un03711A-00#RevJ-#A0#S1

REVISION HISTORY
REV CHG NO DESCRIPTION DATE APPROVED

E- JJ57 Released 27-Apr-03
F- Released 24-Jan-11 M. Altshuler
G- Released 08-Aug-11 M. Altshuler
H- Released 07-Dec-14 M. Altshuler
J- Released 16-Apr-23 R. Burger
ALL SHEETS ARE THE SAME REVISION
FCTN NAME SIGNATURE DATE
PREP M. Benuel cy03623 28-Sep-22 TITLE

Eng.Mgr S. Sas cy08087 29-Sep-22
QA Y. Levi e010515 04-Apr-23 HARNESS MFG,REQT
SIZE CAGE CODE DWG NO.
A 2288A 03711A-00
SCALE NONE
THIS DOCUMENT AND THE INFORMATION CONTAINED IN IT ARE PROPRIETARY AND CONFIDENTIAL TO ELBIT SYSTEMS LTD. NO PERSON OR ENTITY IS ALLOWED TO
COPY, REPRINT, REPRODUCE OR PUBLISH ANY PART OF THIS DOCUMENT, NOR DISCLOSE ITS CONTENTS TO OTHERS, NOR MAKE ANY USE OF IT, NOR ALLOW OR ASSIST
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Table of contents
1. SCOPE ................................................................................................................................................................. 3
1.1 Purpose .............................................................................................................................................................. 3
1.2 Application ........................................................................................................................................................ 3
1.3 Order of precedence .......................................................................................................................................... 3
2. APPLICABLE DOCUMENTS........................................................................................................................... 4
2.1 Military standards .............................................................................................................................................. 4
2.2 General standards .............................................................................................................................................. 4
2.3 Elbit standard .................................................................................................................................................... 4
3. REQUIREMENTS............................................................................................................................................... 5
3.1 Materials ............................................................................................................................................................ 5
3.2 Assembly and Fabrication requirements ........................................................................................................... 5
3.2.1 Harness layout........................................................................................................................................... 5
3.2.2 Tolerances ................................................................................................................................................. 8
3.2.3 Harness terminations .............................................................................................................................. 10
3.2.4 Terminating adapters .............................................................................................................................. 12
3.2.5 Harness jacketing .................................................................................................................................... 47
3.2.6 Heat shrinkable tubing ............................................................................................................................ 48
3.2.7 Braiding of synthetic fibers ..................................................................................................................... 48
3.2.8 Harness transitions ................................................................................................................................. 48
3.2.9 Adjustment of harness thickens to the boot entry size ............................................................................. 50
3.2.10 Airframe harnesses .................................................................................................................................. 51
3.2.11 Adhesive .................................................................................................................................................. 51
3.2.12 Crimp contacts ........................................................................................................................................ 52
3.2.13 Solder contacts/hooks .............................................................................................................................. 52
3.2.14 Solder Sleeve contacts ............................................................................................................................. 52
3.2.15 Sealing plugs ........................................................................................................................................... 53
3.2.16 Spare wires .............................................................................................................................................. 54
3.2.17 RF connectors and cables ....................................................................................................................... 54
3.2.18 Electronic Component in Cable .............................................................................................................. 55
3.2.19 Bend radius ............................................................................................................................................. 56
3.2.20 Securing connectors backshells ............................................................................................................... 56
3.3 Test procedures ............................................................................................................................................... 57
3.3.1 Crimp tensile strength. ............................................................................................................................ 57
3.3.2 Contact retention test. ............................................................................................................................. 58
3.3.3 Conductor Continuity & Resistance ........................................................................................................ 60
3.3.4 Overall shield continuity test ................................................................................................................... 61
3.3.5 Insulation Resistance............................................................................................................................... 63
3.3.6 Dielectric Withstanding Voltage (High potential withstand) .................................................................. 64
3.3.7 Shield - Connector Bonding Conductivity ............................................................................................... 65
3.3.8 First Article Inspection (FAI) .................................................................................................................. 65
3.4 Marking ........................................................................................................................................................... 66
3.4.1 Harness and Cable Marking ................................................................................................................... 66
3.4.2 Wire and Cable Marking (When wire marking is required) .................................................................... 66
3.4.3 Keyway marking ...................................................................................................................................... 67
3.4.4 Cable mode marking ............................................................................................................................... 68
3.5 Workmanship .................................................................................................................................................. 69
3.5.1 Wiring ...................................................................................................................................................... 69
3.5.2 Shielding .................................................................................................................................................. 69
3.5.3 Containment ............................................................................................................................................ 69
3.5.4 Insulation................................................................................................................................................. 69
3.5.5 Clearance ................................................................................................................................................ 69
3.5.6 Soldering ................................................................................................................................................. 69
4. WIRING LIST .................................................................................................................................................... 70
4.1 Wiring list tables ............................................................................................................................................. 70
4.1.1 Serial number .......................................................................................................................................... 70
4.1.2 Wire number / Signal Name .................................................................................................................... 70
4.1.3 Wire type and AWG ................................................................................................................................. 70
4.1.4 Wire length .............................................................................................................................................. 72
4.1.5 From/To................................................................................................................................................... 72
4.1.6 Component .............................................................................................................................................. 72
4.1.7 Contact .................................................................................................................................................... 72
4.1.8 Termination code..................................................................................................................................... 72
4.1.9 Shielded groups ....................................................................................................................................... 73
4.1.10 Wire Group .............................................................................................................................................. 73
4.1.11 Notes ........................................................................................................................................................ 73
5. QUALITY ASSURANCE INSTRUCTIONS .................................................................................................. 74
5.1 Responsibility for inspection ........................................................................................................................... 74
5.2 Quality conformance inspection ...................................................................................................................... 74
6. PACKAGING .................................................................................................................................................... 75
6.1 Packaging requirements .................................................................................................................................. 75
7. DEFINITIONS ................................................................................................................................................... 76
7.1 Wire ................................................................................................................................................................. 76
7.2 Cable ............................................................................................................................................................... 76
7.3 Coaxial cable ................................................................................................................................................... 76
7.4 Harness ............................................................................................................................................................ 76
7.5 Shield .............................................................................................................................................................. 77
7.6 Harness and Cable Jacketing ........................................................................................................................... 77
7.7 Special cables .................................................................................................................................................. 77
1. SCOPE
1.1 Purpose
This specification sets forth requirements for interconnecting electrical wiring
cable and harness assemblies that connect electrical/electronic and
electromechanical components.
Special requirements may exist that are not covered by or are not in
conformance with the requirements of this specification. Engineering
documentation shall contain the details for such requirements.
1.2 Application
The wiring requirements covered by this specification are applicable to wiring
harnesses and accessories for use in the interconnection of electrical and electronic
equipment in military vehicles
1.3 Order of precedence
In the event of conflicts between any of the documents referenced herein and the
contents of this specification, the contents of this specification should be considered
as the superseding requirements.
In the event of conflicts between the engineering drawing and the contents of this
specification, the requirement specification in the engineering documents should be
considered as the determining.
2. APPLICABLE DOCUMENTS
The following specifications and standards, from a part of this specification to the
extent specified herein. Unless otherwise specified, the issues of these documents
shall be the last issues.
2.1 Military standards

