Panduit BlackFin CT-2600 Series User manual

CT-2600 and CT-2600/E
PA26001A01
Rev. 02 5-2009
© Panduit Corp. 2009
PRECAUTIONS AND GENERAL GUIDELINES.............................................................................................1
TOOL SPECIFICATIONS................................................................................................................................4
CT-2600 and CT-2600/E TOOLS....................................................................................................................4
IMPORTANT FEATURES OF THE CT-2600 and CT-2600/E
BATTERY OPERATED CRIMPING TOOLS...................................................................................................5
CRIMP DIES AND ACCESSORIES ................................................................................................................6
DIE SELECTION AND INSTALLATION .........................................................................................................6
TOOL OPERATION.........................................................................................................................................7
MAINTENANCE / INSPECTION......................................................................................................................8
Die Closure Inspection.....................................................................................................................................9
Storage and Transport ...................................................................................................................................10
TROUBLESHOOTING...................................................................................................................................10
DISCONTINUATION OF USE / DISPOSAL..................................................................................................10
USE OF THE BATTERY CARTRIDGE AND CHARGING UNIT..................................................................10
Terminations per Battery Charge...................................................................................................................11
Website: www.panduit.com
Email: [email protected]
EU Website:
www.panduit.com/emea
EU Email: EMEA-
Toolservice[email protected]
Panduit Corp. • USA Headquarters • Tinley Park, IL
Tel: [phone], ext. 3255 • Fax: [phone]
PANDUIT Europe • EMEA Headquarters
Tel: [phone] • Fax: [phone]

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 1 of 11 5-2009
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.
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.
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.
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 could result in severe injury or death.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 2 of 11 5-2009
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 could result in severe injury or death.
WARNING
Wear eye protection when operating or servicing this tool.
Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic
oil.
WARNING
Skin Injection Hazard:
Do not use hands to check for oil leaks. High pressure oil easily punctures skin causing
serious injury, gangrene, or death. If injured, seek medical attention immediately to remove oil.
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.
WARNING
Pinch points:
Keep hands away from the crimping head when crimping.
Failure to observe this warning could result in severe injury or death.
WARNING
An incomplete crimp can cause a fire.
•Use proper terminal 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.
WARNING
Do not dispose of batteries in a fire. They will vent fumes and may explode.
Failure to observe this warning could result in severe injury from harmful fumes or burns from flying debris.
WARNING
Inspect tool and dies before use. Replace any worn or damaged parts. A worn or damaged tool may result in
breakage, striking the operator or nearby personnel.
Failure to observe this warning could result in severe injury or death.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 3 of 11 5-2009
CAUTION
•Do not perform any service or maintenance other than as described in this manual.
Injury or damage to the tool may result.
•This tool is not designed for continuous use.
•After 30 to 40 cycles, allow the tool to cool for 15 minutes.
•Do not place the tool in a vise. The tool is designed for hand-held operation.
•Protect the tool from rain and moisture. Water will damage the 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.
CAUTION
•Do not operate the tool without dies. Damage to the ram or crimping head can result.
•Do not operate tool with the locking flange open. The crimp head must be completely closed and locked in
position before cycling the tool.
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.
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.
IMPORTANT INFORMATION
•Keep the tool head and tool body portion clean and free from debris. 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.
•Always point tool away from others.
•If the tool is kept in cold temperatures below 23oF/-5oC for any extended time, it is advisable to return the tool
to room temperature for 1 hour before using.
•Always verify the proper size terminal for the conductor (wire), by checking the color code and the printing on
the terminal.
•Avoid dropping the tool. Extreme shock may damage the hydraulic circuit and result in malfunction of the
tool.
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.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 4 of 11 5-2009
TOOL SPECIFICATIONS
CT-2600 or CT-2600/E
Battery Operated Crimping
Tools
Weight (including battery) 3.5 lbs. (1,6 kg)
Dimensions: 14” L x 2-3/8” H x 3-1/8” W – with battery
[356 L x 60 H x 80 W] mm
Crimping Time 4 seconds
Crimping Force 4 tons (35 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)
Vibration < 2.5 m/s2
Hydraulic Oil Shell Tellus®T 15
CT-2600BC
Battery Cartridge Battery Type: Nickel Metal-Hydride (Ni-MH)
Output: 9.6 V
Capacity: 2.0 Ah
Charging time: Approx. 45 minutes
(15-20 min. with fast charger)
Makita Battery Charger
Part No.: DC1804
Output: 7.2 V – 18.0 Volt DC
Input: 120 Volt AC, 50~60Hz
Makita Battery Charger
for EU
Part No.: DC1804F
Output: 7,2 V – 18,0 Volt DC
Input: 240 Volt AC, 50~60Hz
NOTE: The CT-2600 and CT-2600/E tools can also use the CT-2500BC, CT-2500CHR and
CT-2500CHR/E battery cartridge and chargers listed below:
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
CT-2600 and CT-2600/E TOOLS
The CT-2600 and CT-2600/E Tools include:
•1 – Battery Operated Crimping Tool (with battery cartridge)
•1 – Spare Battery Cartridge
•1 – Battery Charger
•1 – Tool Case

