STANLEY CT06 Hydraulic Crimping Tool User Manual

: July 9, 2024
: Stanley

Table of Contents

STANLEY CT06 Hydraulic Crimping Tool
Product Information
Product Usage Instructions
Frequently Asked Questions
SAFETY SYMBOLS
SAFETY PRECAUTIONS
TOOL STICKERS & TAGS
HOSE TYPES
HTMA/EHTMA REQUIREMENTS
OPERATION
TOOL PROTECTION & CARE
TROUBLESHOOTING
SPECIFICATIONS
PARTS ILLUSTRATION
Read User Manual Online (PDF format)
Download This Manual (PDF format)

STANLEY CT06 Hydraulic Crimping Tool

Product Information

Specifications

Product Name: CT06 HYDRAULIC CRIMPING TOOL
Model Number: 58543
Version: 9
Manufactured: April 2024

Product Usage Instructions

Safety Precautions
It is essential to follow all safety precautions while operating the CT06 Hydraulic Crimping Tool. Some key safety measures include:

Always wear appropriate safety gear such as goggles, ear protection, safety shoes, gloves, and aprons.
Avoid loose clothing or jewelry that can get caught in the tool.
Maintain proper footing and balance, especially on uneven terrain.
Be aware of buried electrical services before starting work.
Keep the work area clean and free of tripping hazards.
Operate the tool within its rated capacity and only for its intended applications.
Do not inspect, clean, or replace any parts while the hydraulic power source is connected.
Always use replacement parts recommended by STANLEY.
Do not carry the tool by the hoses.
Properly handle the tool and ensure adequate lighting in the work area.
Use proper lifting techniques and maintain a secure footing at all times.
Ensure hoses used near energized transmission lines are labeled nonconductive.
Turn off the power unit or move the hydraulic control valve to neutral before setting the tool down.

Frequently Asked Questions

Q: Can I perform repairs or servicing on the CT06 Hydraulic Crimping Tool myself?

A: It is recommended that all repairs and servicing, other than routine maintenance, should be done by an authorized and certified dealer. Unauthorized repairs can lead to serious injury or death.

Q: How can I find the nearest certified dealer for servicing?

A: To locate the nearest certified dealer, you can contact STANLEY at (503) 6595660 and ask for a Customer Service Representative.

Q: What should I do if I notice damaged or missing safety gear?

A: Replace any damaged or missing safety gear immediately before operating the CT06 Hydraulic Crimping Tool to ensure your safety.

Important
To fill out a product warranty validation form and for information on your warranty. Note: The warranty validation record must be submitted to validate the warranty.

SERVICING:
This manual contains safety, operation, and routine maintenance instructions. STANLEY recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certified dealer. Please read the following warning.

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 certified dealer, call STANLEY at 503-659-5660 and ask for a Customer Service Representative.

SAFETY SYMBOLS

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.
DANGER This safety alert and signal word indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING This safety alert and signal word indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION This safety alert and signal word indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION This signal word indicates a potentially hazardous situation that, if not avoided, may result in property damage.
NOTICE This signal word indicates a situation that, if not avoided, will result in damage to the equipment.
IMPORTANT This signal word indicates a situation that, if not avoided, may result in damage to the equipment.

Always observe safety symbols. They are included for your safety and 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.

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 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 specific work area and local safety regulations. Place the added precautions in the space provided in this manual.
The CT06 Hydraulic Crimping Tool will provide safe and dependable service if operated by 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.
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 become 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.
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 hazards. 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 parts 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.
Always replace hoses, couplings, and other parts with replacement parts recommended by STANLEY. 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 tools 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 certified 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.