SAE AS50881 Wiring, Aerospace Vehicle
MIL-STD-130 Marking
MIL-STD-202 Test Methods for Electronic and Electrical Component
Parts.
MIL-STD-454 Standard General Requirement for Electronic Equipment
MIL-DTL-38999 General Specification For Connector
MIL-TDL-22520G Crimping Tools & Wire Terminations
Detail specification sheet for plug, end seal, electrical
MS27488M connector
2.2 General standards

A-A-59569 Braid, Wire, (Copper, Tin coated or Silver coated,
(QQ-B-575) Tubular or Flat)
IPC J-STD-001 Requirements for Soldered Electrical and Electronic
Assemblies.
IPC-WHMA-A-620A(L) Requirements and acceptance for cable and wire
harness assemblies.
2.3 Elbit standard
34786593P Braiding of Harnesses and cables

20398A-00 First Articles Inspection and testing procedure, cable
assembly
34272202P_E Instructions for Shrink Boots.
40391020P_E Wiring
3. REQUIREMENTS
3.1 Materials
Parts and materials used in the fabrication of electrical wiring cables
and harnesses shall be as specified in the drawings and suitable for
the purpose to satisfy the specified wiring harness requirements.
The parts and materials shall be free from defects that adversely
affect performance or serviceability of the final product.
3.2 Assembly and Fabrication requirements
The harnesses and cable assemblies shall be assembled according to

the applicable harness and cable assembly drawings and according
with this document.
3.2.1 Harness layout

