PANDUIT CT-902HP Family Hydraulic Compression Systems Instruction Manual

PANDUIT CT-902HP Family Hydraulic Compression Systems

Product Information

The CT-902HP family of hydraulic pumps includes five models that are capable of providing 10,000 PSI (700 bar). The models are:

• CT-902HP – 110 V Hydraulic Pump with Hand Pendant Switch
• CT-902HPRCH – 110 V Hydraulic Pump with Remote Control Handle
• CT-902HPRFS – 110 V Hydraulic Pump with Remote Foot Switch
• CT-902HP220 – 220 V Hydraulic Pump with Hand Pendant Switch
• CT-902HP220RFS – 220 V Hydraulic Pump with Remote Foot Switch

Panduit recommends using the CT-902HP family of hydraulic pumps with the CT- 900HPH Hydraulic Pump Hose, which can crimp #8 AWG thru 1500 MCM Panduit Copper Compression Connectors; and #6 AWG thru 1000 MCM Panduit Aluminum Compression Connectors. The user manual includes important safety warnings and precautions that should be followed before operating the hydraulic pump. These include disconnecting the unit from the power supply outlet before performing any service on the pump, wearing safety glasses at all times while using the tool, and not using the tool on live electrical circuits.

Product Usage Instructions

1. Before using the hydraulic pump, ensure that the work area is clean and well-lit to avoid accidents. Do not operate the power tool in explosive atmospheres, and keep children and bystanders away from the work area.
2. The user should be properly trained in the correct procedures required for working around electrical lines.
3. When performing any service on the pump or any of its components, the unit MUST be disconnected from the power supply outlet.
4. Always wear safety glasses while using the tool to avoid eye injuries. Be aware of the ejection of cable tie scrap from the tool.
5. Do not use the tool on live electrical circuits. Keep fingers clear of the crimping tool head area during tool operation.
6. The hydraulic pump should not be used in an explosive atmosphere. Ear protection should be worn when operating the tool.
7. Ensure that the latch is secured before operating the pump to avoid severe tool damage and personal injury.
8. Do not operate the hydraulic pump without dies.
9. Follow the step-by-step guide provided in the user manual for the operation and maintenance of the hydraulic pump.
10. If you encounter any problems, call Panduit technical support at 1-800-777-3300. Note: In the interest of higher quality and value, Panduit products are continually being improved and updated. Consequently, pictures may vary from the enclosed product.

WARNING:
Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

PRECAUTIONS

THE USER SHOULD BE PROPERLY TRAINED IN THE CORRECT PROCEDURES REQUIRED FOR WORK AROUND ELECTRICAL LINES
**| WARNING: When performing any service on this pump or any of its’ components, the unit MUST be disconnected from the power supply outlet.
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**| WARNING: Safety glasses must be worn at all times when using the tool. CAUTION: Be aware of the ejection of cable tie scrap from tool.
**| WARNING: DO NOT USE THIS TOOL ON LIVE ELECTRICAL CIRCUITS
**| WARNING: Keep fingers clear of crimping tool head area during tool operation.
**| WARNING: DO NOT use tool in an explosive atmosphere.
| CAUTION: Ear protection should be worn when operating the tool.
| CAUTION – When using CT-980CH Crimp Head
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SECURE LATCH BEFORE OPERATING
FAILURE TO SECURE LATCH CAN RESULT IN SEVERE TOOL DAMAGE AND PERSONAL INJURY.
**| CAUTION – When using CT-920CH, CT-920CH/CCP, CT-930CH or CT- 940CH Crimp Heads
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DO NOT OPERATE WITHOUT DIES

INTRODUCTION

The CT-902HP family of hydraulic pumps:

• CT-902HP 110 V Hydraulic Pump with Hand Pendant Switch
• CT-902HPRCH 110 V Hydraulic Pump with Remote Control Handle
• CT-902HPRFS 110 V Hydraulic Pump with Remote Foot Switch
• CT-902HP220 220 V Hydraulic Pump with Hand Pendant Switch
• CT-902HP220RFS 220 V Hydraulic Pump with Remote Foot Switch

The CT-902HP family of hydraulic pumps are capable of providing 10,000 PSI (700 bar). Panduit recommends using their CT-902HP family of hydraulic pumps with the CT-900HPH Hydraulic Pump Hose, which can crimp #8 AWG thru 1500 MCM Panduit Copper Compression Connectors; and #6 AWG thru 1000 MCM Panduit Aluminum Compression Connectors. Refer to the product packaging for wire size and crimp designations.