TOOL STICKERS & TAGS

76651
CT06 1650 PSI Combined 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

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 A 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 BY YOUR SAFETY DEPARTMENT INSTRUCTIONS.
A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY.
- DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST.
- DO NOT EXCEED THE RATED WORKING PRESSURE OF THE HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS PRESSURE MAY CAUSE A LEAK OR BURST.
- 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.
- DO NOT LIFT OR CARRY TOOLS BY THE HOSES. DO NOT ABUSE HOSE. DO NOT USE KINKED, TORN, OR DAMAGED HOSE.
MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM. SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL “IN” PORT. THE SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO THE TOOL “OUT” PORT. REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY.
DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN THE LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.
BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.
WEAR HEARING, EYE, FOOT, HAND, AND HEAD PRO-TECTION.
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 THE 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
READ THE 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

SAFETY TAG P/N 15875 (Shown smaller than 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. Three types of hydraulic hose meet this requirement and are authorized for use with STANLEY hydraulic tools. They are:

Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather-resistant thermoplastic or synthetic rubber cover. Hose labeled certiﬁ 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 certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather-resistant thermoplastic or synthetic rubber cover. This hose is not certiﬁ 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 hoses purchased from STANLEY. 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

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 THE CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.
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 THE HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE BY SAFETY DEPARTMENT INSTRUCTIONS.
DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR HANDLING OF THE HOSE COULD RESULT IN A BURST OR OTHER HOSE FAILURE. KEEP THE HOSE AS FAR AWAY AS POSSIBLE FROM THE BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY.
HANDLE AND ROUTE THE 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.
CHECK THE 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.
AFTER EACH USE STORE IN A CLEAN DRY AREA.

(Shown smaller than actual size)

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

DANGER

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.
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN THE CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.
DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR HANDLING OF THE HOSE COULD RESULT IN A BURST OR OTHER HOSE FAILURE. KEEP THE HOSE AS FAR AWAY AS POSSIBLE FROM THE BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY.
HANDLE AND ROUTE HOSTHE E 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.
CHECK THE 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.
AFTER EACH USE STORE IN A CLEAN DRY AREA.

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 recommendations are intended to keep return line pressure (back pressure) to a minimum acceptable level to ensure maximum tool performance.
This chart is intended to be used for hydraulic tool applications only based on STANLEY tool operating requirements and should not be used for any other applications.
All hydraulic hoses must have at least a rated minimum working pressure equal to the maximum hydraulic system relief valve setting.
All hydraulic hoses must meet or exceed specifications as set forth by SAE J517.

Oil Flow| Hose Lengths| Inside Diameter| USE ( Press/Return)| Min. Working Pressure
---|---|---|---|---
GPM| LPM| FEET| METERS| INCH| MM| PSI| BAR
Certified Non-Conductive Hose – Fiber Braid – for Utility Bucket Trucks
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

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175
10-13| 38-49| up to 50| up to 15| 5/8| 16| Both| 2500| 175

10-13

|

38-49

|

51-100

|

15-30

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175

10-13

|

38-49

|

100-200

|

30-60

| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175

13-16

|

49-60

|

up to 25

|

up to 8

| 5/8| 16| Pressure| 2500| 175
3/4| 19| Return| 2500| 175

13-16

|

49-60

|

26-100

|

8-30

| 3/4| 19| Pressure| 2500| 175
1| 25.4| Return| 2500| 175

HTMA/EHTMA REQUIREMENTS

HTMA HYDRAULIC SYSTEM REQUIREMENTS| TYPE I| TYPE II| TYPE RR| TYPE III
---|---|---|---|---
Flow range| 4-6 GPM

(15-23 LPM)

| 7-9 GPM

(26-34 LPM)

| 9-10.5 GPM

(34-40 LPM)

| 11-13 GPM

(42-49 LPM)

Nominal operating pressure

(At the power supply outlet)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

System relief valve setting

(At the power supply outlet)

| 2100-2250 psi

(145-155 bar)

| 2100-2250 psi

(145-155 bar)

| 2200-2300 psi

(152-159 bar)

| 2100-2250 psi

(145-155 bar)

Maximum back pressure

(At the tool end of the return hose)

| 250 psi

(17 bar)

| 250 psi

(17 bar)

| 250 psi

(17 bar)

| 250 psi

(17 bar)

Measured at a max fluid viscosity of: (At minimum operating temperature)| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

| 400 ssu*

(82 centistokes)

Temperature: Sufficient heat rejection capacity to limit maximum fluid temperature to:

(At maximum expected ambient temperature)

| 140° F

(60° C)

| 140° F

(60° C)

| 140° F

(60° C)

| 140° F

(60° C)