3.2.1.1 Fabrication forming board
Fabrication of all wire harnesses or cable assemblies should be
performed by using one or more of the following methods:
 3D dimensional jig (were required).
 2D dimensional jig (Forming board).
 Mylar - which reproduces the scale size (1:1) and shape of the
harness when installed in the vehicle.
All electrical terminations should be located with position, tilt, and
index identical to the final vehicle installation. Connector shells with
inserts should be used to reproduce the mating interface and facilitate
testing. The vehicle itself may be used as the jig to fabricate the
prototype harness in place.
3.2.1.2 Twisting of wires and cables rule and method

Unless otherwise specified in the engineering drawing and/or by harness
board, twisting of wires is required on all cables and harnesses in purpose
to obtain flexibility.
Direction of twist should be performed based on harness throughout.
The preferred direction is the "left hand lay". In some cases it is
acceptable to twist some branches and/or breakouts in a different
direction.
Twisting shall begin as close to the termination as practical without
causing undue stress on the connector. All breakouts shall be twisted
at least one and a half turns over its length. Avoid over-stressing of
the wires during twisting and at breakouts. Branches less than 150
mm long may be left untwisted.
3.2.1.3 Wire lay
3.2.1.3.1 Twisted wire lay.
Unless otherwise specified on the drawing wiring harnesses or cable
assemblies consisting of more than one conductors which terminate in
connectors, and which are subject to flexing when mated and
demated, should be fabricated with a twisted wire lay.
NOTE:
WHEN BUNDLE OR CABLE IS TWISTED ADD 7% TO THE WIRE
OR CABLE LENGTH
3.2.1.3.2 Twisted wire lay pattern
The lay pattern arranges the conductors to obtain uniformity,

maximum flexibility, and minimum diameter. This is best accomplished
by placing the, larger conductor and twisted complexes in or near the
cable core with the smaller conductors in the outer layers. Where this
is found to be impractical due to variables involved, it may be
necessary to place large conductors in the outer periphery and in
other instances small conductors may be roped to obtain uniformity
and flexibility.
Cable lays may be contrahelical (each layer wound in the opposite
direction of the preceding layer) or unidirectional (one direction-pitch
varied), Direction of lay may be either right or left handed and is
defined as the direction of a conductor layer, either clockwise or
counterclockwise. Filler material may be in the form of extruded rod or
multiple filaments (See note 1/).
Tapes are applied as a spiral wrap over the completed cable core to
maintain conduct or placement during subsequent operations. Tape is
also used at a barrier between conductors and jacket.
1/: for Lockheed projects only.

Filler material shall not be used.
Twisting required on all harnesses, Bundles and breakouts less than
½” in diameter should contain approx. two (2) twists per foot (12
inches).
Bundles and breakouts greater than ½” in diameter should contain
approx. 1 twist per foot (12 inches). Left hand lay is preferred.
The following factors should be considered in assembly harnesses

and cables:
 Where harness bundle or cable consists of mixed conductor
sizes and element construction (shielded pairs, coax, etc.), it is
generally advantageous to place the larger elements in the
center or core of the bundle or cable. This allows the larger
conductors to carry a greater portion of the bundle or cable
tensile stress.
 Coaxes should not be placed in the center (core) of the bundle
or cable. This is not always possible but should be avoided.
 A single wire, with or without shield, should not be placed in the
center of the core if possible, as this wire is a straight line pin to
pin and cannot adjust its length when flexed.
 While fillers may be used in any layer in place of a conductor, it
is best economy to put fillers in the outer layer if possible.
 Twisted pairs tend to compact (nest) and, therefore, an
additional reduction in core diameter can be realized. The
reduction varies slightly but is normally 12 percent.
3.2.1.3.3 Cable lay length

“Cable lay length” (See note 1/) is the distance of advance, measured
axially, of one turn of any one component within the cabled group.
For good cable design, lay length should be 8 to16 times the OD of the
harness (refer to table –twisted wires).
The shorter the lay length, the stiffer the cable and, conversely, the
longer the lay length, the more flexible the cable becomes. Lay length
may be decreased to complete a layer which would normally require
filler.
(See note 2/).
See note 1/
8X to 16X
1/ "Lay Length": The distance, parallel to the axis of the cable, in which a
conductor makes one complete turn about that axis is known as the lay
length or pitch length.
2/: for Lockheed projects only.

