Panduit CT-2500 Manuel utilisateur

CT-2500 and CT-2500/E

PA25346A01

Rev. 044-2014

BATTERY OPERATED CRIMPING TOOL

OPERATION MANUAL

•CT-2500 and CT-2500/E Battery Operated Crimping Tools, to be used with

optional Crimp Heads: CT-2525CH, CT-2550CH, CT-2570CH and CT-2500CH

(sold separately).

WARNING

Read and understand all of the instructions and safety

information in this manual prior to operating or servicing this tool.

Retain this manual for future reference.

Email:

techsupport@panduit.com

EU Website:

www.panduit.com/emea

EU Email:

emeatoolservicecenter

@panduit.com

www.panduit.com

Technical Support

1-888-506-5400, Ext. 83255

Panduit Europe • EMEA Service Center

Almelo, Netherlands

Tel: +31 546 580 452 • Fax: +31 546 580 441

CT-2500 TOOL SHOWN WITH CT-2525CH CRIMPING HEAD

Page 1 of 10

TABLE OF CONTENTS

INTRODUCTION ................................................................................................................................2

TOOL SPECIFICATIONS...................................................................................................................2

OPTIONAL ACCESSORIES...............................................................................................................3

CT-2500 and CT-2500/E TOOLS .......................................................................................................3

PRECAUTIONS AND GENERAL GUIDELINES ................................................................................3

IMPORTANT FEATURES OF THE CT-2500 and CT-2500/E

BATTERY OPERATED CRIMPING TOOLS.......................................................................................6

INSTALLATION

Crimping Head Installation...............................................................................................................7

TOOL OPERATION............................................................................................................................7

MAINTENANCE .................................................................................................................................8

Storage and Transport........................................................................................................................8

USE OF THE BATTERY CARTRIDGE AND CHARGING UNIT.........................................................9

Terminations per Battery Charge ......................................................................................................10

Battery Charger.................................................................................................................................10

TROUBLESHOOTING......................................................................................................................10

DISCONTINUATION OF USE / DISPOSAL......................................................................................10

Purpose of this Manual

•This manual is intended to familiarize the user with the safe operation and

maintenance procedures for this tool.

•Use this tool exclusively for its determined use.

•This instruction manual should be available during the entire life span of the tool.

•The operator has to ensure the availability of this instruction manual to the

end user; and to make sure, that the user has read and understood this

instruction manual.

•Mounting and assembly of connecting material with the help of this tool must

only be performed by specially trained personnel.

•Replacement manuals are available upon request.

Page 2 of 10

INTRODUCTION

The CT-2500 and CT-2500/E Battery Operated Crimping Tools can crimp #10 AWG thru #22 AWG

Panduit terminals, disconnects and splices. The Battery Operated Crimping Tool develops up to 1.7

tons (15kN) of compressive force.

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.

Safety

Safety is essential in the use and maintenance of Panduit tools and equipment. This manual and

any markings on the tool provide information for avoiding hazards and unsafe practices related to

the use or service of this tool. Observe all of the safety information provided.

TOOL SPECIFICATIONS

CT-2500 or CT-2500/E

Battery Operated Crimping

Tools

Weight (including battery) 3.3 lbs. (1,5 kg)

Dimensions: 11-3/4” L x 2-3/8” H x 3-1/8” W – with battery

[298 L x 60 H x 80 W] mm

Crimping Time 2 seconds

Crimping Force 1.7 tons (15 kN)

Stroke .35 (9 mm)

Sound Level: 75 dB (A) at 39.3” (1 meter)

Ambient Temperature -4° F to +104° F (-20°C to +40°C)

CT-2500BC

Battery Cartridge Battery Type: Nickel Cadmium (Ni-Cd)

Output: 9.6 V

Capacity: 1.3 Ah

Charging time: Approx. 40 minutes

(15 min. with fast charger)

