TE Connectivity 1976330-1 User manual

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*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

TOOLING ASSISTANCE CENTER

1-800-722-1111

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

Customer Manual

409-10104

19 SEP 14 Rev B

SAFETY PRECAUTIONS

READ THIS FIRST!

.............................................................2

1. INTRODUCTION ..................................................................................................................3

2. DESCRIPTION .....................................................................................................................4

2.1. Electrical Requirements ..............................................................................................4

2.2. Functional Description (Figure 3) ................................................................................4

3. OPERATION ........................................................................................................................5

3.1. Crimping/Die/Splice Selection .....................................................................................5

3.2. Crimping Procedure ....................................................................................................6

3.3. Crimp Inspection .........................................................................................................8

3.4. Finishing the Splice .....................................................................................................9

3.5. Battery Charging .......................................................................................................10

4. MAINTENANCE/INSPECTION ..........................................................................................10

4.1. Daily Maintenance.....................................................................................................11

4.2. Periodic Visual Inspection .........................................................................................11

4.3. Lubrication.................................................................................................................11

5. TROUBLESHOOTING .......................................................................................................12

6. TOOL REPAIR ...................................................................................................................12

7. REVISION SUMMARY .......................................................................................................12

Cordless Electric Power Tool Kit 1976330-1

(For Tooling Revisions C and Above)

ORIGINAL INSTRUCTIONS

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SAFETY PRECAUTIONS —AVOID INJURY

Safeguards are designed into this application equipment to protect operators and maintenance personnel from

most hazards during equipment operation. However, certain safety precautions must be taken by the operator

and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application

equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or

hazardous environment.

Carefully observe the following safety precautions before and during operation of the equipment:

Always wear approved eye protection while operating

equipment.

Always wear appropriate ear protection while using

equipment.

Moving parts can crush and cut. Always keep guard(s)

in place during normal operation.

Electrical shock hazard.

Always turn off the main power switch and disconnect

the electrical cord from the power source when

performing repair or maintenance on the equipment.

Never insert hands into installed equipment.

Never wear loose clothing or jewelry that may catch in

moving parts of the equipment.

Never alter, modify, or misuse the equipment.

TOOLING ASSISTANCE CENTER

CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

The Tooling Assistance Center offers a means of providing technical assistance when required.

In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the

application equipment when problems arise which your maintenance personnel are unable to correct.

INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER

When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person

familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many

difficulties can be avoided in this manner.

When calling the Tooling Assistance Center, be ready with the following information:

1. Customer name

2. Customer address

3. Person to contact (name, title, telephone number, and extension)

4. Person calling

5. Equipment number (and serial number if applicable)

6. Product part number (and serial number if applicable)

7. Urgency of request

8. Nature of problem

9. Description of inoperative component(s)

10. Additional information/comments that may be helpful

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Figure 1

1. INTRODUCTION

This manual covers the operation and maintenance of Cordless Electric Power Tool Kit 1976330-1, which is

used to apply COPALUM* Splices to solid-conductor wire. See Figure 1. Read this manual carefully before

attempting to operate the tool for the first time. The performance of the tool depends largely on the intelligent

use of the information contained in this manual.

NOTE

This manual is for tooling revisions C and above.

The tool is used in the TE Connectivity Aluminum Wire Re- termination Program, which provides materials and

procedures to modify branch circuits in aluminum- wired homes in compliance with the National Electrical

Code. The program is intended only for qualified electricians and uses only materials listed by Underwriters

Laboratories.

The program consists of permanently joining a short length, or pigtail, of solid-copper wire to existing number

12 and 10 solid aluminum wires in 15 ampere and 20 ampere branch circuits. The wires are spliced using

COPALUM splices and TE tooling. The pigtailed copper wire is then connected to the electrical device.

Ordinary branch-circuit wiring methods are used. Aluminum-to-aluminum wire splices are modified by

permanently joining the wires using COPALUM splices and TE tooling.

This program covers modifications of all 15 ampere and 20 ampere branch circuit connections, such as plug

receptacles, switch devices, junction boxes, and all field-wired appliances, such as lighting fixtures, garbage

disposals, furnace fans and controls, electrical accessories on gas appliances, exterior lighting fixtures, breaker

boxes, and other electrical panels.

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

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DANGER

Denotes an imminent hazard that may result in moderate or severe injury.

CAUTION

Denotes a condition that may result in product or equipment damage.