Filler material shall not be used.
Twisted wires, Twist Min. / Max. per 1 Feet and Twisting for
Electro-Magnetic Compatibility (EMC) - Table.
2 Cond. 3 Cond. 4 Cond. 5 Cond. 6 Cond. 7 Cond. 8 Cond.

Wire
Max
Max
Max
Max
Max
Max
Max
Min
Min
Min
Min
Min
Min
Min
Gage
6 2 4 2 4 1 2 1 2 1 2 1 2 1 2
8 3 6 3 6 1.5 3 1.5 3 1.5 3 1.5 3 1 2
10 4 8 4 8 2 4 2 4 2 4 2 4 1.5 3
12 5 10 5 10 3 6 2.5 5 2 4 2 4 2 4
14 6 12 6 12 3 6 3 6 2.5 5 2.5 5 2.5 5
16 7 14 7 14 4 8 3.5 7 3 6 3 6 3 6
18 8 16 8 16 5 10 4 8 3.5 7 3.5 7 3 6
20 9 18 9 18 6 12 5 10 4 8 4 8 3.5 7
22 &
10 20 10 20 8 16 7 14 5 12 5 12 5 11
More
3.2.1.3.4 Parallel wire lay.

When specified on the drawing a wiring harness or cable assembly
shall be fabricated in a parallel wire lay.
3.2.2 Tolerances
3.2.2.1 Connector and adapter angular tolerances
The angle between the connector keyway and centerline of 45° or
90° adapters shall be as specified in the drawing.
The angular tolerance between the connector keyway and centerline
of 45° or 90° adapters shall be as specified in Table 1.
3.2.2.2 Connector and boot angular tolerances

Unless otherwise specified, angular tolerance between the connector
keyway and the centerline for 45º or 90°boot shall be + 5°
NOTE:
THE ANGLE IS MEASURED BY LOCKING ON THE FACE VIEW OF
THE CONNECTOR
Table 1 - Angular Tolerance
Connector Shell size Angular tolerance in degree
08 + 15
09 + 15
10 + 10
11 + 10
12 + 10
13 + 10
14 + 7.5
15 + 7.5
16 + 7.5
17 + 7.5
18 +5
19 + 5
20 +5
21 +5
22 +5
23 +5
24 +5
25 +5
28 +5
32 +5
36 +5
40 +5
3.2.2.3 Dimensional tolerance
The dimensional tolerances of length dimensions shall be as follows:
Length (mm)/[in.] Tolerances (mm))/[in.]
0 to 299 [0 to 11.8] +12.7 [+0.5]

- 0 [-0]
300 to 2999 [11.8 to 118] +25 [+1.0]
- 0 [-0]
3000 to 4999 [118 to 196.8] +50 [+2.0]
- 0 [-0]
5000 to 9999 [196.8 to 394] +100 [+4.0]
- 0 [-0]
10000 to 14999 [394 to 590.5] +150 [+6.0]
- 0 [-0]
15000 to 19999 [590.5 to 787.4] +200 [+8.0]
- 0 [-0]
20000 and up [787.4 and up] + 1%
-0
3.2.3 Harness terminations
Harness and shields termination to the backshell shall be as shown in
the following illustrations:
3.2.3.1 Inter Shield - Straight to the backshell
3.2.3.2 Internal Shield & Single Overall Layer - Shield terminations to a soldering point
(360°)
3.2.3.3 Straight to the backshell
3.2.3.4 Internal Shield & Double Overall Layer
NOTE:
ALL SOLDER POINTS CAN BE AT THE SAME LOCATION
3.2.4 Terminating adapters
3.2.4.1 EMI adapter
When the harness include shielded wire(s) and/or overall shield(s),
EMI backshell shall be used to adapt between the shielded wire(s)
and/or overall shield(s) and the metal body of the connector.
The backshell shall be tightened to the connector as specified in Table

2 for metals and composite adapters with standard tools.
The EMI backshell coating shall be conductive and compatible to the

connector coating.
When the cable is bending near the connector, EMI backshell of 90°
or 45° is recommended to be used.
Angular boot for shielded wire shall be used when specified in drawing
and its parts list
A suitable heat shrinkable boot shall be installed on the EMI adapter

(if required).
There are several types of EMI adapters:

