Splicing Using Insulated Moisture Proof Butt Connector

Splicing using insulated moisture proof butt connector

Table for insulated moisture proof butt connectors







Prepare the cables







- Select a suitable butt connector according to cable area.
- Cut the cables
- Strip cables to strip length as shown in table above.

Splicing cables of different areas







If the cable areas are so different that they will not fit in the same butt connector, do as follows:

- Select butt connector to fit the larger cable.
- Strip the smaller cable to double length and bend the stripped section double.

Splice with several cables (branch point)







Select a butt connector large enough to take the cables to be inserted on the same side.

If a single cable is to be inserted on one side of the butt connector it will more than likely have too small an area compared to the opening in the butt connector.

Strip the cable to double length and bend it double.

Locate the butt connector in the crimp tool







Use the crimp tool recommended Other tools.

Locate the butt connector in crimp tool jaws Use the correct insert that matches the area of the butt connector.

- Apply pressure to the tool grips until the insert in the jaws retains the without deforming it.
- Insert cables in both ends of the so that each stripped section of core is up against the center divider in the butt connector.

Crimping a butt connector

Before completing crimping:







- Check that the butt connector is correctly located in the crimp tool forming section.
- Check the cables are still in the correct position in the butt connector.

If the butt connector is not correctly located, abort the crimp operation.

On most crimp tools of this type there is a locking device that can be released to open the tool. See picture.

Complete the crimping operation:







- Press the tool grips together to close the jaws

Do not release pressure on the grips until the tool has fully completed the crimp operation. Not until then will complete crimping have occurred and the tool can be opened.

Inspect the crimped butt connector







If the butt connector has been correctly crimped both crimping points should be uniformly compressed.

All cables should be crimped in place towards the center of the butt connector and not displaced towards the ends.

Pull the cables to ensure that none are loose.

Shrink butt connector using heat gun







After crimping the butt connector it must be shrunk using a heat gun.

The butt connector has an internal layer of glue which is released when heated and flows out and around the cables. The glue and crimp together provide a mechanically robust and moisture proof splice.

- Use a heat gun with a high enough rating to shrink the crimped butt connector.

Inspect results of shrinking







Check the shrinking results. If ok the glue should have been forced out of the ends of the butt connector and around the splice.

Replacing a cable

If a cable must be replaced

If a cable is damaged it cannot be used again. The damage can be mechanical, electrical or the cable might be too short for crimping new cable terminals. The cable must be replaced or spliced.

Selecting a new cable

NOTE: A new cable must always be of the same type as the one it replaces: the same length, insulation, core area and preferably the same color.

Select a new cable that matches the old.

Cable length
Measure the original cable length.

Cable area
Measure diameter on the original cable with a vernier caliper. Always replace cables with a cable of the same diameter or a cable that is nearest in dimension to the original.

The cable area is stated on the wiring diagram (applies to 850 cars).

NOTE: It is always the cable core only that is used as the basis for cable area, not the area of the cable core and insulation together.

Color
Cable insulation color - if possible always use a cable of the same color when replacing cables.

The color code for the cable is stated on the wiring diagram (applies to 850 and 900 cars).

- Refer to color coding table Color coding table for color codes.

Install new cable
Use the same routing as the original cable and clamp the cable in appropriate cable clamp, tie etc.

If a new cable tie is used do not leave sharp edges when cutting.

Color coding table

Abbreviations used for cables and connectors/housings.

Color Abbreviated form

Black SB
Brown BN
Red R
Orange OR
Yellow Y
Green GN
Blue BL
Violet VO
Grey GR
White W
Pink P
Ivory I
Light blue LBL
Light brown LBN
Natural NL

Cable color coding with two colors
If the cable color code has two colors it appears in abbreviated form like this:

Example
Y/R (or Y-R) Is Yellow/Red.

The cable has a yellow insulation with a red stripe.