9
SplicingTechnique
Splicing Copper Wire Using Splice Sleeves. Special Tools:
•
EL-38125-10 Splice Sleeve Crimping Tool
•
J-38125-5A Ultra Torch Special Tool
•
J-38125-8 Splice Sleeve Crimping Tool
Note: The DuraSeal splice sleeves have the following 2 critical features:
•
A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
•
A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the
instructions below in order to splice copper wire using DuraSeal splice sleeves.
Splice Sleeve Color Crimp Tool Nest Color
W i r e G a u g e m m ² / ( A W G )
3 Crimp Nests 4 Crimp Nests
Salmon (Yellow-Pink)
19168446
Red (1) or Red/Green (1)
Red (2)
0.5–0.8/(18–20)
Blue
19168447
Blue (2)
Blue (3)
1.0–2.0/(14–16)
Yellow
19168448
Yellow (3)
Yellow (4)
3.0–5.0/(10–12)
Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands
are damaged. You must obtain a clean strip with all of the wire strands intact.
Opentheharnessbyremovinganytape:
•
Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in
order to avoid wire insulation damage.
•
Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.
Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness
branches, or connectors.
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