Stanley Black Decker Automobile Parts CT06 User Manual

CT06  
1650 PSI  
HYDRAULIC  
CRIMPING TOOL  
Safety, OperatiOn and Maintenance  
USer ManUaL  
© 2010 Stanley Black & Decker, Inc.  
New Britain, CT 06053  
U.S.A.  
58543 7/2011 Ver. 3  
 
TABLE OF CONTENTS  
SAFETY SYMBOLS ..................................................................................................................................................4  
SAFETY PRECAUTIONS..........................................................................................................................................5  
TOOL STICKER & TAGS ..........................................................................................................................................6  
HOSE TYPES............................................................................................................................................................7  
HOSE RECOMMENDATIONS ..................................................................................................................................8  
FIGURE 1. TYPICAL HOSE CONNECTIONS.......................................................................................................8  
HTMA REQUIREMENTS...........................................................................................................................................9  
OPERATION............................................................................................................................................................10  
FIGURE 2. OC/CC SETUP..................................................................................................................................10  
TOOL PROTECTION & CARE................................................................................................................................14  
TROUBLESHOOTING ............................................................................................................................................15  
SPECIFICATIONS...................................................................................................................................................16  
CT06 PARTS ILLUSTRATION.................................................................................................................................17  
CT06 PARTS LIST...................................................................................................................................................18  
IMPORTANT  
To ll out a Product Warranty Recording form, and for information on your warranty,  
visit Stanleyhydraulic.com and select the Warranty tab.  
(NOTE: The warranty recording form must be submitted to validate the warranty).  
SERVICING THE STANLEY HYDRAULIC CRIMPING TOOL. 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 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 authorized and certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this  
manual and ask for a Customer Service Representative.  
CT06 User Manual ◄ 3  
 
SAFETY SYMBOLS  
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair ac-  
tions 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.  
DANGER  
WARNING  
CAUTION  
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 avoid-  
ed, may result in property damage.  
CAUTION  
NOTICE  
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 dam-  
age to the equipment.  
IMPORTANT  
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 mainte-  
nance personnel.  
4 ► CT06 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.  
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.  
These safety precautions are given for your safety. Re-  
view them carefully before operating the tool and before  
performing general maintenance or repairs.  
Always operate the tool within its rated capacity.  
Do not use the tool for applications for which it was  
not designed.  
Supervising personnel should develop additional pre-  
cautions relating to the specific work area and local  
safety regulations. If so, place the added precautions in  
the space provided in this manual.  
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.  
The model CT06 Hydraulic Crimping Tool will provide  
safe and dependable service if operated in accordance  
with the instructions given in this manual. Read and un-  
derstand 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.  
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 condi-  
tion.  
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.  
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 leg-  
ible. Replace any that are damaged or missing.  
Do not operate a damaged, improperly adjusted, or  
incompletely assembled tool. Do not carry tool by  
the hoses.  
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.  
Keep the handles dry, clean and free of oil.  
Ensure adequate lighting for the area where the tool  
is being used.  
Always wear personal protection equipment (PPE)  
such as goggles, ear and head protection, and safe-  
ty shoes at all times when operating the tool. Use  
gloves and aprons when necessary.  
Use proper lifting techniques when handling the  
tool. Do not overreach. Maintain secure footing and  
balance at all times.  
Never wear loose clothing or unrestrained long hair  
that can get entangled in the working parts of the  
tool.  
When using tools near energized transmission lines,  
be sure to use only hoses labeled and certified non-  
conductive.  
Keep all parts of your body away from the tool and  
maintain proper footing and balance at all times.  
Turn off the power unit or move the hydraulic control  
valve to neutral before setting the tool down.  
Do not rely exclusively upon the safety devices built  
into the tool.  
To avoid personal injury or equipment damage, all  
tool repair, maintenance and service must only be  
performed by authorized and properly trained per-  
sonnel.  
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 danger-  
ous terrain conditions.  
CT06 User Manual ◄ 5  
 