Minimum cooling capacity at a temperature difference between ambient and fluid temps

| 3 hp

(2.24 kW)

40° F

(22° C)

| 5 hp

(3.73 kW)

40° F

(22° C)

| 6 hp

(5.22 kW)

40° F

(22° C)

| 7 hp

(4.47 kW)

40° F

(22° C)

Note: Do not operate the tool at oil temperatures above 140° F (60° C). Operation at higher temperatures can cause the operator discomfort with the tool.
Filter minimum full-flow filtration| 25 microns| 25 microns| 25 microns| 25 microns
Sized for flow of at least:

(For cold temp startup and maximum dirt-holding capacity)

| 30 GPM

(114 LPM)

| 30 GPM

(114 LPM)

| 30 GPM

(114 LPM)

| 30 GPM

(114 LPM)

Hydraulic fluid, petroleum-based (premium grade, anti-wear, non-conductive) Viscosity (at a minimum and maximum operating temps)| 100-400 ssu

(20-82

centistokes)

| 100-400 ssu

(20-82

centistokes)

| 100-400 ssu

(20-82

centistokes)

| 100-400 ssu

(20-82

centistokes)

Note: When choosing a hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

CLASSIFICATION

EHTMA HYDRAULIC SYSTEM REQUIREMENTS| | | | |
---|---|---|---|---|---

Flow range

| 3.5-4.3 GPM

(13.5-16.5

LPM)

| 4.7-5.8 GPM

(18-22 LPM)

| 7.1-8.7 GPM

(27-33 LPM)

| 9.5-11.6 GPM

(36-44 LPM)

| 11.8-14.5 GPM

(45-55 LPM)

Nominal operating pressure

(At the power supply outlet)

| 1870 psi

(129 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

| 1500 psi

(103 bar)

System relief valve setting

(At the power supply outlet)

| 2495 psi

(172 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

| 2000 psi

(138 bar)

Note:
These are general hydraulic system requirements. See the tool specification page for tool-specific requirements.

OPERATION

Careful inspection of the tool and hydraulic system before startup is important for the safe, reliable operation of the tool.

The following items should be checked daily at the start and the end of each work shift.

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.
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. Refer to “Die Load Verification” on page 11.

SETUP AND TEST
Verify the crimping force before operating the tool.

OPEN CENTER/CLOSED CENTER SETUP
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:

TO CHANGE THE CURRENT SETTING:

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 fluid may be trapped in the tool, preventing complete movement of the adapter. Remove the return coupling to allow the hydraulic fluid to escape.
Loosen the 2 setscrews on the cylinder.
Turn the adapter until it stops:
- Counterclockwise (CCW) to change to closed center (creates gap)
- Clockwise (CW) to change to open center (closes gap)
Tighten the two setscrews.

LATCH NIB REPLACEMENT
The CT06 Hydraulic Crimping Tool has two main components in the 4-point compression head:

The cam yoke assembly forms the base of the compression head. It functions as a movable piston die to provide the crimping force.
The latch assembly bridges the cam yoke across the end of the head. The latch nib in the center of the assembly is the stationary die.

The following procedure describes how to remove and replace the latch nibs.

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.

If the hydraulic hoses are connected:
- Turn the hydraulic system control valve OFF.
- Disconnect first the hydraulic input (supply)
Clean the surfaces of the die holder to remove any dirt or grease.
Pull the pin out to release the latch.
Rotate the latch away from the head to provide access to the nib/nest die.
To release the nib/nest die, drive the roll pin out of the center of the latch.
Remove the nib/nest die by rotating it out and around the small pivot pin inside the latch.
Insert the new nib/nest die, rotating it around the pivot pin as in step 6. Make sure the nib/nest die is oriented so the notched side faces the pivot pin.
Press the nib/nest die firmly until it locks into place.
Drive the roll pin into the center of the latch to retain the nib/nest die.
Close the latch. Insert the latch pin.

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 fittings 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 fluid, causing rapid wear and early failure of internal parts.

Check the flow indicators (arrows) stamped on the couplers to ensure oil flows in the proper direction. The female coupler on the tool is the inlet coupler. Connect the output (return) hose first and disconnect it last to minimize trapped pressure within the tool.

