TE Connectivity 1976330-1 User manual

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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
1
LED ((Red)
Indicator for battery charge controls, tool functions and faults
2
Battery
Re-chargeable 3aH Li-Ion Battery
3
Control Button
Switch to start the crimping procedure
4
LED (White)
Indicator to illuminate the work area
5
Ring
Device to secure crimping tool
6
Housing
Ergonomically formed plastic housing
7
Crimp Chambers
Integral die set with two crimping chambers
Figure 3
1
2
6
7
5
4
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
1
---
---
1
No. 8 (RED)
608501-1
RED
DOT
2
---
---
---
---
1
---
1
3
---
---
---
2
---
---
1
---
1
1
---
1
1
---
---
1
---
1
---
1
---
2
---
1
---
3
---
2
---
1
---
---
2
---
1
No. 6 (BLUE)
608502-1
BLUE
DOT
3
---
---
1
4
---
---
1
---
2
---
---
---
3
---
---
4
---
---
---
---
1
---
2
---
2
1
---
---
3
---
1
3
---
1
---
4
---
1
---
5
---
---
---
---
4
---
---
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.

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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
a
b
c
d
e
f

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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