TOOL STICKER & TAGS  
58500  
CT06 1650 PSI Combined Sticker  
NOTE:  
D A N G E R  
D A N G E R  
THE INFORMATION LISTED  
ON THE STICKERS SHOWN,  
MUST BE LEGIBLE AT ALL  
TIMES.  
1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CER-  
TIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC  
TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN  
DEATH OR SERIOUS INJURY.  
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 CON-  
NECTED 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.  
BEFORE USING HOSE LABELEDAND CERTIFIEDAS NON-  
CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE  
HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE  
SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR-  
RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY  
DEPARTMENT INSTRUCTIONS.  
REPLACE DECALS IF  
THEY BECOME WORN OR  
DAMAGED. REPLACEMENTS  
ARE AVAILABLE FROM  
YOUR LOCAL STANLEY  
DISTRIBUTOR.  
2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC-  
TION INTO THE BODY OR CAUSE OTHER 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 SYSTEMAND/OR SEVERE PERSONAL INJURY.  
A. DO NOT EXCEED SPECIFIED FLOW AND PRESSURE  
FOR THIS TOOL. EXCESS FLOW OR PRESSURE MAY  
CAUSE A LEAK OR BURST.  
5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA.  
KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.  
B. DO NOT EXCEED RATED WORKING PRESSURE OF  
HYDRAULIC HOSE USED WITH THIS TOOL. EXCESS  
PRESSURE MAY CAUSE A LEAK OR BURST.  
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.  
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.  
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.  
I M P O R T A N T  
I M P O R T A N T  
READ OPERATION MANUAL AND  
SAFETY INSTRUCTIONS FOR THIS  
TOOL BEFORE USING IT.  
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.  
USE ONLY PARTS AND REPAIR  
PROCEDURES APPROVED BY  
STANLEY AND DESCRIBED IN THE  
OPERATION MANUAL.  
TAG TO BE REMOVED ONLY BY  
TOOL OPERATOR.  
TAG TO BE REMOVED ONLY BY  
TOOL OPERATOR.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SAFETY TAG P/N 15875 (Shown smaller then actual size)  
6 ► CT06 User Manual  
 
HOSE TYPES  
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy-  
draulic system. There are three types of hydraulic hose that 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 certified 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 certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber in-  
ner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This  
hose is not certified 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  
D A N G E R  
D A N G E R  
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.  
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.  
FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-  
ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND  
ELECTRIC LINES.  
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.  
2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE  
ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-  
TING 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.  
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.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SIDE 1  
SIDE 2  
(Shown smaller than actual size)  
THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.  
D A N G E R  
D A N G E R  
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.  
5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKSABRASIONS, 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.  
2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY  
TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-  
TRIC LINES.  
6. AFTER EACH USE STORE IN A CLEAN DRY AREA.  
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.  
SEE OTHER SIDE  
SEE OTHER SIDE  
SIDE 1  
SIDE 2  
(Shown smaller than actual size)  
CT06 User Manual ◄ 7  
 
HOSE RECOMMENDATIONS  
8 ► CT06 User Manual  
 
HTMA REQUIREMENTS  
TOOL CATEGORY  
HYDRAULIC SYSTEM  
REQUIREMENTS  
FLOW RATE  
TYPE I  
4–6 gpm  
(15–23 lpm)  
TYPE II  
TYPE III  
TYPE RR  
9–10.5 gpm  
(34–40 lpm)  
7–9 gpm  
(26–34 lpm)  
11–13 gpm  
(42–49 lpm)  
TOOL OPERATING PRESSURE  
(At the power supply outlet)  
2000 psi  
(145–155 bar)  
2000 psi  
(138 bar)  
2000 psi  
(138 bar)  
2000 psi  
(138 bar)  
SYSTEM RELIEF VALVE SETTING  
(At the power supply outlet)  
2100–2250 psi  
(145–155 bar)  
2100–2250 psi 2100–2250 psi 2200–2300 psi  
(145–155 bar)  
(145–155 bar)  
(145–155 bar)  
MAXIMUM BACK PRESSURE  
(At 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:  
400 ssu*  
400 ssu*  
400 ssu*  
400 ssu*  
(At min. operating temperature)  
(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)  
TEMPERATURE  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
140 °F  
(60 °C)  
Sufficient heat rejection capacity  
to limit max. fluid temperature to:  
(At max. expected ambient temperature)  
Min. cooling capacity  
3 hp  
5 hp  
7 hp  
6 hp  
at a temperature difference of  
between ambient and fluid temps  
(2.24 kW)  
40 °F  
(3.73 kW)  
40 °F  
(4.47 kW)  
40 °F  
(5.22 kW)  
40 °F  
(22 °C)  
(22 °C)  
(22 °C)  
(22 °C)  
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-flow filtration  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
25 microns  
30 gpm  
(114 lpm)  
Sized for flow of at least:  
(For cold temp. start-up and max. dirt-holding  
capacity)  
HYDRAULIC FLUID  
100–400 ssu*  
100–400 ssu*  
100–400 ssu*  
100–400 ssu*  
Petroleum based  
(20–82 centistokes)  
(Premium grade, anti-wear, non-conductive)  
VISCOSITY  
(At min. and max. operating temps)  
NOTE:  
When choosing 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  
CT06 User Manual ◄ 9  
 