 Nut-ring connection adapter
 Braided adapter
 External lock adapter (Tinel, Band-It)
 Ring connection adapter
 Shield termination ring adapter (Hexashield, Tag
Ring)
3.2.4.1.1 Nut-ring connection adapter
Those adapters connect the overall shield of the cable directly to the
adapter by nut-ring method. The individual (inner) shields and/or the
overall shield are hold between the nut-ring and the backshell body.
In this series there are options to connect only the overall shield
between the ring and the backshell body or combination of overall
shield and individual shield.
In this series the cable secure to the backshell by shrink boot or strain
relief.
 Advantages
Short adapter, suited for cases with space limitations.
 Disadvantages
Connection of shields is not well secured. During working on the site
(to fix pin connection or other work that requires opening of the
adapter) some individual (inner) shields might not be able to be
terminated again.
3.2.4.1.2 Braided adapter
Those adapters have a shield sock attached to the rear of the adapter
body. The method of shield attachment is usually by means of
crimping, soldering or magnaforming. This shield sock is then
attached to the overall shield on the harness.
In this series the cable secure to the backshell by shrink boot.
 Advantages
A short adapter with very good termination of the shield.
 Disadvantages
Does not enable straight connection of individual shields to the
adapter. Harness with individual shields should use additional
methods, as defined here, to terminate the individual shields to the
shield sock.
3.2.4.1.3 External lock adapter (Tinel, Band-It)
Those adapters connect the individual (inner) shields and/or the

overall shield of the cable directly to the adapter by Tinel-lock or Band-
it method. The shields are held between the external lock and the
backshell body.
In this series there are options to connect only the overall shield
between the ring and the backshell body or combination of overall
shield and individual shield.
relief.
 Advantages
A short adapter with very good termination for the shield,
recommended for use as EMI backshell.
 Disadvantage s(for tinel lock method only)

Tinel Lock is a difficult connection to replace and is difficult to use on
cables with individual shields and overall shields.
3.2.4.1.4 Ring connection adapter
Those adapters connect the individual (inner) shields and/or the

overall shield of the cable directly to the adapter by conical ring(s)
method. In this series there are options to connect only the overall
shield between the ring and the backshell body or combination of
overall shield and individual shield. In this series the cable is secure to
the backshell by strain relief.
 Advantages
Short adapter where there is a limitation of space.
 Disadvantages
The connections of shields are not well secured. During working on
the site (to fix pin connection or other work that requires opening of
the adapter) some individual (inner) shields might not be able to be
terminated again.
3.2.4.1.5 Shield termination ring adapter (Hexashield, Tag Ring)
Those adapters connect the shielded wires in to a ring method of

entering a new device that connects all the individual shields to the
adapter and the overall shied are connected to the adapter in the
same method as External lock adapter.
relief.
 Advantages
Adapter with excelent termination of the shield recommended for high
frequrncy digital signals (LVDS, SMPTE, 1Gb ethernet, USB2 ect.)
 Disadvantages
Very expensive.
Long adapter.
Table 2 - Metal’s backshell
Shell size Group 1 Group 2

Inches Pound Inches Pound
Medium and Light duty Heavy duty
Min. Max. Min. Max.
A, 8, 9 35 45 65 80
B, 3, 10, 10SL, 11 35 45 90 100
C, 7, 12, 12S, 13 35 45 130 140
D, 14, 14S, 15 35 45 140 150
E, 16, 16S, 17 35 45 140 150
F, 18, 19, 27 35 45 140 150
G, 20, 21, 37 75 85 165 175
H, 22, 23 75 85 165 175
J, 24, 25 ,61 75 85 165 175
28, 29 115 125 180 190
32, 33 115 125 180 190
36 115 125 180 190
40 165 175 200 210
44 165 175 200 210
48 165 175 200 210
Notes:
1. Group 1 values based on 80% of MIL –C-85049 Light duty thread
strength.
2. Use Group 1 values for all composite connector accessories.
3. Group 1 values based on of MIL –C-85049 Heavy duty thread strength.
Group 1 Group 2
Medium and Light duty Heavy duty connector family
connector family
MIL-C-5015, MS31XX Series MIL-C-5015, MS34XX Series
MIL-C-26482, Series I MIL-C-22992
MIL-C-26500 MIL-C-28840
MIL-C-26599 MIL-C-38999, Series III & IV
MIL-C-38999, Series I & II MIL-C-81703, Series III
MIL-C-81511, Series I, II, III, IV MIL-C-83723, Series I, II, III
MIL-C-81703, Series I MIL-C-24682, Series II
Table 3 – Torque values for cable clamp screws.
Screw size Recommended

