Panduit CT-902HP Installation guide

CT-902HP Family
PA27876A01
Rev. 023-2017
HYDRAULIC COMPRESSION SYSTEMS
OPERATION and MAINTENANCE INSTRUCTIONS
© Panduit Corp. 2017 Original Instructions
PRECAUTIONS ......................................................................................................................1
INTRODUCTION......................................................................................................................2
SYSTEM SPECIFICATIONS....................................................................................................4
OPTIONAL ACCESSORIES....................................................................................................4
GENERAL GUIDELINES FOR MAINTENANCE OF TOOLS ..................................................5
PUMP OPERATION ................................................................................................................5
PREVENTIVE MAINTENANCE ...............................................................................................6
TROUBLESHOOTING.............................................................................................................6
CONTACT INFORMATION .....................................................................................................6
WARNING: Read all safety warnings, instructions, illustrations and
specifications provided with this power tool. Failure to follow all instructions
listed below may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
Email:
techsuppor[email protected]
www.panduit.com
Technical Support
Tel: [phone]
CT-902HP PUMP SHOWN

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FAMILY
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PRECAUTIONS
DANGER
THE USER SHOULD BE PROPERLY TRAINED
IN THE CORRECT PROCEDURES REQUIRED
FOR WORK AROUND ELECTRICAL LINES
WARNING: When performing any service on this pump
or any of its’
components, the unit MUST be disconnected
from the power
supply outlet.
WARNING: Safety glasses must be worn at all times when using the tool.
CAUTION: Be aware of the ejection of cable tie scrap from tool.
WARNING: DO NOT USE THIS TOOL ON LIVE ELECTRICAL CIRCUITS
WARNING: Keep fingers clear of crimping tool head area during tool
operation.
WARNING: DO NOT use tool in an explosive atmosphere.
CAUTION: Ear protection should be worn when operating the tool.
CAUTION – When using CT-980CH Crimp Head
SECURE LATCH BEFORE OPERATING
FAILURE TO SECURE LATCH CAN RESULT IN SEVERE TOOL DAMAGE
AND PERSONAL INJURY.
CAUTION – When using CT-920CH, CT-920CH/CCP, CT-930CH or
CT-940CH Crimp Heads
DO NOT OPERATE WITHOUT DIES

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INTRODUCTION
The CT-902HP family of hydraulic pumps:
CT-902HP 110 V Hydraulic Pump with Hand Pendant Switch
CT-902HPRCH 110 V Hydraulic Pump with Remote Control Handle
CT-902HPRFS 110 V Hydraulic Pump with Remote Foot Switch
CT-902HP220 220 V Hydraulic Pump with Hand Pendant Switch
CT-902HP220RFS 220 V Hydraulic Pump with Remote Foot Switch
The CT-902HP family of hydraulic pumps are capable of providing 10,000 PSI (700 bar). Panduit recommends
using their CT-902HP family of hydraulic pumps with the CT-900HPH Hydraulic Pump Hose, which can crimp #8
AWG thru 1500 MCM Panduit Copper Compression Connectors; and #6 AWG thru 1000 MCM Panduit Aluminum
Compression Connectors. Refer to the product packaging for wire size and crimp designations.
This manual will guide you step-by-step in operation and maintenance of your Hydraulic Pump.
If you have problems not covered, call:
1-800-777-3300
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.
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.
1) Work area safety
a) Keep work area clean and well lit.Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to
lose control.
2) Electrical safety
a) Always disconnect plug from outlet before performing any service on the pump.
b) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
c) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
d) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase
the risk of electric shock.
e) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
f) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of electric shock.
g) If operating a power tool in a damp location is unavoidable, use a ground fault circuit
interrupter (GFCI)” protected supply. Use of an GFCI reduces the risk of electric shock.
3) Personal safety
a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do
not use a power tool while you are tired or under the influence of drugs, alcohol or
medication. A moment of inattention while operating power tools may result in serious personal
injury.