This manual will guide you step-by-step in operation and maintenance of your Hydraulic Pump. If you have problems not covered, call: 1-800-777-3300

The information contained in this literature is based on our experience to date and is believed to be reliable. It is intended as a guide for use by persons having technical skill at their own discretion and risk. We do not guarantee favorable results or assume any liability in connection with its use. Dimensions contained herein are for reference purposes only. For specific dimensional requirements consult the factory. This publication is not to be taken as a license to operate under, or a recommendation to infringe any existing patents. This supersedes and voids all previous literature, etc.

NOTE:
In the interest of higher quality and value, Panduit products are continually being improved and updated. Consequently, pictures may vary from the enclosed product.

1. Work area safety
   • Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
   • Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2. Electrical safety
   • Always disconnect plug from outlet before performing any service on the pump.
   • Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
   • Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
   • Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
   • Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
   • When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
   • If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI)” protected supply. Use of a GFCI reduces the risk of electric shock.
3. Personal safety
   • Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
   • Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.
   • Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
   • Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
   • Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
   • Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
   • If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
   • Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
4. Power tool use and care
   • Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
   • Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
   • Disconnect the plug from the power source, before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
   • Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
   • Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
   • Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
   • Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
   • Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5. Service
   • Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Periodic Maintenance:
Make sure tool is clean before each use.

SYSTEM SPECIFICATIONS

• CT-902HP Family Hydraulic Pumps Hydraulic Pump pressure is factory preset at 10,000 PSI ± 200 PSI (700 bar) and is to be used with the following Remote Hydraulic Crimp Heads: CT-920CH, CT-920CH/CCP, CT-930CH, CT-940CH, and Dieless CT-980CH. The pump shuts off when the cycle is complete. Will not release until the down button is activated.
• Dimensions:
  • 9.5 L x 10.5 W x 15.5 H in.
  • 241 L x 267 W x 393 H (mm)
• Weight: 15.4 (kg) / 34.0 lbs.
• Housing:
  • Color – TOP BASE
  • 110V Blue Black
  • 220V Yellow White/Gray

Pump

• Tank Capacity: 2 Liters
• Fluid Type: Shell Tellus Hydraulic Oil S2 V 15
• Motor/110V/220V
  • Type: Commutator Commutator
  • R.P.M.: 1200 1200
  • Voltage: 110 V 220 V
  • Watts: 715 W 340 W
  • Frequency: 50/60 Hz 50/60 Hz
  • Current: 6.5 A 3.2 A
  • Horsepower: ½ ½
• Delivery @ 200 psi 157 cubic inches/minute
• Delivery @ 10,000 psi 19 cubic inches/minute
• CT-902HPRCH Hydraulic Pump with Remote Control Handle (hardwired at factory)
  • RCH Dimensions: 155 L x 167 H x 34 W (mm) 6.1 L x 6.6 H x 1.4 W in.
  • Weight: 3.0 (kg) / 6.6 lbs.
• CT-902HPRFS Hydraulic Pump with Remote Foot Switch (hardwired at the factory)
• RFS Dimensions: 243 L x 173 H x 180 W (mm) 9.6 L x 6.8 H x 7.1 W in.
• Weight: 3.5 (kg) / 7.7 lbs.

OPTIONAL ACCESSORIES

• CD-920 / CD-940 Refer to the product packaging for wire size and crimp designations or contact

• Compression Dies Panduit Customer Service for specific die application information.

• CT-900HPH Hydraulic Pump Hose: Electrically non-conductive 10 ft. hose. Supplied pre-filled with hydraulic fluid for fast start up.

• PG-1 Verifies the PSI reading of the CT-902HP Hydraulic Pump.

• Pressure Gauge

  • Dimensions:
    228 L x 114 H x 38 W (64 dial face) (mm)
    9.0 L x 4.5 H x 1.5 W (2.5 dial face) in.

  • Weight: 1.4 (kg) / 3.0 lbs.

• CG-920 / CG-940 / CG-980 Compression Gauges Verifies the compression force of Panduit compression tools and remote crimp heads.

  • Dimensions:
    228 L x 102 H x 38 W (102 dial face) (mm)
    9.0 L x 4.0 H x 1.5 W (4.0 dial face) in.

• Weight: 1.6 (kg) / 3.5 lbs.

GENERAL GUIDELINES FOR MAINTENANCE OF TOOLS

1. Always verify the proper size connector for the conductor, by checking the color code and the printing on the connector.

2. NOTE: CONNECTIONS UTILIZING THIS TOOL ARE U.L. LISTED AND C.S.A. CERTIFIED ONLY WHEN PANDUIT COMPRESSION CONNECTORS ARE USED. USE OF ANY OTHER BRAND OF COMPRESSION CONNECTORS IS NOT RECOMMENDED.
   Consult product packaging, Panduit catalog or website for information on recommended connectors.