OPERATION  
PRE-OPERATION  
Careful inspection of the tool and hydraulic system be-  
fore startup is important for safe, reliable operation of the  
tool.  
Cylinder  
Open-Center (no gap)  
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. Op-  
erating the tool without dies can deform the crimping  
heads. Refer to Die Installation for instructions.  
Trigger  
Adapter  
Handle  
2. Connect hoses. Wipe all hose couplers with a clean,  
lint-free cloth before making connections. Dirty cou-  
plers can contaminate the hydraulic lines and pre-  
vent a good seal at the connection.  
Top View of Tool  
Figure 2. OC/CC Setup  
2. Loosen the 2 setscrews on the cylinder.  
3. Turn the adapter until it stops:  
3. Check all fasteners for tightness.  
4. Check the equipment for oil leaks. If leaks are ob-  
served, do not use the tool; have the equipment ser-  
viced before use.  
Counter clockwise (CCW) to change to closed  
center (creates gap)  
5. Check the tool and hydraulic system for proper op-  
eration and performance.  
Clockwise (CW) to change to open center (clos-  
es gap)  
6. If the equipment does not appear to operate prop-  
erly, have it serviced before use.  
4. Tighten the two setscrews.  
7. Periodically verify the crimping force of the tool. Re-  
LATCH NIB REPLACEMENT  
fer to Die Load Verification.  
The CT06 Hydraulic Crimping Tool has two main com-  
ponents in the Anderson compression head:  
SETUP AND TEST  
Verify the crimping force before operating the tool.  
The cam yoke assembly forms the base of the com-  
pression head. It functions as a movable piston die  
to provide the crimping force.  
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:  
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.  
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 fluid may be  
trapped in the tool, preventing complete movement  
of the adapter. Remove the return coupling to allow  
the hydraulic fluid to escape.  
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.  
10 ► CT06 User Manual  
 
OPERATION  
1. If the hydraulic hoses are connected:  
2. Connect the tool to an appropriate hydraulic power  
source. Follow the Hydraulic Hose Connection safe-  
ty guidelines and instructions in this section. If pos-  
sible, use the hydraulic power source you plan to  
use for crimping.  
Turn the hydraulic system control valve OFF.  
Disconnect first 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. Position the test slug within the nibs.  
4. Actuate the tool to squeeze the test slug.  
5. Release the test slug and then measure it.  
3. Pull the pin out to release the latch.  
4. Rotate the latch away from the head to provide ac-  
cess to the nib/nest die.  
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 get the  
correct die load.  
5. To release the nib/nest die, drive the roll pin out of  
the center of the latch.  
6. Remove the nib/nest die by rotating it out and around  
the small pivot pin inside the latch.  
6. When the value is within the acceptable range, turn  
the hydraulic system control valve OFF and discon-  
nect the hoses from the tool.  
7. 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.  
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.  
8. Press the nib/nest die firmly until it locks into place.  
9. Drive the roll pin into the center of the latch to retain  
the nib/nest die.  
10. Close the latch. Insert the latch pin.  
Open Center: No gap  
Closed Center: Approximately 1/4-inch (6.4-mm)  
gap  
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 cou-  
plers and cause overheating of the hydraulic system.  
If the setting is not correct for your hydraulic system, fol-  
low the instructions in this section, OC/CC Adjustment,  
to make the change.  
CHECK POWER SOURCE  
Before installing the hoses, wipe the fittings and the en-  
tire 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 pars.  
Using a calibrated flowmeter 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.  
Check the flow indicators (arrows) stamped on the cou-  
plers to ensure oil flows in the proper direction. The fe-  
male coupler on the tool is the inlet coupler.  
The hydraulic fluid temperature should be at least 80  
°F/27 °C for this test.  
It is a good practice to connect the output (return) hose  
first and disconnect it last to minimize or avoid trapped  
pressure within the tool.  
CONNECT HOSES  
1. Wipe all hose couplers with a clean, lint-free cloth  
before making connections.  
1. Connect the output hose to the OUT or T port on  
the tool.  
2. Connect hoses from the hydraulic power source to  
the tool fittings or quick disconnects. It is good prac-  
tice to connect the return hose first and disconnect it  
last to minimize or eliminate trapped pressure within  
the wrench.  
2. Connect the input hose to the IN or P port.  
3. Be sure all hose connections are tight.  
DIE LOAD VERIFICATION  
3. Observe the flow indicators stamped on the main  
body assembly and the hose couplers to ensure  
that the flow is in the proper directions. The female  
couple on the tools “IN” port is the inlet (pressure)  
coupler.  
1. Use Anderson test slugs to verify the crimping force  
in the tool.  
CT06 User Manual ◄ 11  
 