Max Torque
(Inch-pound)
2-56 2.5
4-40 5.2
6-32 10.0
8-32 20.0
10-32 24.0
0.250-20 40.0
Note: Torque Requirements in Inch-pounds for Corrosion-Resistant

screws only.
3.2.4.2 Non EMI adapter

The backshell shall be tightened to the connector as specified in Table
2 for metal's adapter and Table 3 for composite adapter with standard
tools.
There are several types of non EMI adapters:

 Shrink boot adapter
 Strain relief adapter
 Quick tie adapter
3.2.4.2.1 Shrink boot adapter

Those adapters connect the shrink boot to the adapter with a groove
that accommodates the heat shrinkable boot lips.
Shrink boot adapter shall be terminated to the harness as shown in
the following drawing.
3.2.4.2.2 Strain relief adapter
Those adapters are holding the wires between two clamps. A rubber
bushing or self adhesive tape shall be inserted between the wires and
the clamp to prevent pinching of the wires.
Strain relief adapter shall be terminated to the harness as shown in
the following drawing.
POSITION OF TAPE IN THE CABLE CLAMP

CABLE CLAMPS BACKSHELL CORRECT DERICTION ASSEMBLY
3.2.4.2.3 Quick tie adapter
Those adapters are holding the wires with plastic tie strap or lacing
tape. A rubber bushing or self adhesive tape shall be inserted
between the wires and the plastic tie strap or lacing tape to prevent
pinching of the wires.
Quick tie adapter shall be terminated to the harness as shown in the
following drawing.
3.2.4.3 Heat shrinkable boot
The heat shrinkable boot shall be uniformly shrunk to minimum

diameters, determined by the bundle's size, with no evidence of
cracks, splits, abrasions or excessive adhesive. All joints shall be
sealed watertight using adhesive specified on the applicable harness
or cable drawing. Excessive adhesive on the outside of the harness
jacketing shall be removed. Maximum heating temperature for boot
heating near composite material backshell shall be up to 180° C.
3.2.4.4 Overall shield
Unless otherwise specified in the drawing, when an EMI shield is

specified in the drawing, it shall meet the requirements of A-A-59569
or QQ-B-575 (or equivalent). The shield shall provide at 90 percent
(%) optical coverage and shall be covered with flexible convoluted
jacketing.
Each branch of the assembly shall contain one continuous piece of
shield.
Unless otherwise specified in the drawing, when two layers of overall

shield are used, a Mylar wrap or heat shrinkable tube shall be used to
insulate between the two layers along the entire length of the harness,
except at end points.
At each point where a piece of shielding ends, the shield shall be
trimmed and sealed to eliminate frayed ends.
A Teflon wrap or glass cloth tape shall be used under the shield
termination to avoid damage to the harness.
Where there is a connection between two parts of overall shields
along the Shielded harness, the connection shall be soldered or
weaved 360° around the harness branch as required by the drawing.
METHOD 1–SPLICING METAL BRAIDED SLEEVES BY SOLDERING
METHOD 2–SPLICING METAL BRAIDED SLEEVES BY BRAIDING MACHINE (/3)
/3 Preferable method for Land system projects
3.2.4.5 Ground termination of shielded group
A shielded group is a group of wires with overall shield within harness

branch with or without overall shield of the branch.
If the group contains shielded wire/wires, those wires shall be
connected to the group overall shield in according to paragraph
3.2.4.6
A flat braid (pig tail) with ratio of 1:10 width to length shall be used to
connect the shielded group to the overall shield or backshell and shall
be less than 50 mm for cable that requires working on the site and
less than 25 mm for non repairable cable on site.
The length of the flat braid (pig tail) from the internal shield to the
overall shield or backshell shall be less than 50 mm.
Unterminated shield ends shall be covered with heat shrinkable tubing
and shall extend no more than 10 mm on each side of the shield end.
Each shield shall be trimmed and sealed to eliminate any frayed ends
prior to installing sleeves.
3.2.4.6 Ground termination of shielded individual wire/s
The individual shield termination shall be used to connect wire shield

to the ground point (overall shield, bending ring or backshell).
Mfg. Part E-Max F-Min G-Min

