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Industrial Crimp Quality Handbook
Doc No: TM-640160065 Release Date: 00-00-02
UNCONTROLLED COPY
Page 14 of 27
Revision: C Revision Date: 12-23-09
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
Insulation Barrel Colors
The colors on the insulation barrel (red, blue, and
yellow) are used to indicate the wire range. The
colors repeat themselves and are an industry
standard color-coding. See the Chart below.
Color Code Wire Range (AWG)
Yellow 24-26
Red 18-22
Blue 14-16
Yellow 10-12
Red 8
Blue 6
Yellow 4
There are different kinds of barrels with different
shades of the same color, which are used for
different barrel styles. PVC and Nylon take the color
differently. In the 14-16 AWG range (blue) for
example, the PVC barrels will be dark blue. The
nylon barrels will be a lighter, translucent blue.
When using the lighter blue terminals, the secondary
sleeve will be crimped in addition to the wire barrel
crimp. The actual shade of color has nothing to do
with quality of the insulation.
5.4 Splices
Molex offers standard and special splices for nearly
every type of wiring need.

Butt Splices
On this connector, the
stripped wires are
inserted from each end
and they "butt" in the
center. Then a crimp at
each end secures the
connection.

Step Down Butt Splices
The Step Down Butt Splice is the perfect solution
when two wires need
to be inserted in one
end of a splice and a
single wire in the
other end.

Avikrimp

Butt Splice
With the extra metal sleeve and nylon insulation,
these splices should be used when heavy vibration
is anticipated and a
strong strain relief is
needed.

Nylon Closed–End Connector
Used in a wide variety of
situations to “pigtail” or tie
together two or more wires.

Funnel Entry Butt Splice
In the past, the crimping of machine terminated butt
splices has been difficult and nearly impossible if
attempted on a piece of robotic equipment. Now,
with our new Funnel Entry Butt Splice, the end that
will be crimped by the crimping press is funneled to
allow quick and easy
wire insertion.

Perma-Seal Splices™
The tough sleeve of Perma-Seal splices resist
abrasion and cutting. This protective helps to
maintain the insulation and sealing properties even
in hostile
environments, not
to mention
unbeatable strain
relief.