© Panduit Corp. 2017 OPERATION MANUAL CT-902HP
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b) Use personal protective equipment. Always wear eye protection. Protective equipment such as a
dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will
reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to
power source and/or battery pack, picking up or carrying the tool. Carrying power tools with
your finger on the switch or energizing power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This enables better control of
the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from
moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection facilities, ensure
these are connected and properly used. Use of dust collection can reduce dust-related hazards.
h) Do not let familiarity gained from frequent use of tools allow you to become complacent and
ignore tool safety principles. A careless action can cause severe injury within a fraction of a
second.
4) Power tool use and care
a) Do not force the power tool. Use the correct power tool for your application. The correct power
tool will do the job better and safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source, before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures reduce the risk of starting
the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with
the power tool or these instructions to operate the power tool. Power tools are dangerous in the
hands of untrained users.
e) Maintain power tools and accessories. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s operation. If
damaged, have the power tool repaired before use. Many accidents are caused by poorly
maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are
less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc. in accordance with these instructions,
taking into account the working conditions and the work to be performed. Use of the power tool
for operations different from those intended could result in a hazardous situation.
h) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles
and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5) Service
a) Have your power tool serviced by a qualified repair person using only identical replacement
parts. This will ensure that the safety of the power tool is maintained.
For technical support or repair, see Contact Information on Page 6.
Periodic Maintenance:
Make sure tool is clean before each use.

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SYSTEM SPECIFICATIONS
CT-902HP Family Hydraulic Pump pressure is factory preset at 10,000 PSI ±200 PSI (700 bar),
Hydraulic Pumps and is to be used with the following Remote Hydraulic Crimp Heads: CT-920CH,
CT-920CH/CCP, CT-930CH, CT-940CH and Dieless CT-980CH. Pump shuts off when
cycle is complete. Will not release until down button is activated.
Dimensions: 9.5 L x 10.5 W x 15.5 H in.
241 L x 267 W x 393 H (mm)
Weight: 15.4 (kg) / 34.0 lbs.
Housing: Color – TOP BASE
110V Blue Black
220V Yellow White/Gray
Pump
Tank Capacity: 2 Liters
Fluid Type: Shell Tellus Hydraulic Oil S2 V 15
Motor
110V
220V
Type:
Commutator
Commutator
R.P.M.:
1200
1200
Voltage:
110 V
220 V
Watts:
715 W
340 W
Frequency:
50/60 Hz
50/60 Hz
Current:
6.5 A
3.2 A
Horsepower:
½
½
Delivery @ 200 psi 157 cubic inches/minute
Delivery @ 10,000 psi 19 cubic inches/minute
CT-902HPRCH Hydraulic Pump with Remote Control Handle (hardwired at factory)
RCH 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.
CT-902HPRFS Hydraulic Pump with Remote Foot Switch (hardwired at factory)
RFS 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.
OPTIONAL ACCESSORIES
CD-920 / CD-940 Refer to product packaging for wire size and crimp designations; or contact
Compression Dies Panduit Customer Service for specific die application information.
CT-900HPH Electrically non-conductive 10 ft. hose. Supplied pre-filled with hydraulic fluid
Hydraulic Pump Hose for fast start up.
PG-1 Verifies the PSI reading of the CT-902HP Hydraulic Pump.
Pressure Gauge Dimensions: 228 L x 114 H x 38 W (64 dial face) (mm)
9.0 L x 4.5 H x 1.5 W (2.5 dial face) in.
Weight: 1.4 (kg) / 3.0 lbs.
CT-902HPRFS Pump Shown

