D-406-0002

Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices Product Facts n Protects splices from water, condensation, salt, and corrosion n Provides strain relief n Protects against vibration in rugged environments n Completely insulates and protects electrical connections n Has adhesive lining for protection that is more reliable than conventional splices n UL, CUL, and Lloyd’s listed R Applications n n n Automotive/truck wiring repair and maintenance. n Marine electronics. n Fleet maintenance. Automotive accessory installations. n OEM automotive/truck/RV wire harness fabrication. n Commercial wiring (pumps/pools/spas). Appliances. Specifications/Approvals Series D-406 — Agency UL and CUL listed 91J4, File E87681 Lloyd’s listed, File 65 247 HH 02-93 Raychem RB-107 — L Product Dimensions Butt Splices ØA min. Part No. Available in: Americas Europe Asia Pacific n n n D-406-0001 D-406-0002 D-406-0003 Butt Splice Dimensions A L Min. Nom. 3.68 [.145] 31.75 [1.25] 4.57 [.180] 31.75 [1.25] 6.35 [.250] 38.10 [1.50] Color Conductor Red Blue Yellow 22–18 16–14 12–10 Wire Dimensions Insulation Insulation O.D. (Max.) O.D. (Min.) 3.56 [.140] 1.40 [.055] 4.45 [.175] 2.03 [.080] 6.22 [.245] 2.79 [.110] 8-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices (Continued) Product Selection Process 1. Determine wire size. 2. Select part number. Product Characteristics (Typical) Wire Size AWG 22–18 16–14 12–10 Operating temperature Shrink ratio Physical properties Chemical properties Electrical properties mm2 Part No. Color 0.38–0.95 1.2–2.5 3–6 D-406-0001 D-406-0002 D-406-0003 Red Blue Yellow -55°C to 125°C [-67°F to 257°F] Approximately 2:1 Cut-through resistance: 31 kg [70 lb] Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb]; yellow: 27.2 kg [60 lb] Not flame-retardant No cracking after heat aging for 168 h at 160°C [320°F] Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water Dielectric strength: 2500 Vac Insulation resistance: 1000 megohms at 100 Vdc Installation Requirements Installation For proper installation of these devices, the correct crimp tool and a heating tool with a reflector attachment must be used. The Raychem AD-1522 crimp tool and HL1802E heating tool are recommended. 1. Select splice of appropriate size. Strip wire 7.5 mm (5/16 in). Insert into crimp barrel. You will find ordering information for these tools in Section 10. Refer to Raychem installation procedure RPIP 821-00 for detailed instructions. 2. Crimp using Raychem AD-1522 crimp tool for preinsulated crimps. 8 Electrical Interconnect Products 3. Heat crimped splice with heat gun until tubing recovers and adhesive flows. 8-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171