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409-10104 

Rev B 

7 of 12 

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] 

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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