CT-2002CH

PA29258A01 Rev. 00 6-2018 CT-2002CH REMOTE CRIMP HEAD HYDRAULIC COMPRESSION TOOL © Panduit Corp. 2018 TABLE OF CONTENTS SYSTEM SPECIFICATIONS ..................................................................................................................... 1 OPTIONAL ACCESSORIES (sold separately) .......................................................................................... 1 PRECAUTIONS AND GENERAL GUIDELINES........................................................................................ 2 DIE SELECTION ....................................................................................................................................... 4 DIE INSTALLATION .................................................................................................................................. 4 TOOL OPERATION .................................................................................................................................. 5 MAINTENANCE ........................................................................................................................................ 6 PERIODIC MAINTENANCE ................................................................................................................ 6 CLEANING AND LUBRICATION OF TOOL HEAD.............................................................................. 6 VISUAL INSPECTION ......................................................................................................................... 6 FORCE INSPECTION / CALIBRATION............................................................................................... 6 CONTACT INFORMATION ....................................................................................................................... 6 Email: techsupport@panduit.com Technical Support Tel: 1-800-777-3300 EU Website: www.panduit.com/emea EU Email: emeatoolservicecenter @panduit.com www.panduit.com Panduit Europe • EMEA Service Center Almelo, Netherlands Tel: +31 546 580 452 • Fax: +31 546 580 441 OPERATION MANUAL © Panduit Corp. 2018 CT-2002CH SYSTEM SPECIFICATIONS Output: 6.0 tons / 5.4 (metric tons) Input: 10,000 PSI / 700 (kg/cm2) hydraulic pressure provided by a separate hydraulic pump system (Panduit CT-902HP Hydraulic Pump and CT-900HPH 10 foot Hydraulic Hose). NOTE: CONNECTIONS UTILIZING THIS TOOL ARE U.L. LISTED AND C.S.A. CERTIFIED ONLY WHEN PANDUIT COPPER COMPRESSION CONNECTORS AND DIES ARE USED. USE OF ANY OTHER BRAND OF COMPRESSION CONNECTORS IS NOT RECOMMENDED. Consult product packaging, Panduit catalog or website, www.panduit.com, for information on recommended compression connectors. Weight: Dimensions: 6.0 lbs. / 2.7 (kg) CT-2002CH Carrying Case: Included with CT-2002CH Tool 12.0 L x 3.5 H x 2.2 W in. 305 L x 89 H x 56 W (mm) 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. OPTIONAL ACCESSORIES (sold separately) Compression Dies - for CT-2002CH Hydraulic Pump System – for the CT-2002CH Refer to Panduit catalog or Sales Office for part numbers and specific die application information. CT-902HP Hydraulic Pump System is factory preset at 2 10,000- PSI / 700 (kg/cm ). Pump shuts off when cycle is complete. Will not release until the down switch is activated. CT-900HPH Electrically non-conductive 10 ft. hose. Supplied pre-filled with hydraulic fluid for fast start up. CT-902RCH Remote Control Handle To ease operation of the Hydraulic Tool System 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. Remote Foot Switch allows for hands free operation 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. Verifies the PSI reading of the CT-902HP Hydraulic Pump. CT-902RFS Remote Foot Switch PG-1 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. CT-2002CH: PA29258A01_00 Page: 1 of 6 6-2018 OPERATION MANUAL © Panduit Corp. 2018 CT-2002CH PRECAUTIONS AND GENERAL GUIDELINES This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. WARNING Hazards which, if not avoided, COULD result in severe injury or death. CAUTION Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. WARNING Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. WARNING Electric Shock Hazard: This tool is not insulated. When using this unit on or near energized electrical lines, use proper personal protective equipment. WARNING Wear eye protection when operating or servicing this tool. Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil. WARNING Skin Injection Hazard: Oil under pressure easily punctures skin causing serious injury, gangrene, or death. If you are injured by escaping oil, seek medical attention immediately. • Do not use hands to check for leaks. • Depressurize the hydraulic system before servicing. WARNING Keep hands away from the tool head when crimping. WARNING Do not use solvents or flammable liquids to clean this tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. Do not use tool in or near a highly flammable or explosive atmosphere and/or materials. CT-2002CH: PA29258A01_00 Page: 2 of 6 6-2018 © Panduit Corp. 2018 OPERATION MANUAL CT-2002CH WARNING • • • • An incomplete crimp can cause a fire. Use proper compression connector and cable combinations. Improper combinations can result in an incomplete crimp. The relief valve will sound to indicate a completed crimp. If you do not hear the sound of the relief valve, the crimp is not complete. Inspect tool before use. A worn or damaged tool may result in breakage striking the operator or nearby personnel. CAUTION • • • • Do not perform any service or maintenance other than as described in this manual. Injury or damage to the tool may result. Do not place the tool in a vise. The tool is designed for hand-held operation. Protect the tool from rain and moisture. Use this tool for the manufacturer’s intended purpose only. IMPORTANT INFORMATION • • • • • • • • 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 mechanical parts. When not using the tool, regularly check that no foreign matter or debris exists in the open areas between the indenters in the tool head. Soap and a damp cloth should be used to clean the tool body. Always store the tool in its clean, dry carrying case when not in use. DO NOT press trigger and release button simultaneously. Damage to trigger linkage may result. Always point tool away from others. o o 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. Avoid dropping the tool. Extreme shock may damage the hydraulic circuit and result in malfunction of the tool. Always verify the proper size compression connector for the conductor, by checking the color code and the printing on the compression connector. CT-2002CH: PA29258A01_00 Page: 3 of 6 6-2018 © Panduit Corp. 2018 OPERATION MANUAL CT-2002CH DIE SELECTION Match index number and color on die (see Figure 2 below) to index number and color band on compression connector. DIE IDENTIFICATION FOR USE WITH MATCHED COMPRESSION CONNECTOR NOTE: DIES ARE DESIGNED TO PRODUCE THE HIGHEST QUALITY CONNECTIONS WHEN USED WITH PANDUIT COMPRESSION CONNECTORS. USE OF ANY OTHER BRAND OF COMPRESSION CONNECTORS IS NOT RECOMMENDED WITH CD-2001 DIES. FIGURE 2 PANDUIT DIE INDEX NUMBER-COPPER AND ALUMINUM COMPRESSION DIES DIE COLOR DOT CODE-COPPER COMPRESSION CONNECTORS DIE POCKET NUMBER (MIRROR IMAGE AS SHOWN) FRONT VIEW ALUMINUM DIE INDEX COLOR DOT COPPER DIE INDEX COLOR DOT REAR VIEW 1. Always verify correct die set by die part number. 2. Color coding dot for verification may be found on the front and/or back of die set (not applicable to die sets with a letter suffix). DIE INSTALLATION (See Figure 1 on Page 3) CAUTION: DO NOT operate tool without dies installed. 1. Remove any current dies from the tool ram by depressing both of the related die release buttons (nearest the die half to be removed) and pull die out of tool. CAUTION: DO NOT let the ram contact the crimp head. CT-2002CH: PA29258A01_00 Page: 4 of 6 6-2018 OPERATION MANUAL © Panduit Corp. 2018 CT-2002CH 2. Select the appropriate dies to match the compression connector to be crimped. Consult product packaging, Panduit catalog or website, www.panduit.com, for information on recommended compression connectors. 3. Align one of the die halves in the die cavity contour of crimp head. While pressing both of the appropriate die release buttons, slide the die half in so that it is centered in the die cavity of the crimp head. Release the die release buttons and verify that the die is locked in place. 