NOTE

Highlights special or important information.

NOTE

Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.

Figure 2 lists tool kit specifications.

TOOL NUMBER

1976330-1 (Rev C and Above)

Dimensions (Approximate)

Height

337.8 mm [13.3 In.]

Width

76. 2 mm [3.0 In.]

Length

317.5 mm [12 .5 In.]

Weight

4.67 Kilograms [10.3lb]

Battery Pack Life

Approximately 300 crimps on a full charge

Figure 2

2. DESCRIPTION

Cordless Electric Power Tool Kit 1976330-1 is a portable hand tool kit featuring an integral die set with two

crimping chambers. (Refer to Figure 3.) These crimp chambers allow the tool operator to splice a wide variety

of wire sizes and combinations without having to repeatedly remove and replace die sets.

The kit contains a battery powered crimp tool, a battery pack, and a battery charger. The kit also contains the

carrying case for these components.

2.1. Electrical Requirements

The tool is powered by a removable, rechargeable battery pack, which is supplied with a recharging unit. The

recharging unit operates on 115 Vac line power, and charges the battery pack from full discharge to full charge

in approximately 30 minutes.

2.2. Functional Description (Figure 3)

With a fully-charged battery pack installed in the tool, the operator places a splice onto the wire to be crimped.

The splice is then loaded into the appropriate crimp chamber of the tool.

When the control button is pressed, the motor starts, operating a hydraulic cylinder, which pushes up on the die

anvil, bottoming the dies. A special feature of the tool ensures that each splice is fully crimped before the dies

reopen. This feature provides high-quality, consistent crimps.

The hydraulic unit incorporates an automatic retraction feature which returns the piston to its starting position

when the maximum operation pressure is reached. The integrated pressure sensor automatically identifies the

achieved crimping force during every crimping operation. If the set operating pressure is not met, an audible

alert sounds and a red LED flashes (see Figure 15).

The tool is equipped with a microprocessor which shuts off the motor automatically after the crimp is

completed, indicates service intervals, low battery conditions, and performs internal checks sending out audible

and optical warning signals in case of a detected fault.

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The unit is equipped with a special brake which stops the forward motion of the dies when the control button is

released.

The crimping head can be rotated 330° in order to gain better access to tight corners and other difficult working

conditions.

NOTE

The tool is designed to provide a complete crimp with every cycle. When the control button is pressed and held, the tool will

cycle until it has returned to the starting position.

DANGER

Keep fingers clear of the crimping dies during the crimping operation.

3. OPERATION

3.1. Crimping/Die/Splice Selection

Depending on the size and type of wires encountered, the operator will use one of two splice sizes, along with

the corresponding die set in the tool. To determine the correct splice and die set for your application, refer to

Figure 3. Find the correct size, composition, and combination of wires encountered, then determine the correct

splice as shown in Figure 4.

Also listed is the color code found on the splice and on the proper die set on the tool.

ITEM NUMBER

DESCRIPTION

FUNCTION

LED ((Red)

Indicator for battery charge controls, tool functions and faults

Battery

Re-chargeable 3aH Li-Ion Battery

Control Button

Switch to start the crimping procedure

LED (White)

Indicator to illuminate the work area

Ring

Device to secure crimping tool

Housing

Ergonomically formed plastic housing

Crimp Chambers

Integral die set with two crimping chambers

Figure 3

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WIRE COMBINATION BY SIZE (AWG) AND COMPOSITION●

SPLICE SIZE, COLOR

CODE, AND KIT PART

NUMBER

COLOR CODE

ON DIES

Aluminum (AL)

Copper (CU)

No. 12

No. 10

No. 14

No. 12

---

No. 8 (RED)

608501-1

RED

DOT

---

No. 6 (BLUE)

608502-1

BLUE

DOT

---

NOTE: ●Solid wires ONLY. For other combinations, call the Tooling Assistance Center at 1-800-722-1111. For proper installation, ALL splices are used with Heat Shrink

Tubing supplied in each splice kit.

Figure 4

3.2. Crimping Procedure

CAUTION

Make sure that you are using the correct COPALUM splice and crimp chamber for the aluminum wire or aluminum and copper

wire size combinations that you are going to crimp. The color dot code stripe on the splice and the color code and dot on the

crimping dies MUST match. Do not alter COPALUM splices by removing the internal perforated inserts. If you have any

questions concerning proper application, contact your local TE Representative.

Insert the battery pack in the tool.