© Panduit Corp. 2017 OPERATION MANUAL CT-902HP
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CG-920 / CG-940 / CG-980 Verifies the compression force of Panduit compression tools and
Compression Gauges remote crimp heads.
Dimensions: 228 L x 102 H x 38 W (102 dial face) (mm)
9.0 L x 4.0 H x 1.5 W (4.0 dial face) in.
Weight: 1.6 (kg) / 3.5 lbs.
GENERAL GUIDELINES FOR MAINTENANCE OF TOOLS
1. Always verify the proper size connector for the conductor, by checking the color code and the printing on the
connector.
2. NOTE: CONNECTIONS UTILIZING THIS TOOL ARE U.L. LISTED AND C.S.A. CERTIFIED ONLY WHEN
PANDUIT COMPRESSION CONNECTORS ARE USED. USE OF ANY OTHER BRAND OF
COMPRESSION CONNECTORS IS NOT RECOMMENDED.
Consult product packaging, Panduit catalog or website for information on recommended
connectors.
3. Daily maintenance is important to keep the tool in good working condition. 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 parts.
Always replace the dust cap on the coupler, and store the tool in its clean, dry carrying case when not in use.
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
piston and tool head. Solvent can be used on the tool head to remove any foreign matter or debris. A tool
that is dirty with excessive foreign matter may jam and become damaged during operation.
4. The hydraulic system has been calibrated and sealed at the factory. Consult our Customer Service
Department or your local distributor if hydraulic problems are experienced.
5. 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 our Customer Service Department at:
1-800-777-3300.
5. Avoid dropping the tool. Extreme shock may damage the hydraulic circuit or tool head, and result in
malfunction of the tool.
6. 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.
PUMP OPERATION
1. Connect male hose fitting to female tool fitting. (Panduit Part No. for hose is: CT-900HPH.)
Vent tank by turning air vent lever (A) [see photo on Page 2] to upright position (replace cotter pin).
Leave vent open during tool operation.
2. Insert electric cord (3 prong plug) into appropriate power outlet for unit being used.
3. Depress the “DOWN” button on remote control switch to determine if solenoid is operational.
(A “clicking” sound will be heard.)
4. The “UP” button activates motor to generate hydraulic pressure. Depress and hold for ram advance.
5. To stop ram advance, release “UP” button. Oil pressure will remain constant until “DOWN” button is
depressed to relieve pressure. The pump will automatically shut off when the maximum pressure is reached.
6. To retract ram, depress and hold in the “DOWN” button. Oil in tool cylinder will return to tank and tool will be
ready to begin next cycle. Retraction of the ram may be stopped by releasing the “DOWN” button.

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FAMILY
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PREVENTIVE MAINTENANCE
Maintenance should be performed monthly, whenever possible damage has occurred, or as often as operating
conditions warrant.
1. Operate CT-902HP pump on 110 volts AC only, or voltages between 95 and 120. Do not operate pump on
voltages less than 95 volts, or on DC current.
Operate CT-902HP220 pump on 220 volts AC only, or voltages between 200 and 242. Do not operate pump on
voltages less than 200 volts, or on DC current.
2. Level of oil is to be maintained above the red dot in center of port window. To add oil, unscrew entire oil vent
fitting from tank with a wrench. Using a funnel, pour oil into the tank opening. Recommended hydraulic oil:
Shell Tellus Hydraulic Oil S2 V 15 or approved equivalent. Replace fitting.
3. When attaching hoses, be sure all couplers are securely fastened. Always keep couplers clean by wiping oil
and debris from surfaces before connecting hoses to pump or tool.
4. Never move pump by pulling on the electrical cords.
5. Always store pump with the air vent in the closed position.
TROUBLESHOOTING
If system locks up under pressure, perform the following steps:
•Verify that the solenoid on pump is making an audible “click”.
•If above step checks out, determine which fitting needs to be tightened.
•When pump is released, does the hose stay rigid or flex back down?
•If the hose stays rigid, the problem is in the connection from pump to hose.
•If the hose flexes down, the problem is in the connection from hose to tool head.
•To tighten couplers, use channel lock pliers or pipe wrench; (wrap couplers to avoid causing damage).
•When you feel the couplers tighten, depress the release on the pump; (pressure should be released).
•Tool head should retract. Finish tightening couplers by hand.
CONTACT INFORMATION • For Technical Support:
Panduit USA, Tinley Park, IL
USA Tel: [phone]
Website: www.panduit.com
E-mail: [e-mail]
Panduit Canada Headquarters
Markham Ontario, Canada
Canada Tel.: [phone] or 800-387-9689
Fax.: [phone]
Website: www.panduit.com
E-mail: [e-mail]
Panduit Latino America, Guadalajara,
Jalisco, Mexico
Latino America Tel.: [phone]
Fax.: [phone]
Website: www.panduit.com
E-mail: [e-mail]
Panduit China, Beijing
Xuanwumen Xidajie Xicheng District
Beijing, China
Tel: [phone] • Fax: [phone]
Toll Free Customer Service - North China: 10800
6500 211 • South China: 10800 2650 211
E-mail: [e-mail]
Panduit Singapore – Sales Office
Singapore, Republic of Singapore
Tel: [phone] • Fax: [phone]
E-mail: [e-mail]