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 5 of 11 5-2009
IMPORTANT FEATURES OF THE CT-2600 and CT-2600/E
BATTERY OPERATED CRIMPING TOOLS
•The hydraulic unit incorporates an automatic retraction which returns the ram 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 ram/dies when
the trigger is released. This allows the terminal to be held in position for easy wire insertion prior
to crimping.
•To simplify operation and gain better access to tight corners and other constrained working
areas, the crimping head may be rotated, by hand, 360° relative to the tool body.
•The tool is lightweight and provides good handling characteristics through its small frame size
and ergonomic design.
Fig. 1
Description Function
1. Crimp Head Crimp head holds crimping dies
2. Ram Advances dies during crimping cycle
3. Ram Retract Button Button to open the crimp dies in case of an error or emergency
4. Battery Locking
Device Switch for unlocking the battery
5. Battery Cartridge Rechargeable Ni-MH battery, 9.6 V
6. Low Battery
Indicator LED flashes to indicate low battery
7. Trigger Actuator to start the crimping cycle
8. Locking Flange Opens for easy access and installation of crimp dies

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 6 of 11 5-2009
CRIMP DIES AND ACCESSORIES (sold separately)
CD-2600 Series Compression Dies Consult PANDUIT catalog or website for part numbers and
specific die application information.
CT-2600BC Replacement Battery Cartridge
CT-2500CHR Replacement Battery Charger
CT-2500CHR/E Replacement Battery Charger for Europe
Makita 7.2 Volt – 18.0 Volt DC replacement battery charger Makita Part No.: DC1804
Makita 7.2 Volt – 18.0 Volt DC replacement battery charger for EU Makita Part No.: DC1804F
Replacement Makita Batteries and Battery Chargers are available for purchase from local Makita
products distributors.
DIE SELECTION AND INSTALLATION
Refer to product packaging label to verify terminal to die combinations.
NOTE: DIES ARE DESIGNED TO PROVIDE THE HIGHEST QUALITY CRIMPING WHEN USED WITH
PANDUIT TERMINALS. CONNECTIONS UTILIZING THIS TOOL ARE LISTED PER U.L. 486A AND
C.S.A. CERTIFIED ONLY WHEN PANDUIT TERMINALS ARE USED. USE OF ANY OTHER BRAND
OF TERMINALS IS NOT RECOMMENDED WITH CD-2600 DIES.
NOTE: Remove battery from tool before removing or installing dies in the crimp head.
1. Remove any current dies from the tool ram by opening locking flange in crimp head and pulling die
out of tool.
CAUTION: Do Not let the ram contact the crimp head.
2. Select the appropriate dies to match the terminal to be crimped.
1. Slide one of the die halves into the crimp head until it snaps into place.
2. Properly position the remaining die half into the crimp head until it snaps into place, and close the
locking flange.
3. Replace the battery and slowly activate the tool to ensure that the die halves are properly aligned
without binding or interference in the crimp head.
NOTE: DO NOT operate tool if dies are not properly aligned and snapped (locked) in place.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 7 of 11 5-2009
TOOL OPERATION
LED Display
This tool is equipped with a special circuit board incorporating several important features to inform the
user about the current status of the unit. The LED signals in the following cases:
SIGNAL DURATION WHEN IT OCCURS WHAT IT MEANS
A few seconds of
flashing Battery insertion Self check – O.K.
Glowing for 20
seconds After crimp Battery discharged
Flashing for 20
seconds (2Hz) After crimp Time for inspection and preventive maintenance
20 sec. glowing and
flashing intermittently After crimp Battery discharged –
Time for inspection and
preventive maintenance
Preparing Wire and Positioning Terminals
Follow the instructions for appropriate wire strip length and crimp die as marked on the terminal
packaging. Position terminal centrally under crimp die as shown in Figures 2-4 on Page 7.
NON-INSULATED TERMINALS (P Series) PRE-INSULATED TERMINALS
(PV and PK Series)
P8 & P6 P4 & P2 PV8 – PV2
Fig. 2 Fig. 3 Fig. 4
Crimping Terminals
ATTENTION: The crimping process can be interrupted at any time by releasing the
trigger. After having terminated the crimping process, remove
battery to avoid unintended starts.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 8 of 11 5-2009
1. To simplify operation, the crimp head may be rotated by hand 360orelative to the tool body.
2. Depress ram retract button 2-3 times to ensure that ram is fully retracted.
3. Carefully place terminal centrally between dies as shown above. Activate trigger until terminal is
held by dies.
CAUTION: Do Not crimp terminal.
4. Check to ensure conductor (wire) size and dies properly match the terminal size being used.
Insert the stripped conductor into the terminal.
5. Depress the trigger until the crimp is completed. The relief valve will sound when the crimp is
completed, and the crimp dies will automatically open as the ram returns to its initial position.
6. Remove the crimped terminal/conductor wire and repeat the operation for a new terminal.
CAUTION: Do Not press trigger and release button simultaneously. Damage to trigger
linkage may result.
NOTE:
•By sliding the ram retract button 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 ram.
MAINTENANCE / INSPECTION
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.
After Use:
1. Wipe all tool surfaces clean with a damp cloth and mild detergent.
2. Place the tool in the carrying case. Store in a cool, dry place.
3. Charge the battery.
Monthly Maintenance
1. Thoroughly clean all surfaces.
2. Oil the locating pins.
Annually or After 10,000 Crimps
Return tool to PANDUIT Tool Division