Connect the output hose to the OUT or “T” port on the tool.
Connect the input hose to the IN or “P” port.
Be sure all hose connections are tight.

DIE LOAD VERIFICATION

Use test slugs to verify the crimping force in the tool.
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.
Position the test slug within the nibs.
Actuate the tool to squeeze the test slug.
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 psi (114 bar), adjust the relief valve on the CT to obtain the correct die load.
When the value is within the acceptable range, turn the hydraulic system control valve OFF and disconnect the hoses from the tool.

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 2.

Open Center: No gap
Closed Center: Approximately 1/4-inch (6.4-mm) approximately 1/4-inch (6.4-mm) gap

If the setting is not correct for your hydraulic system, follow “Open center/closed center setup” on page 10 to make the change.

CHECK POWER SOURCE
Using a calibrated flow meter and pressure 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.

CONNECT HOSES

Wipe all hose couplers with a clean, lint-free cloth before making connections.
Connect hoses from the hydraulic power source to the tool fittings or quick disconnects. Connect the return hose first and disconnect it last to minimize trapped pressure within the wrench.
Observe the flow indicators stamped on the main body assembly and the hose couplers to ensure that the flow is in the proper direction. 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 difficult to connect. Whenever possible, connect the free ends of the hoses.

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 CTs 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 separate and has a different function.

Perform steps 1 through 5 under “Die Load Verification” on page 11.
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:
- Turn the hydraulic system control valve OFF.
- Remove the plug from the end of the relief valve, below the trigger guard.
- Using a hex wrench, turn the adjusting screw. Clockwise (CW) to increase pressure or Counterclockwise (CCW) to decrease pressure.
- Replace the plug in the relief valve and retest. Repeat the adjustment if necessary.

TOOL OPERATION
Observe all safety precautions when operating the tool. Road Safety and hydraulic system requirements before operating the tool for the first time.

CONDUCTOR PREPARATION

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.
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.
Install the connector sleeve onto the conductor.

STARTUP

Clean the nibs on the tool. Remove all traces of lubrication from each tool nib before crimping.
Pull the ringed latch pin out of the latch. Rotate the latch away from the crimping head and then place the crimping head over the connector sleeve on the conductor. Close the latch and reinstall the ringed latch pin.
Move the hydraulic system control valve to the ON position.
Warning
The crimping force between the dies in the tool head can cause severe personal injury. Keep hands away from the die area when operating the tool.
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.
Position the tool as follows:
- Connector sleeves
  Center the sleeve between all four nibs in the compression head. Place the sleeve so the nibs make the first crimp adjacent to the center-band mark.
  Make sure the connector sleeve is carefully centered between all four nibs in the tool.
- 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.
Squeeze the trigger to crimp the connector.
Release the trigger to retract the nibs.
Repeat the crimp as required.
After the last crimp, make sure the nibs in the crimping head are fully retracted.
Pull out the latch pin and rotate the latch away from the crimping head.
Remove the tool by lifting it clear of the cable.

SHUTDOWN

Move the hydraulic system control valve to the OFF position.
Disconnect the hydraulic hoses from the tool: first the input (supply) hose, then the output (return) hose.
Insert plugs in the hose ends, couplers, or tool ports, as applicable.
Wipe the tool thoroughly with a clean, dry cloth.
Clean any foreign matter or joint compound from the die holder surfaces.

COLD WEATHER OPERATION

IMPORTANT
Use an oil with the recommended specification from the HTMA Requirement table. Using oil that is too viscous (thick) can damage the hydraulic system.

If the tools are to be used during cold weather, preheat the hydraulic fluid at low engine speed. When using the normally recommended fluids, the fluid 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 the use of fluid 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.

TOOL PROTECTION & CARE

NOTICE
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 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 a female quick disconnect) is connected to the opposite port. Do not reverse circuit flow. This can cause damage to internal seals.
Always replace hoses, couplings, and other parts with replacement parts recommended by STANLEY. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
Do not exceed the rated flow. Rapid failure of the internal seals may result. Refer to “Specifications” on page 16 for the correct flow rate.
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 on the pressure side of the system.
Do not use the tool for applications for which it was not intended.