Refer to Figure 4, select the proper splice, and proceed as follows:

1. Make sure that each wire extends a minimum of 25.4 mm [1 in.] from any electrical box or wall

surface.

2. If more wires must be spliced than allowed on the table in Figure 4, use “piggy back”crimps to splice

all wire. Refer to Figure 5.

409-10104

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Figure 5

3. Strip each wire to the proper length as indicated in Figure 6. When stripping the wires, do NOT nick or

cut the conductors. If a conductor is damaged, cut the wire and strip it again.

Figure 6

4. Place the correct splice on the stripped wire.

5. Insert the correct splice into the crimping chamber with the color code dot matching the color code

stripe on the splice. The back of the splice should bottom against the urethane stop behind the

crimping dies.

6. Press the control button of the tool until the moving anvil grips the splice. Check for proper positioning

of splice in the crimp chamber.

DANGER

Keep fingers away from the crimping area when operating the tool.

7. Continue to press the control button to crimp the splice. The tool should cycle and stop. Release the

control button immediately when the cycle stops. Allow tool to retract fully open position before

pressing control button again. If the tool stops mid-cycle, the battery pack must be changed. Refer to

Paragraph 3.5, Battery Charging, for detailed information on replacing the pack.

8. When the tool stops, remove the crimped splice from the tool. See Figure 7.

NOTE: Not to Scale.

25.4 [1.00]

Min.

Strip Length

19.05 [.750]

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Figure 7

3.3. Crimp Inspection

1. Refer to Figure 8 and check each splice for the following:

a. Crimp centered in splice.

b. Splice size stamped on splice agrees with wire combination shown in Figure 4.

c. Die proof mark present on underside of splice (- for No.8 dies, = for No.6 dies).

d. Wire ends extend past splice end.

e. No wire insulation in crimped splice; no cross-overs

f. No open crack at splice seam.

2. Check each crimped splice with the secondary crimp gage to be sure of a proper crimp. Find the gage

end with the color code dot matching the color code stripe on the splice. Align the splice as shown in

Figure 9 and insert the splice into the gage. The splice should enter the gage easily.

Figure 8

3. If the splice does not meet the gage test, check that the proper wire sizes and combinations listed in

Figure 4 were used, cut off the splice, strip the wires, and apply a new splice.

4.57 [0.18] Typ

(3.30 [0.13] Min.)

Trim Wire Ends After

Crimping Connector

NOTE: No. 8 Splice Shown

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If the splice still does not meet the gage test, the tool must be returned to TE for service. Refer to Page 2

of this manual for details.

Figure 9

3.4. Finishing the Splice

1. Place a 38.1 mm [1 .50 in.] section of heat shrink tubing over the crimped splice. The splice should be

centered in the tubing, with approximately 12.7 mm [.50 in.] of tubing on either side of splice. See

Figure 10.

2. Heat the tubing with the heat gun until the tubing shrinks to the shape of splice. Do NOT overheat

wires. Refer to Figure 11.

NOTE

Also apply tubing to bare ground wires.

Figure 10

Figure 11

3. For stranded copper wire attached directly to a device, use a wire nut to connect the stranded wire to

a solid copper pigtail. Refer to Figure 12.

Color Dot Code

Splice

Secondary

Crimp Gage

38.1 [1.50]

(Approx.)

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Figure 12

3.5. Battery Charging

To remove the battery pack, push the release button on the battery pack. Pull the pack out and replace with a

fully-charged pack.

CAUTION

The battery pack cavity in the tool is keyed to prevent damage to the tool that could be caused by installing the battery pack

incorrectly. Do not defeat this keying feature.

DANGER

Keep fingers away from the crimping area when changing the battery pack.

To charge the battery pack, make sure that the charging unit is plugged in, then insert the pack into the

charging unit, as shown in Figure 13. The battery pack will be fully charged when the charger indicator

becomes green. A full charge takes about 30 minutes.

Figure 13

4. MAINTENANCE/INSPECTION

These instructions have been approved by the TE Design, Production, and Quality Control Engineers to

provide documented maintenance and inspection procedures. Through TE test laboratories and the inspection

of production assembly, the procedures described herein have been established to ensure the quality and

reliability of Cordless Electric Power Tool 1976330-1.

DANGER:

Do NOT use the wire nut to

connect the stranded copper

wire directly to the aluminum

wire.

To Device

Battery Pack

Charging Unit

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