CT-2500CHR

Battery Charger Output: 7.2 V - 14.4 Volt DC

Input: 120 Volt AC, 50~60Hz

CT-2500CHR/E

Battery Charger for EU Output: 7,2 V – 14,4 Volt DC

Input: 230 Volt AC, 50~60Hz

This manual will guide you step-by-step in the set-up, operation, and maintenance of your

CT-2500 or CT-2500/E Tool. Proper maintenance is vital to the continued trouble-free

operation of the tool. If you have a problem not covered in the manual, call:

1-(888) 506-5400, Ext. 83255

Ask for one of our Tool Service Technicians

Page 3 of 10

OPTIONAL ACCESSORIES

CT-2525CH or

CD-525

Crimping head or die insert for installing the following Panduit products:

#26 – #22 AWG insulated terminals and splices,

#22 – #10 AWG fully insulated disconnects, insulated parallel splices; and

specific #22 – #14 AWG barrel insulated disconnects.

CT-2550CH or

CD-550

Crimping head or die insert for installing the following Panduit products:

#22 – #10 AWG insulated terminals and splices;

and specific insulated disconnects.

CT-2570CH or

CD-570

Crimping head or die insert for installing most of the following Panduit

products:

#22 – #10 AWG and 0,5 – 6,0 mm2non-insulated terminals, disconnects;

and specific non-insulated splices.

CT-2500CH

Crimping head (frame only); to be used with crimping die inserts CD-525,

CD-550 or CD-570.

Replacement Batteries and Battery Chargers are sold separately.

CT-2500BC

Replacement Battery Cartridge

CT-2500CHR

Replacement Battery Charger

CT-2500CHR/E

Replacement Battery Charger for Europe

CT-2500 and CT-2500/E TOOLS

The CT-2500 and CT-2500/E Tools include:

•1 – Battery Operated Crimping Tool (with battery cartridge)

•1 – Spare Battery Cartridge

•1 – Battery Charger

•1 – Tool Case

PRECAUTIONS AND GENERAL GUIDELINES

IMPORTANT SAFETY INFORMATION

SAFETY ALERT SYMBOL

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.

DANGER

Immediate hazards which, if not avoided, WILL result in severe injury or death.

Page 4 of 10

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.

The operator has to ensure the

availability of this instruction manual to the end user; and to make sure, that the

user has read and understood this instruction manual.

Failure to observe this warning can result in severe injury or death.

WARNING

Electric Shock Hazard:

This tool is not insulated. When using this unit on or near energized electrical

lines, use proper personal protective equipment.

Failure to observe this warning can result in severe injury or death.

WARNING

Wear eye protection when operating or servicing this tool.

Failure to wear eye protection can result in serious eye injury from flying debris.

WARNING

•Do not use solvents or flammable liquids to clean the crimping tool. Solvents

or flammable liquids could ignite and cause serious injury or property

damage.

•During the operation of electric motors, sparks can occur which might ignite

highly flammable or explosive liquids and materials.

•Do not use tool in or near a highly flammable or explosive atmosphere and/or

materials.

WARNING

Keep hands away from the crimping tool head when crimping.

Failure to observe this warning can result in severe injury or death.

Page 5 of 10

WARNING

Do not dispose of batteries in a fire. They will vent fumes and may explode.

Failure to observe this warning can result in severe injury from harmful fumes or burns from flying

debris.

WARNING

Inspect tool before use. A worn or damaged tool may result in breakage striking the operator or

nearby personnel.

Failure to observe this warning can result in severe injury, death or property damage.

CAUTION

• Do not place the tool in a vise. The crimping tool is designed for hand-held operation.

• Protect the crimping tool from rain and moisture. Water will damage the crimping tool and battery.

Crimping tools should not be operated in pouring rain or under water.

• Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions can result in injury or property damage.

CAUTION

Do not allow anything to contact the battery terminals.

• Do not immerse the batteries in liquid. Liquid may create a short circuit and damage the battery. If

batteries are immersed, contact your service center for proper handling.

• Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive

objects may create a short circuit and damage the battery.

• Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage

the battery.

Failure to observe these precautions can result in injury or property damage.

CAUTION

• Do not store the battery at more than 140°F (60°C). Damage to the battery can result.

• Do not use another manufacturer’s charger. Other manufacturers’ chargers may overcharge and

damage the battery.

• Do not attempt to open the battery. It contains no user-serviceable parts.

Failure to observe these precautions can result in injury or property damage.

CAUTION

Do not perform any service or maintenance other than as described in this manual. Injury or damage

to the tool may result.

Failure to observe this precaution can result in injury and property damage.

Page 6 of 10

IMPORTANT FEATURES OF THE CT-2500 and CT-2500/E

BATTERY OPERATED CRIMPING TOOLS

•The hydraulic unit incorporates an automatic retraction which returns the piston into its starting

position when the maximum force is reached.

•The unit is equipped with a special brake which stops the forward motion of the piston/dies

when the trigger is released.

•To simplify operation and gain better access to tight corners and other difficult working areas,

the crimping head may be rotated, by hand, 360° relative to the tool body.

•The tool is very lightweight and provides good handling through an ergonomic design.

Description Function

Piston Advances dies during crimping cycle

Crimping Head Adapter

Adapter for interchangeable crimping heads.

Crimping head secured by locating pins.

Retract Slide Bar to open the crimping dies in case of an error or emergency

Unlocking Device Switch for unlocking the battery

Battery Rechargeable Ni-Cd battery, 9.6 V

Low Battery Indicator LED flashes to indicate low battery

Trigger Actuator to start the crimping cycle

Locating Pins Pins to secure crimping head to crimping head adapter

Figure 1

CT-2500 TOOL

RETRACT

SLIDE

LOW BATTERY

INDICATOR

BATTERY

UNLOCKING DEVICE

TRIGGER

LOCATING PINS (2)

PISTON

CRIMPING HEAD

ADAPTER

Page 7 of 10

INSTALLATION

CRIMPING HEAD REMOVAL / INSTALLATION

1. Rotate crimping head adapter fully --

clockwise (see Figure 2).

2. Press retract slide to lower piston

completely.

3. Pull out the pins for mounting a different

crimping head on the adapter, or to

change the crimping dies.

4. Before installing different crimping head,

slide the crimping dies to the full open

position. Lock the head with the locating

pins (see Figure 3), paying attention that

the pins are locked securely before

starting.

ATTENTION:

The product to be crimped must be the type specified for the crimping head and die

combination. See specific crimping head information on Page 3.

TOOL OPERATION

Crimping using the CT-2525CH, CT-2550CH and CT-2500CH

(equipped with Locator):

1. The Locator shall be used to assist in positioning the product

to be crimped (see Figure 3 above).

2. Position the product in the proper die position by matching the

product color and the die position color code (see Figure 4).

3. Press the trigger until the crimping head jaws just touch the

terminal, holding the product securely.

4. Insert the wire.

5. Pull and hold the trigger until the tool has completed the

operating cycle of crimping. The jaws will open automatically.

6. Remove the finished crimped product and wire combination.

Crimping using the CT-2570CH:

1. Position the product in the proper die position by matching the size (wire gage).

2. Press the trigger until the crimping head jaws just touch the terminal, holding the product

securely.

3. Insert the wire.

4. Pull and hold the trigger until the tool has completed the operating cycle of crimping. The jaws

will open automatically.

5. Remove the finished crimped product and wire combination.

Page 8 of 10

ATTENTION:

The crimping process can be interrupted at any time by releasing the trigger.

After having terminated the crimping process and prior to changing the heads,

remove battery to avoid unintended starts.

NOTE:

•By sliding the retract slide in the direction of the battery, the dies can be retracted in case of

an error or emergency.