4. Align the remaining die half in the die cavity contour of the ram. While depressing both of the appropriate die release buttons on the ram, slide the die half in so that it is centered in the die cavity of the ram. Release the die release buttons and verify that the die is locked in place. TOOL OPERATION (See Figure 1 on Page 3) 1. The CT-2002CH Tool Head must be operated with a compatible hydraulic pump system, capable of developing and sustaining 10,000 PSI (700 kg/cm2). The Panduit CT-902HP Hydraulic Pump and CT-900HPH High Pressure Hose (electrically non-conductive; 10 foot long) are recommended. This system's fittings are matched to the tool head fittings 2. The CT-2002CH Tool Head has been charged with hydraulic fluid at the factory. Remove the dust cap from the connector coupling on the tool. CAUTION: Upon removing the dust cap, be sure to keep the hydraulic fittings on the tool head, hydraulic pump and hydraulic hose free from contaminates. Failure to do so may lead to malfunction of the tool head and/or hydraulic pump. 3. Connect the coupling of the tool head onto the coupling of the hydraulic hose, ensuring a fully threaded, tight connection. 4. Refer to the operation manual provided with your particular hydraulic pump system for the specific set-up operation, and maintenance of the hydraulic pump. Verify that the open areas between the ram and tool head are free of foreign matter and debris that could jam or damage the tool during operation. Cycle the tool head 2 or 3 times by activating the hydraulic pump. Be sure dies are in the tool head prior to cycling the tool. Check for leaks at all connections. 5. Carefully place the compression connector between the dies so that the dies will crimp between the color bands on the compression connector. Activate the pump to advance the ram until the compression connector is held by the dies. CAUTION: DO NOT crimp the compression connector at this time. 6. Verify that the conductor size and dies properly match the compression connector size being used. Insert the conductor completely into the compression connector barrel. 7. Begin crimping by activating the hydraulic system. The Panduit CT-902HP Hydraulic Pump incorporates a by-pass valve which, when activated, shuts off the pump when the crimp is completed. 8. Deactivate the hydraulic system to retract the ram for removal or repositioning of the compression connector/conductor assembly. Refer to product packaging if multiple crimps are required. CT-2002CH: PA29258A01_00 Page: 5 of 6 6-2018 © Panduit Corp. 2018 OPERATION MANUAL CT-2002CH MAINTENANCE PERIODIC MAINTENANCE 1. Daily maintenance is important to keep the tool in good working condition. Keep the head clean and free of debris. Excessive dirt and grit can contribute to the premature wear of the tool's mechanical parts. Always replace the dust cap on the connector fitting, and store the tool in its clean, dry carrying case when not in use. 2. 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 ram and tool head. Thoroughly clean and lubricate the tool head. A tool that is dirty with excessive foreign matter may jam and become damaged during operation. 3. The hydraulic system has been calibrated and sealed at the factory. 4. 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 Technical Support at 1-800-777-3300. CLEANING AND LUBRICATION OF TOOL HEAD Thorough cleaning and lubrication of the tool head is recommended annually, depending on usage. It is recommended that the CT-2002CH Tool be returned to Panduit Global Service Center for proper maintenance by our trained service staff. VISUAL INSPECTION 1. Visually inspect tool for cracks or damage that may affect tool performance. 2. Visually inspect indenters for cracks, chips or damaged surfaces. 3. Visually inspect tool for loose or missing components and evidence of loss of hydraulic fluid. 4. If tool is damaged, or if parts are missing, contact Panduit Technical Support. FORCE INSPECTION / CALIBRATION Inspect the compression force of the crimp head monthly, whenever possible damage has occurred, or as often as operating conditions warrant. The tool output force can be certified by using a Panduit Compression Gauge, PG-1 (purchased separately, see Optional Accessories on Page 1); or return tool to Panduit Global Service Center for maintenance and calibration. CONTACT INFORMATION Panduit Global Service Center (USA) 16530 W. 163rd Street Lockport, IL 60441 Technical Support: 1-800-777-3300 CT-2002CH: PA29258A01_00 Panduit EMEA Service Center (EUR) EMEA Tool Service Center Bedrijvenpark Twente 360 7602 KL Almelo tel + 31 546 580 451 Page: 6 of 6 6-2018