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409-10104 

Rev B 

3 of 12 

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. 

 

Summary of Contents for 1976330-1

Page 1: ...m 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...

Page 2: ...lry 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 Th...

Page 3: ...s 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 a...

Page 4: ...eable 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 minut...

Page 5: ...ered 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...

Page 6: ...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...

Page 7: ...l 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 Conti...

Page 8: ...ck 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 th...

Page 9: ...tered 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 overhea...

Page 10: ...n 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 MAI...

Page 11: ...and skill and established company standards Remove all excess lubrication from the crimping area of the tool Check dies for damage or excessive wear Inspect the crimping area for metal particles The p...

Page 12: ...damage the seal of the tool 3 The red LED flashes three times and simultaneously three audible alert warning signals occur see Figure 15 Serious fault If this fault occurs repeatedly contact the Tool...

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