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Summary of Contents for TE Connectivity 1976330-1
- Page 1 Cordless Electric Power Tool Kit For tooling revisions C and above Part number 1976330-1 Customer Manual 409-10104 20 JUL 2023 Rev C Original instructions...
- Page 2 © Copyright 2023 TE Connectivity Ltd. family of companies. All rights reserved. TE Connectivity, TE Connectivity (logo), and TE (logo) are trademarks. Other logos and product or company names may be trademarks of their respective owners. PRODUCT INFORMATION +1 800 522 6752 This controlled document is subject to change.
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Page 3: Table Of Contents
409-10104 Contents Introduction ..............................5 Description ..............................6 Operation ................................ 8 Crimping ..............................8 Inspecting the crimp ..........................11 Finishing the splice ..........................13 Maintenance ..............................14 Charging the battery pack ........................14 Daily maintenance ..........................15 Periodic visual inspection ........................15 Lubrication ............................ - Page 4 409-10104 SAFETY PRECAUTIONS — AVOID INJURY — READ THIS FIRST! NOTE Keep all decals clean and legible. Replace them when DANGER necessary. Inspect the tool and jaws/dies before each use. Replace any worn or damaged parts. A damaged or DANGER improperly assembled tool can break and strike nearby ELECTRIC SHOCK HAZARD personnel.
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Page 5: Introduction
TE Application Tooling personnel. Contact TE Field Service for more information (refer to section 6). 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. Read this manual carefully before attempting to operate the tool for the first time. -
Page 6: Description
409-10104 2 Description Cordless Electric Power Tool Kit 1976330-1 is a portable, battery powered 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 remove and replace die sets. - Page 7 409-10104 feature of the tool produces high-quality, consistent crimps by ensuring that each splice is fully crimped before the dies reopen. When the control button is released, a brake stops the forward motion of the dies. An integrated pressure sensor measures the crimping force during every crimping operation. An automatic retraction feature returns the piston to its starting position when the maximum operating pressure is achieved.
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Page 8: Operation
409-10104 3 Operation 3.1 Crimping 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. Depending on the size and type of wires, the operator will use one of two splice sizes, along with the corresponding die set in the tool. - Page 9 409-10104 NOTE If more wires must be spliced than allowed by Table 2, use piggyback crimps as shown in Figure 2. Figure 2: Piggyback crimp Aluminum wire Copper wire To fixture To box 2. Ensure that each wire extends a minimum of 25.4 mm [1 in.] from any electrical box or wall surface (Figure 3).
- Page 10 409-10104 4. Place the correct splice on the stripped wire. 5. Identify the correct crimping chamber for this splice. The color code dot on the dies must match the color code stripe on the splice. 6. Insert the correct splice into the crimping chamber until the back of the splice butts against the urethane stop behind the crimping dies.
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Page 11: Inspecting The Crimp
409-10104 3.2 Inspecting the crimp 1. Check each splice for the features shown in Figure 5. Figure 5: Features of a good crimp (#8 splice shown) No wire insulation in crimped splice and no cross-overs 3.30 [0.13] minimum, 4.57 [0.18] typical Crimp is centered in splice Wire extends past end of splice No open crack at seam of splice... - Page 12 409-10104 5. Insert the splice into the gage. The splice should enter the gage easily. Figure 6: Inserting splice into secondary crimp gage Secondary crimp gage Color code dot Splice 6. If the splice does not meet the gage test, verify that the proper wire sizes and combinations listed in Table 2 were used.
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Page 13: Finishing The Splice
409-10104 3.3 Finishing the splice 1. Place a 38.1 mm [1 .50 in.] section of heat shrink tubing over the crimped splice. 2. Center the splice in the tubing (Figure 7), with approximately 12.7 mm [.50 in.] of tubing on each side of the splice. -
Page 14: Maintenance
Through TE test laboratories and the inspection of production assembly, the procedures in this manual have been established to ensure the quality and reliability of Cordless Electric Power Tool 1976330-1. 4.1 Charging the battery pack To remove the battery pack, push the release button on the battery pack. -
Page 15: Daily Maintenance
409-10104 4.2 Daily maintenance Make each operator aware of (and responsible for) the following daily maintenance requirements: Remove dust, moisture, and other contaminants with a clean, soft brush or soft, lint-free cloth. Do not use objects that could damage the tool. ... -
Page 16: Lubrication
409-10104 4.4 Lubrication Lubricate the tool at regular intervals (Table 4) to ensure minimum wear and dependable service. Use any good grade SAE™ 20 motor oil. Figure 11 indicates the proper lubrication areas. Table 4: Lubrication schedule How tool is used When to lubricate In daily production Daily... -
Page 17: Troubleshooting
409-10104 5 Troubleshooting If the red LED is flashing or an audible alert sounds, refer to Table 5 for problems, probable causes, and remedies. If the problem cannot be resolved by the action recommended in Table 5, contact TE Field Service (see section 6, Replacement and repair). -
Page 18: Replacement And Repair
409-10104 6 Replacement and repair Tool rental and training is available through your TE Field Service representative. For field service, go to the Service and Repair page on the TE website, or send an e-mail to Fieldservicesnortharmerica@te.com. Figure 12: Service and repair 7 Revision summary Since the last revision of this document, the following changes were made: ...
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