OPERATION  
NOTE:  
STARTUP  
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 together.  
1. Clean the nibs on the tool. Remove all traces of lu-  
brication from each tool nib before crimping.  
2. 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.  
TOOL RELIEF VALVE ADJUSTMENT  
The relief valve on a universal pressure CT can be ad-  
justed to increase or decrease the tool’s crimping force.  
Standard CT’s do not have a relief valve.  
3. Move the hydraulic system control valve to the ON  
position.  
The crimping tools relief valve is located below the trig-  
ger guard. The relief valve on the hydraulic system is  
totally separate and has a different function.  
WARNING  
1. Perform steps 1 through 5 under Die Load Verifica-  
tion.  
The crimping force between the dies in the tool head  
can cause severe personal injury.  
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:  
Keep hands away from the die area when operating  
the tool.  
a. Turn the hydraulic system control valve OFF.  
b. Remove the plug from the end of the relief valve,  
below the trigger guard.  
4. 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.  
c. Using a hex wrench, turn the adjusting screw.  
Clockwise (CW) to increase pressure or Coun-  
terclockwise (CCW) to decrease pressure.  
5. Position the tool as follows:  
a. Connector sleeves  
d. Replace the plug in the relief valve and retest.  
Repeat the adjustment if necessary.  
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.  
TOOL OPERATION  
Observe all safety precautions when operating the tool.  
Read Safety and Hydraulic System Requirements, be-  
fore operating the tool for the first time.  
Make sure the connector sleeve is carefully  
centered between all four nibs in the tool.  
b. H-Frame Connectors:  
CONDUCTOR PREPARATION  
Place the connector in the tool so the main  
groove is positioned between the top nib and ei-  
ther side nib. Make sure the positioning grooves  
mate with two of the nibs.  
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.  
6. Squeeze the trigger to crimp the connector.  
Be sure not to nick or cut the strands of the conduc-  
tor.  
2. Remove any oxide or foreign matter from the ex-  
posed 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 connector sleeve onto the conductor.  
12 ► CT06 User Manual  
 
OPERATION  
7. Release the trigger to retract the nibs.  
8. Repeat the crimp as required.  
COLD WEATHER OPERATION  
9. After the last crimp, make sure the nibs in the crimp-  
ing head are fully retracted  
IMPORTANT  
10. Pull out the latch pin and rotate the latch away from  
the crimping head.  
Use an oil with the recommended specification from  
the HTMA Requirement table. Using oil that is too  
viscous (thick) can damage the hydraulic system.  
11. Remove the tool by lifting it clear of the cable.  
SHUTDOWN  
1. Move the hydraulic system control valve to the OFF  
position.  
If the tools is to be used during cold weather, preheat the  
hydraulic fluid at low engine speed. When using the nor-  
mally recommended fluids, fluid temperature should be  
at or above 50°F/10°C (400 ssu/82 centistokes) before  
use.  
2. Disconnect the hydraulic hoses from the tool: first  
the input (supply) hose, then the output (return)  
hose.  
Damage to the hydraulic system or compression tool  
can result from use with fluid that is too viscous or too  
thick.  
3. Insert plugs in the hose ends, couplers or tool ports,  
as applicable.  
4. Wipe the tool thoroughly with a clean dry cloth.  
STORAGE  
5. Clean any foreign matter or joint compound from the  
die holder surfaces.  
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.  
CT06 User Manual ◄ 13  
 
