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Stanley CT06, Safety And Operation Manual

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Stanley CT06 Safety And Operation Manual Download Page 8

2  Safety

CT06 Hydraulic Crimping Tool

Page  4

2 SAFETY

This section includes the following safety topics:

• hazard alert definitions

• general safety

• safety labels and tags

Operators and maintenance personnel 

MUST

 comply with the safety guidelines

given in this manual and printed on the labels and tags attached to the equipment
and hoses.

These safety rules are for your safety. Review them carefully before operating
the tool or performing any maintenance or repairs.

Supervising personnel may specify additional rules for your work area to
comply with your company policies and local safety regulations. Enter any
added precautions in the space provided on the last page of this section.

Hazard  Alerts

The following terms are used in this manual and on the labels and tags on
the tool.

 DANGER

Indicates the presence of a hazard that will cause severe
personal injury, death, or substantial property damage if
the warning is ignored.

WARNING

Indicates the presence of a hazard that can cause severe
personal injury, death, or substantial property damage if
the warning is ignored.

CAUTION

Indicates the presence of a hazard that will or can cause
minor personal injury or property damage if the warning is
ignored.

    CAUTION

Indicates the presence of a hazard that can or will cause
property damage if the warning is ignored.

IMPORTANT

Calls attention to operation or maintenance information that is
important for the safety, efficiency, and useful life of the
equipment, but is not hazard-related.

Summary of Contents for CT06

Page 1: ...ping Tool Safety and Operation Manual Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 USA Phone 503 659 5660 Fax 503 652 1780 Copyright 2002 The Stanley Works OPS USA VERSION US Pat No 6 490 962 58543 08 02 Ver 1 ...

Page 2: ...he prior written consent of The Stanley Works This exception does not permit copies to be made for others whetherornotsold Underthelaw copyingincludestranslatinginto anotherlanguage format ormedium Thiscopyrightnoticemustappear on any permitted copies Printed in U S A August 2002 Stanley Hydraulic Tools 3810 SE Naef Road Phone 503 659 5660 Milwaukie OR 97267 5698 USA Fax 503 652 1780 ...

Page 3: ...ons 7 3 HYDRAULIC SYSTEM REQUIREMENTS Hydraulic Safety 8 System Requirements 9 Hose Requirements 10 Installation Requirements 11 4 SETUP AND TEST OC CC Adjustment 12 Latch Nib Replacement 13 Hydraulic Hose Connection 14 Die Load Verification 15 Tool Relief and Adjustment 16 5 OPERATION Pre operation Checkout 17 Daily Maintenance 17 OC CC Setting 18 Hydraulic Power Source Check 18 Cold Weather Oper...

Page 4: ...Contents CT06 Hydraulic Crimping Tool Page ii 6 TROUBLESHOOTING Troubleshooting Guide 22 7 PARTS LIST Parts List 24 Exploded View Illustration 25 ...

Page 5: ... r o f r e p e b Read sections 1 through 5 of this manual before using the tool for the first time The CT06 Hydraulic Crimping Tool has been designed and manufactured with high quality materials and workmanship It will provide efficient and reliable service when used as directed Continuing product development may result in changes that are not reflected in this manual If you have any questions reg...

Page 6: ... 34 lpm Optimum flow 8 gpm 30 lpm Pressure minimum 1650psi 114 bar Compression tooling Anderson VC6 FT FC6 FTV FC6 FTR or FC6 FTVR Crimpingforce 6 tons 1650 psi 5443 kg 114 bar Wire size capacity See tooling manufacturer s specifications Porting size 8 SAE Weight ____ lb ____ kg Dimensions Length ____ in ____ cm Width ____ in ____ cm Refer to Section 3 Table 3 1 for detailed hydraulic system requi...

Page 7: ...failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage cau...

Page 8: ...on the last page of this section Hazard Alerts The following terms are used in this manual and on the labels and tags on thetool DANGER Indicates the presence of a hazard that will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Indicates the presence of a hazard that can cause severe personal injury death or substantial property damage if the wa...

Page 9: ...ded by Stanley Hydraulic Tools Refer to the parts list at the end of this manual for part numbers To avoid personal injury or equipment damage all tool maintenance repair and service must be performed by properly trained personnel Personal Safety Always wear safety equipment such as goggles head protection and safety shoes when operating the tool Never wear loose clothing or unrestrained long hair...

Page 10: ...ic system High pressure oil can be very dangerous Know your equipment and operate it properly Section 3 Hydraulic System Requirements includes specific hydraulic system safety issues Read and understand them before using the tool Safety Label and Tag The safety label and tag shown below are attached to the crimping tool at the factory Read and understand each one before operating the equipment If ...

Page 11: ...k 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 I M P O R T A N T READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPA...

Page 12: ... the task is complete or stopped for an extended period of time Do not inspect or clean the tool while the hydraulic power source is con nected Accidental engagement of the equipment can cause serious injury The return hose must be connected to the OUT or T port on the crimping tool The supply hose must be connected to the IN or P port Reversing connections or direction of flow can cause severe pe...

Page 13: ...imum cooling capacity 5 hp 3 73 kW at a temperature difference of 40 F 22 C between ambient and fluid temperature 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 Minimum full flow filtration 25 µm Sized for flow of at least 30 gpm 114 lpm for cold temperature startup and maximum dirt holding capacit...

Page 14: ...rizedforusewithStanleyhydraulictoolsareas follows Labeled and Certified Nonconductive the only hose authorized for use near electrical conductors Fabric Braided not certified or labeled nonconductive must never be used near electrical conductors Wire Braided conductive and must never be used near electrical conductors To help ensure your safety a DANGER tag is attached to every hose purchased from...

