/4000 kg.
Tool over-crimps. Die load more
than 5 tons/4540 kg.
Trigger difcult to operate. Hoses connected to wrong ports on
Hoses connected to wrong ports on
tool.
Hydraulic system pressure too low. Check hydraulic power source for
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
Improper die set for wire and
connector.
Hydraulic system pressure too high. Check hydraulic power source for
Relief valve set too high. Decrease relief valve pressure.
tool.
Excessive back-pressure. If back-pressure is greater than
Trigger guard bent and binding on
spool in bore.
Make sure hoses are connected and
the couplers are tight.
valve ON.
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.
correct ow and pressure.
distributor.
Install proper die set.
correct ow and pressure.
Connect input (supply) line to IN port.
Connect output (return) line to OUT
port.
250 psi/17 bar, clear the return line
obstruction or restriction.
Repair or replace trigger assembly.
CT04 User Manual ◄ 15
SPECIFICATIONS
Capacity ........................................................................................................................................ #6 - 4/0 Conductor
Crimping Force .......................................................................................... 4.4 tons @ 1650 psi / 4000 kg @ 114 bar
Pressure Range................................................................................................................................ 1650 psi/114 bar
Flow Range .................................................................................................................................3-9 gpm / 11-34 lpm
Optimum Flow ..................................................................................................................................... 8 gpm / 30 lpm
Porting ............................................................................................................................................................3/8 NPT
Hose Whips & Couplers ......................................................................................................................................... No
Weight ...................................................................................................................................................12 lbs / 5.4 kg
Overall Length ..............................................................................................................................20 inches / 50.8 cm
Overall Width ...............................................................................................................................3.75 inches / 9.5 cm
16 ► CT04 User Manual
CT04 ILLUSTRATION
CT04 User Manual ◄ 17
CT04 PARTS LIST
ITEM
NO.
1 00118 1 RETAINING RING
2 00144 12 HSHCS
3 07626 2 O-RING ■
4 09330 1 O-RING ■
5 00294 1 O-RING ■
6 00360 1 O-RING ■
7 00831 1 ROD WIPER■
8 00936 1 ADAPTER
9 01259 1 O-RING ■
10 01534 1 ROLL PIN
11 01608 4 STEEL BALL
12 01809 1 VALVE SPOOL
13 01812 1 VALVE SPOOL SCREW
14 07736 1 SETSCREW
15 16556 1 SPRING
16 18050 1 BACK-UP RING ■
17 20428 1 O-RING ■
18 20430 1 RETAINING RING EXTERNAL
19 20747 1 C FRAME – BROCK
20 21255 2 SETSCREW
21 21424 1 RELIEF VALVE
22 22147 2 CAPSCREW
23 38622 1 VALVE SLEEVE
24 39925 1 COMPRESSION SPRING
25 39939 1 VALVE HANDLE
26 51182 1 TRIGGER GUARD
27 51183 1 TRIGGER
28 52534 2 SETSCREW
29 58439 1 ADAPTER
30 58440 1 RETAINING RING
31 58441 1 SLEEVE
32 58442 1 OIL TUBE
33 58483 1 O-RING ■
PART
NO. QTY DESCRIPTION
ITEM
NO.
34 58501 1 CT04 1650 PSI COMBINED STICKER
35 58533 1 T-SEAL ■
36 58534 1 CYLINDER
37 58535 1 PISTON
38 58536 1 CYLINDER HEAD
39 58538 1 PUSH ROD
40 350850 1 O-RING ■
41 58594 1 RETAINING RING EXTERNAL
42 67259 1 CHECK VALVE ASSY
PART
NO. QTY DESCRIPTION
58549 1 SEAL KIT
(■ INDICATES PART IN SEAL KIT)
18 ► CT04 User Manual
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon
503-659-5660 / Fax 503-652-1780
www.stanleyhydraulics.com
Loading...