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 9 of 11 5-2009
DIE CLOSURE INSPECTION: CT-2600 AND CT-2600/E
Die Closure inspection is made by using the GO/NO-GO gaging dimensions listed in Fig. 6.
TO PERFORM DIE CLOSURE INSPECTION
A. Clean die and plug gage surfaces.
B. With crimp dies properly installed in crimp head, slowly activate tool until dies bottom
under light pressure.
C. Using the proper gage member, insert the GO side into the die – it must pass
completely through the closure.
D. Reverse the gage and try to insert the NO-GO side into the die closure (Do Not use
excessive force). The NO-GO side may partially enter the die closure but must not
pass completely through.
E. If both the GO and NO-GO conditions are met; the tool is dimensionally correct.
F. If the above procedure fails to satisfy all GO and NO-GO conditions, contact your local
PANDUIT Sales Office.
Fig. 5
Fig. 6
CRIMP
DIE
JAW CLOSURE
DIMENSIONS
PIN GAGE DIA. in. (mm)
GAGE ELEMENT DIAMETERS
in. (mm)
GO “G” NO-GO “NG”
CD-2600-P8 .148 - .154 (3.759 – 3.911) .1480 - .1483
(3.7592 – 3.7668) .1537 - .1540 (3.9039 – 3.9116)
CD-2600-P6 .194 - .200 (4.927 – 5.080) .1940 - .1943
(4.9276 – 4.9352) .1997 - .2000 (5.0723 – 5.0800)
CD-2600-P4 .220 - .226 (5.588 – 5.740) .2200 - .2203
(5.5880 – 5.5956) .2257 - .2260 (5.7327 – 5.7404)
CD-2600-P2 .315 - .321 (8.001 – 8.153) .3150 - .3153
(8.0010 – 8.0086) .3207 - .3210 (8.1457 – 8.1534)
CD-2600-PV8 .188 - .194 (4.775 – 4.927) .1880 - .1883
(4.7752 – 4.7828) .1937 - .1940 (4.9199 – 4.9276)
CD-2600-PV6 .228 - .234 (5.791 – 5.943) .2280 - .2283
(5.7912 – 5.7988) .2337 - .2340 (5.9359 – 5.9436)
CD-2600-PV4 .315 - .321 (8.001 – 8.153) .3150 - .3153
(8.0010 – 8.0086) .3207 - .3210 (8.1457 – 8.1534)
CD-2600-PV2 .355 – .361 (9.017 – 9.169) .3550 - .3553
(9.0170 – 9.0246) .3607 - .3610 (9.1617 – 9.1694)

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 10 of 11 5-2009
STORAGE AND TRANSPORT
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.
TROUBLESHOOTING
Before You Begin:
1. Make sure that the battery is charged. Recheck the battery after several minutes to make
sure the battery is holding its charge.
2. Use a nonflammable contact cleaner or pencil eraser to clean the electrical contacts on
the battery and crimping tool.
3. Reinstall the battery and check the tool again.
Problem Probable Cause Probable Remedy
Tool is inoperative.
Dirt, contaminants, etc., in ram
area of tool. Clean tool.
Crimping tool battery contacts
damaged. Reform contacts.
Tool components worn or
damaged. Return tool to PANDUIT Tool Division.
Dies stop during
operation.
Oil level is low. Return tool to PANDUIT Tool Division.
Air in hydraulic system. Pull trigger and hold retract button simultaneously. Hold for approximately 10
seconds.
LED glows for 20
seconds Battery charge low. Charge or replace battery.
Tool loses oil. Damaged internal seal. Return tool to PANDUIT Tool Division.
DISCONTINUATION OF USE / DISPOSAL
•The battery cartridge must be specially disposed of according environmental Battery
Guidelines.
•For the disposal of the remaining parts, please reference environmental guidelines.
•Because of possible environmental damage, we recommend disposal of the tool by
professional companies.
ATTENTION:
Do not dispose of the unit in your
residential or commercial waste, as it
would be hazardous to the
environment.
USE OF THE BATTERY CARTRIDGE (CT-2600BC) and
CHARGING UNIT (CT-2600CHR or CT-2600CHR/E
The charging unit is run with a nominal voltage of 120 V (CT-2600CHR), or (230 V for
CT-2600CHR/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.

CT-2600 and CT-2600/E
CT-2600 & CT-2600/E PA26001A01_02 Page: 11 of 11 5-2009
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.
ATTENTION:
Do Not place the battery in your pocket or in your toolbox if there are any
conductive materials in it such as coins, keys, tools or other metallic parts.
TERMINATIONS PER BATTERY CHARGE
The estimated number of terminations before the battery will need to be recharged is dependent on
variables such as the terminal size and type being terminated, ambient temperature, and time lapsed
between termination cycles as well as other variables.