3. Daily maintenance is important to keep the tool in good working condition. Keep the tool head portion clean and free from debris. Excessive dirt and grit can contribute to the premature wear of the tool’s internal parts. Always replace the dust cap on the coupler, and store the tool in its clean, dry carrying case when not in use. Particular attention should be made in keeping the tool head openings free of foreign matter and debris. When using the tool, regularly check that no foreign matter or debris exists in the open areas between the piston and tool head. Solvent can be used on the tool head to remove any foreign matter or debris. A tool that is dirty with excessive foreign matter may jam and become damaged during operation.

4. The hydraulic system has been calibrated and sealed at the factory. Consult our Customer Service Department or your local distributor if hydraulic problems are experienced.

5. As long as the daily maintenance procedures are adequately carried out, the tool will provide quality service for years. However, if problems are experienced, please contact our Customer Service Department at: 1- 800-777-3300.

6. Avoid dropping the tool. Extreme shock may damage the hydraulic circuit or tool head, and result in a malfunction of the tool.

7. If the tool is kept in cold temperatures below 23°F/-5°C for any extended time, it is advisable to return the tool to room temperature for 1 hour before using.

PUMP OPERATION

1. Connect male hose fitting to female tool fitting. (Panduit Part No. for the hose is: CT-900HPH.) Vent tank by turning the air vent lever (A) [see photo on Page 2] to the upright position (replace cotter pin). Leave the vent open during tool operation.
2. Insert the electric cord (3-prong plug) into the appropriate power outlet for the unit being used.
3. Depress the “DOWN” button on the remote control switch to determine if the solenoid is operational. (A “clicking” sound will be heard.)
4. The “UP” button activates the motor to generate hydraulic pressure. Depress and hold for ram advance.
5. To stop ram advance, release the “UP” button. Oil pressure will remain constant until the “DOWN” button is depressed to relieve pressure. The pump will automatically shut off when the maximum pressure is reached.
6. To retract ram, depress and hold in the “DOWN” button. Oil in the tool cylinder will return to the tank and the tool will be ready to begin the next cycle. Retraction of the ram may be stopped by releasing the “DOWN” button.

PREVENTIVE MAINTENANCE

Maintenance should be performed monthly, whenever possible damage has occurred, or as often as operating conditions warrant.

1. Operate CT-902HP pump on 110 volts AC only, or voltages between 95 and 120. Do not operate pump on voltages less than 95 volts, or on DC current. Operate CT-902HP220 pump on 220 volts AC only, or voltages between 200 and 242. Do not operate pump on voltages less than 200 volts, or on DC current.
2. Level of oil is to be maintained above the red dot in center of port window. To add oil, unscrew entire oil vent fitting from tank with a wrench. Using a funnel, pour oil into the tank opening. Recommended hydraulic oil: Shell Tellus Hydraulic Oil S2 V 15 or approved equivalent. Replace fitting.
3. When attaching hoses, be sure all couplers are securely fastened. Always keep couplers clean by wiping oil and debris from surfaces before connecting hoses to pump or tool.
4. Never move pump by pulling on the electrical cords.
5. Always store pump with the air vent in the closed position.

TROUBLESHOOTING

If system locks up under pressure, perform the following steps:

• Verify that the solenoid on pump is making an audible “click”.
• If above step checks out, determine which fitting needs to be tightened.
• When pump is released, does the hose stay rigid or flex back down?
• If the hose stays rigid, the problem is in the connection from pump to hose.
• If the hose flexes down, the problem is in the connection from hose to tool head.
• To tighten couplers, use channel lock pliers or pipe wrench; (wrap couplers to avoid causing damage).
• When you feel the couplers tighten, depress the release on the pump; (pressure should be released).
• Tool head should retract. Finish tightening couplers by hand.

CONTACT INFORMATION

For Technical Support:

Panduit USA, Tinley Park, IL USA Tel: 1-800-777-3300

Website: www.panduit.com

E-mail: techsupport@panduit.com

| Panduit Canada Headquarters Markham Ontario, Canada

Canada Tel.: 905-475-6922 or 800-387-9689

Fax.: 905-475-6998

Website: www.panduit.com

E-mail: cs-tp-canada@panduit.com

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Panduit Latino America, Guadalajara, Jalisco, Mexico
Latino America Tel.: 52 (333) 666 2501
Fax.: 52 (333) 666 2510
Website: www.panduit.com E-mail: cs- la@panduit.com| Panduit China, Beijing
Xuanwumen Xidajie Xicheng District Beijing, China
Tel: 8610 6641 0371 • Fax: 8610 6641 0375
Toll Free Customer Service – North China: 10800 6500 211 • South China: 10800 2650 211
E-mail: cs-ap@panduit.com
Panduit Singapore – Sales Office Singapore, Republic of Singapore
Tel: 65 6379 6700 • Fax: 65 6379 6759
E-mail: cs-ap@panduit.com|

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