TROUBLESHOOTING

If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem. When diagnosing faults in the operation of the crimping tool, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the grinder as listed in the table. Use a flow meter known to be accurate. Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.

PROBLEM

| CAUSE|

SOLUTION

---|---|---
The tool does not operate.| Hydraulic hoses are not connected properly.| Make sure the hoses are connected

and the couplers are tight.

Hydraulic control valve OFF.| Turn the hydraulic system control valve ON.
The hydraulic system not functioning.| Check the hydraulic power unit for correct flow and pressure.
Couplers or hoses blocked.| Remove obstruction.
A pressure port check valve is

installed in the tool return port.

| Install the pressure port check valve in

the pressure port.

The tool operates in reverse (the piston advances/retracts when the trigger is squeezed).| Hoses connected to the wrong ports on the tool.| Connect the input (supply) line to the IN port. Connect an output (return) line to the OUT port.
Tool under-crimps. Die load less than 6 tons/5443 kg.| Hydraulic system pressure is too low.| Check the hydraulic power source for correct flow and pressure.
The relief valve is set too low.| Increase relief valve pressure.
Dirt or obstruction between dies.| Remove obstruction. Clean die area.
The piston seal is worn or damaged.| Contact an authorized STANLEY distributor.
Improper die set for wire and connector.| Install proper die set.
Tool over-crimps. Die load of more than 6 tons/5443 kg.| Hydraulic system pressure is too high.| Check the hydraulic power source for correct flow and pressure.
The relief valve is set too high.| Decrease relief valve pressure.
Trigger is difficult to operate.| Hoses connected to the wrong ports on the tool.| Connect the input (supply) line to the IN port. Connect an output (return) line to the OUT port.
Excessive back-pressure.| If back pressure is greater than 250 psi/17 bar, clear the return line obstruction or restriction.
Trigger guard bent and binding on the spool in the bore.| Repair or replace trigger assembly.

SPECIFICATIONS

Capacity ………………………………………………………………………..#10-750 MCM Aluminum and #10-500 MCM Copper
Crimping Force…………………………………………………………………………………. 6 tons @ 1650 psi / 5443 kg @ 114 bar
Pressure Range……………………………………………………………………………………………………………….. 1650 psi/114 bar
Flow Range………………………………………………………………………………………………………………. 3-9 GPM/11-34 LPM
Optimum Flow………………………………………………………………………………………………………………….. 8 GPM/30 LPM
Porting……………………………………………………………………………………………………………………………………………-8 SAE
Hose Whips & Couplers………………………………………………………………………………………………………………………… No
Weight………………………………………………………………………………………………………………………………….13 lbs/5.9 kg
Overall Length……………………………………………………………………………………………………………….20 inches/50.8 cm
Overall Width…………………………………………………………………………………………………………………7.25 inches/18 cm

PARTS ILLUSTRATION

CT06 PARTS ILLUSTRATION

CT06 PARTS LIST

ITEM NO.

| PART NO.| QTY|

DESCRIPTION

---|---|---|---
1| 00114| 1| ROLL PIN
2| 00118| 1| RETAINING RING
3| 00144| 12| HSHCS
4| 07626| 2| O-RING ■
5| 09330| 1| O-RING ■
6| 00294| 1| O-RING ■
7| 00360| 1| O-RING ■
8| 00769| 2| HSHCS
9| 00936| 2| ADAPTER
10| 01259| 1| O-RING ■
11| 01534| 1| ROLL PIN
12| 01608| 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| 79307| 1| FLIP-TOP CRIMPING HEAD
18| 07427| 1| CAUTION STICKER
19| 16556| 1| SPRING
20| 18050| 1| BACK-UP RING ■
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| 76651| 1| COMBINED CT06 1650 PSI STICKER
34| 58520| 1| CYLINDER
35| 58521| 1| PISTON
36| 58522| 1| CYLINDER HEAD
37| 58523| 1| T-SEAL ■
38| 58525| 1| PUSH ROD
39| 58594| 1| RETAINER RING
40| 67259| 1| CHECK VALVE ASSY
| 58550| 1| SEAL KIT
(■ INDICATES PART IN SEAL KIT)