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 con-  
nection.  
Do not exceed the rated flow. Refer to Specifications  
in this manual for correct flow rate. Rapid failure of  
the internal seals may result.  
The hydraulic circuit control valve must be in the  
“OFF” position when coupling or uncoupling  
hy-  
Always keep critical tool markings, such as warning  
stickers and tags legible.  
draulic tools. Failure to do so may result in damage  
to the quick couplers and cause overheating of the  
hydraulic system.  
Do not force a small tool to do the job of a large tool.  
Tool repair should be performed by experienced  
personnel only.  
Always store the tool in a clean dry space, safe from  
damage or pilferage.  
Make certain that the recommended relief valves  
are installed in the pressure side of the system.  
Make sure the circuit PRESSURE hose (with male  
quick disconnect) is connected to the “IN” port. The  
circuit RETURN hose (with female quick discon-  
nect) is connected to the opposite port. Do not re-  
verse circuit flow. This can cause damage to internal  
seals.  
Do not use the tool for applications for which it was  
not intended.  
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.  
14 ► CT06 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 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 flowmeter known to be accurate.  
Check the flow with the hydraulic oil temperature at least 80 °F/27 °C.  
PROBLEM  
CAUSE  
SOLUTION  
Tool does not operate.  
Hydraulic hoses not connected  
properly.  
Make sure hoses are connected  
and the couplers are tight.  
Hydraulic control valve OFF.  
Hydraulic system not functioning.  
Couplers or hoses blocked.  
Turn the hydraulic system control  
valve ON.  
Check hydraulic power unit for  
correct flow and pressure.  
Remove obstruction.  
Pressure port check valve is  
installed in tool return port.  
Install pressure port check valve in  
pressure port.  
Tool operates in reverse (piston  
advances/retracts when trigger is  
squeezed).  
Hoses connected to wrong ports on Connect input (supply) line to IN  
tool.  
port. Connect output (return) line to  
OUT port.  
Tool under-crimps. Die load less  
than 6 tons/5443 kg.  
Hydraulic system pressure too low. Check hydraulic power source for  
correct flow and pressure.  
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  
distributor.  
Improper die set for wire and  
connector.  
Install proper die set.  
Tool over-crimps. Die load more  
than 6 tons/5443 kg.  
Hydraulic system pressure too high. Check hydraulic power source for  
correct flow and pressure.  
Relief valve set too high.  
Decrease relief valve pressure.  
Trigger difficult to operate.  
Hoses connected to wrong ports on Connect input (supply) line to IN  
tool.  
port. Connect output (return) line to  
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  
spool in bore.  
Repair or replace trigger assembly.  
CT06 User Manual ◄ 15  
 
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  
16 ► CT06 User Manual  
 
CT06 PARTS ILLUSTRATION  
CT06 User Manual ◄ 17  
 
CT06 PARTS LIST  
ITEM PART  
ITEM PART  
NO.  
NO.  
QTY DESCRIPTION  
NO.  
NO.  
QTY DESCRIPTION  
1
00114  
00118  
00144  
07626  
09330  
00294  
00360  
00769  
00936  
01259  
01534  
01608  
01809  
01812  
04054  
04794  
67013  
07427  
16556  
18050  
21424  
22147  
38622  
39925-1  
39939  
51182  
51183  
52534  
58439  
58440  
58441  
58442  
58500  
58520  
58521  
58522  
58523  
58525  
58594  
67259  
1
1
12  
2
1
1
1
2
2
1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
ROLL PIN  
58550  
1
SEAL KIT  
(■ INDICATES PART IN SEAL KIT)  
2
RETAINING RING  
HSHCS  
3
4
O-RING ■  
5
O-RING ■  
6
O-RING ■  
7
O-RING ■  
8
HSHCS  
9
ADAPTER  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
O-RING ■  
ROLL PIN  
STEEL BALL  
VALVE SPOOL  
VALVE SPOOL SCREW  
O-RING ■  
O-RING ■  
FLIP-TOP CRIMPING HEAD  
CAUTION STICKER  
SPRING  
BACK-UP RING ■  
RELIEF VALVE  
CAPSCREW  
VALVE SLEEVE  
COMPRESSION SPRING  
VALVE HANDLE  
TRIGGER GUARD  
TRIGGER  
SETSCREW  
ADAPTER  
RETAINING RING  
SLEEVE  
OIL TUBE  
COMBINED CT06 1650 PSI STICKER  
CYLINDER  
PISTON  
CYLINDER HEAD  
T-SEAL ■  
PUSH ROD  
RETAINER RING  
CHECK VALVE ASSY  
18 ► CT06 User Manual  
 
 
Stanley Hydraulic Tools  
3810 SE Naef Road  
Milwaukie, Oregon  
503-659-5660 / Fax 503-652-1780  
IMPORTANT  
To ll out a Product Warranty Recording form, and for information on your warranty,  
visit Stanleyhydraulic.com and select the Warranty tab.  
(NOTE: The warranty recording form must be submitted to validate the warranty).  
 

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