Page 15: ...kinked Do not use hose to pull or lift tools power units etc D O N O T R E M O V E T H I S T A G D O N O T R E M O V E T H I S T A G Side 1 Side 2 D A N G E R See other side 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...

Page 16: ... n e d i c c a t n e v e r p o T l o o t e h t g n i t s u j d a e r o f e b s e s o h e h t t c e n n o c s i d The CT06 Hydraulic Crimping Tool can be configured 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 open center no gap Figure 4 1 closed center approximately inch 6 4 mm gap To change th...

Page 17: ... n e d i c c a t n e v e r p o T s e i d g n i l l a t s n i e r o f e b s e s o h e h t t c e n n o c s i d 1 If the hydraulic hoses are connected Turn the hydraulic system control valve OFF Disconnect the hydraulic hoses first the hydraulic input supply hose then the output return hose 2 Clean the surfaces of the compression head to remove any dirt or grease 3 Pull the pin out to release the lat...

Page 18: ...plers and cause overheating of the hydraulic system 2 Before installing the hoses wipe the fittings and the entire length of the hoses with a clean dry lint free cloth to remove any dirt or moisture Dirty connections can contaminated the hydraulic fluid causing rapid wear and early failure of internal parts G N I N R A W e s u a c n a c l o o t e h t o t w o l f c i l u a r d y h f o n o i t c e r...

Page 19: ...ow the safety guidelines and instructions in Hydraulic Hose Connection earlier in this section If possible use the hydraulic power source you plan to use for crimping 2 Position the test slug within the nibs 3 Actuate the tool to squeeze the test slug 4 Release the test slug and then measure it If the indicated value is low or high and the system pressure relief valve setting is greater than 1650 ...

Page 20: ...mistotallyseparateandhasadifferentfunction 1 Perform steps 1 5 in Section 4 Die Load Verification 2 Iftheloadtesterindicationiswithintheacceptablerange thetool srelief valve is set correctly If it is not adjust the valve as follows TurnthehydraulicsystemcontrolvalveOFF Removetheplugfromtheendofthereliefvalve belowthetriggerguard Usingahexwrench turntheadjustingscrew clockwise CW to increase pressu...

Page 21: ...he start and the end of each work shift 1 If the hoses are not connected follow the instructions in Section 4 Hydraulic Hose Connection 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 2 Check all fasteners for tightness 3 Check the equipment for oil leaks If leaks are observed...

Page 22: ...gauge check the hydraulic power source at the tool s input port Make sure the system maintains an operating flow in the range of 3 9 gpm 11 34 lpm within a pressure range of 1650 2000 psi 114 140 bar The hydraulic fluid temperature should be at least 80 F 27 C for this test Cold Weather Operation IMPORTANT Use an oil with the recommended specifications listed in Table 3 1 Using oil that is too vis...

Page 23: ...endofthe 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 3 Install the connec...

Page 24: ... band mark IMPORTANT Make sure the connector sleeve is carefully centered between all four nibs in the tool A small connector can damage the tool if it becomes wedged between the nibs H frame connectors Place the connector in the tool so the main groove is positioned between the top nib and either side nib Make sure the positioning grooves mate with two of the nibs G N I N R A W c e h T e s u a c ...

Page 25: ...ose then the output return hose 3 Wipethetoolthoroughlywithacleandrycloth 4 Cleananyforeignmatterorconnectorsleeve jointcompoundfromthetool headsurfaces 5 Close the latch and insert the latch pin Storage Replace any damaged or missing safety labels and tags before storing the tool Otherwise thetoolmightbeimproperlyusedbysomeonewhoisnotfamiliar withthesafetyrequirements Store the tool in a clean dr...

Page 26: ...ing the hydraulic control valve to OFF is not sufficient Troubleshooting Guide If symptoms of poor performance develop use Table 6 1 as a guide to help determine the cause of the problem Table 6 1 Potential tool problems causes and corrective action Problem Cause Corrective Action Tool does not operate Hydraulic hoses not connected properly Make sure the hoses are connected and the couplers are ti...

Page 27: ...authorized Stanley distributor Tool over crimps die load more Hydraulic system pressure too high Check hydraulic power source for correct than 6 tons 5443 kg flow and pressure Universal CT tool relief valve set too high Decrease relief valve pressure Trigger difficult to operate Hoses connected to wrong ports on tool Connect input supply line to IN port Connect output return line to OUT port Exces...

Page 28: ... 4 Steel Ball 13 01809 1 Valve Spool 14 01812 1 Valve Spool Screw 15 04054 1 O Ring 16 04794 1 O Ring 17 07248 1 Cover Set Anderson 18 07427 1 Caution Label 19 16556 1 Spring 20 18050 1 Back Up Ring 21 21424 1 Relief Valve 22 22147 2 Cap Screw 23 38622 1 ValveSleeve 24 39925 1 Compression Spring 25 39939 1 ValveHandle 26 51182 1 Trigger Guard 27 51183 1 Trigger 28 52534 2 Setscrew 29 58439 1 Adapt...

Page 29: ...Page25 ...

Page 30: ...lude Air compressors Alternators Breakers Cable cutters Chain saws Chipping hammers Circle saws Crimping tools Cutoff saws Diamond chain saws Diggers Drills Earth augers Grinders Ground Rod drivers Hammer drills Hydrant saver tools Impact wrenches Mounted Breakers Mounted Compactors Pole chain saws Post drivers Post pullers Power units Pruners Pumps Railroad Tools Saw carts Shears Sinker drills Ta...

Page 31: ...Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA Tel 503 659 5660 Fax 503 652 1780 HydraulicTools ...

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