•The terminal can first be pre-clamped. This allows the operator to adjust the position of the

terminal during the crimping cycle. To use this feature, push the trigger until the die contacts

the terminal and then release the trigger. The terminal can now be re-positioned or even the

wire can still be inserted into the terminal.

•The crimping cycle is terminated when the dies are completely closed and the maximum

crimping force is reached, which is indicated by the auto retraction of the piston.

MAINTENANCE

Daily Maintenance

Before Use:

1. Inspect dies for wear or damage such as cracks, gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is detected, contact PANDUIT Tool Division.

WARNING

Skin Injection Hazard:

•Do not use hands to check for leaks.

•High pressure oil easily punctures skin causing serious injury, gangrene, or

death. If injured, seek medical help immediately to remove oil.

After Use:

1. Wipe all tool surfaces clean with a damp cloth and mild detergent.

WARNING

•Do not use solvents or flammable liquids to clean the crimping tool. Solvents

or flammable liquids could ignite and cause serious injury or property damage.

2. Place the tool in the carrying case. Store in a cool, dry place.

3. Charge the battery.

Monthly Maintenance

STORAGE AND TRANSPORT

1. Thoroughly clean all surfaces.

Always store the tool in its clean, dry carrying

case when not in use, and during transport.

The battery cartridge and the battery charging

unit should be protected against humidity and

dust.

2. Oil the locating pins.

Annually or After 10,000 Crimps

Return tool to Panduit Tool Division

Page 9 of 10

USE OF THE BATTERY CARTRIDGE (CT-2500BC) AND

CHARGING UNIT (CT-2500CHR AND CT-2500CHR/E

The charging unit is run with a nominal voltage of 120 V (CT-2500CHR), or (230 V for

CT-2500CHR/E) and a frequency of 50-60 Hz. New batteries must be charged prior to use. To

remove the battery, actuate the battery lock and pull it out of the tool. To charge the battery,

connect the power plug of the charging unit with the power supply and slide the battery into the

charging unit. The charging time is 40 minutes. The charging level of the battery cartridge can be

checked by the right LED (multi-color) of the charging unit.

Indicator

Color

Left LED (Red) Right LED (Multi-color)

Red Charging unit ready to operate Battery defective

Red Flashing Charging unit out of order.

New or unused batteries whose

nominal capacity is not sufficient.

Battery too hot or too cold.

Remove battery.

Safety components possibly defective.

Green – Charging cycle starts

Green Flashing –

Battery fully charged.

Charging unit switches automatically into a

maintaining mode. Battery can stay in charger

for indefinite time w/o being damaged.

Yellow

– Battery at least 90% charged.

Charging cycle can be terminated.

– If the right LED does not light up, the circuit of

the battery is disconnected or the battery is

incorrectly polarized.

•If the nominal capacity of the battery is not achieved, e.g. at first charge, the battery is not

necessarily faulty. Full capacity can be achieved after (3) charging/discharging cycles.

•When the speed of the tool decreases noticeably, the battery must be recharged.

ATTENTION:

Do Not recharge a partially discharged battery as a precaution.

•Charge the battery at room temperature between 50°F and 104°F (10°C and 40°C).

•If charging a battery which has recently been used, or which has been exposed to sun for a

long period of time (T>149°F / T>65°C), the right LED may flash red. In this case, remove

battery out of charger. The charging procedure can be re-started after the battery has

cooled down.

•Charging batteries at low temperatures – under 41°F (5°C) is not recommended. Increase

battery temperature before starting the charging cycle.

•Do Not expose the charging unit to rain or snow.

•Do Not charge a battery in the vicinity of explosive materials and gases.

•No other batteries (e.g. dry batteries or car batteries, etc.) are to be used in the tool or in the

charging unit.

•Do Not use the cord to transport the charging unit, or to pull the plug out of a wall socket with

force.

•Do Not insert foreign objects into the ducts of the charging unit. Pull the plug of the charging

unit after charging. Do Not disassemble the charging unit or battery.

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