Mil Part Number
Number Inch/mm Inch/mm Inch/mm
M83519/1-1 S0101R 0.105/2.67 0.035/0.89 0.020/0.51
M83519/1-2 S0R02R 0.145/3.68 0.055/1.34 0.030/0.76
M83519/1-3 S0103R 0.200/5.08 0.085/2.16 0.050/1.27
M83519/1-4 S0104R 0.255/6.48 0.130/3.30 0.070/1.78
M83519/1-5 S0105R 0.300/7.62 0.170/4.32 0.100/2.54
There are three methods to connect the individual shielded cable to

the overall shield or backshell.
 Method 1: Shield "pig-tail" at the ends of the cable closest to the EMI
backshell, (Preferred method)
 Method 2: Window method with solder sleeve near the shield grounding /
terminating point.
 Method 3: Heat shrinkable solder sleeves at the end of the cable with flat
braid that shall be a similar size to the wire shield and shall be as closest
to the EMI backshell (Less preferred method)
One of the three methods or a combination of them can be used in

branch ends.
NOTE:
WHEN SHIELD PIG-TAIL OR SOLDER SLEEVE IS USED AT THE
END OF THE SHIELDED CABLE, THE WIRES IN SHIELDED
TWISTED CABLE SHALL BE TWISTED BETWEEN THE SHIELD
TERMINATION AND THE CONNECTOR GROMMET
3.2.4.7 Solder sleeve at the ends of the cable
PIG TAIL
The length of the flat braid to the overall shield or backshell shall be
less than 50 mm for cable that requires working on the site and less
than 25 mm for non repairable cable.
The flat braid (pig tail) can be assembled from both ends of the solder
sleeve either to the front (connector side) or to the rear (shield side),
the big end of the solder sleeve shall be where the flat braid or the
wire exists from.
The solder sleeves shall be staggered so that the diameter of the wire
bundle will remain equally.
NOTES:
SHIELDED WIRE TERMINATION SHALL BE AS CLOSE AS
POSSIBLE TO THE CONNECTOR GROMMET
3.2.4.8 Solder sleeve at the mid of the cable (window)
PIG TAIL
The length of the flat braid to the overall shield or backshell shall be
less than 50mm for cable that requires working on the site and less
than 25 mm for non repairable cable on site.
The flat braid can exist from both ends of the solder sleeve either to
the front (connector side) or to the rear (shield side). The big end of
the solder sleeve shall be where the flat braid or the wire exists from.
The shield length from the "window" opening to the rear connector
grommet shall be no more than 25 mm.
The solder sleeves shall be staggered so that the diameter of the wire
3.2.4.9 Shield tail at the end of the cable
SHRINK TUBE (IF REQUIRED)
The length of the shield tail to the overall shield or backshell shall be
less than 50 mm for cable that requires working on the site and less
than 25 mm for non repairable cable.
The shield tail shall be staggered so that the diameter of the wire
NOTES:
SHIELDED WIRE TERMINATION SHALL BE AS CLOSE AS
POSSIBLE TO THE CONNECTOR GROMMET
3.2.4.10 Shield termination for MUX-BUS, LVDS & ETHERNET cables
NOTE:
USE METHOD 2 TO FOR M/B, LVDS & ETHERNET CABLES (see paragraph
3.6.3.2)
Shield tail preparation
Prepare 0.5 cm of shield tail shield.
Plate one end of it with 1 cm of tin and the other end with 0.5 cm of tin
0.5 cm
Window preparation
Open a "window" of approx. 5 mm in the cable jacket. Unless otherwise specified in

the drawing, the opening shall be 200 mm from the cable end.
Cable end
0.5cm
20 cm
Shield tail connection to the window:

0.5 cm tin plated shield tail
Solder sleeve
Cables Layout and Cables Ferrule End Termination- Method 1
 Form the cables into two groups as shown in the photo.

 Measure the distance between the solder sleeve and the cable shield end to
verify that the inner cable shields end will be inside the backshell.
 Use shrinkable RNF sleeve (10mm) to cover the inner shield end.
 Twist the wires as close as possible near to rear backshell.
1.5 cm
3.5 cm max
Depends on the
backshell length
Connect the cables end to the connector:

Connect the backshell to the connector:
 Wrap Teflon tape over the solder sleeves area.
Teflon wrap
Shield tails
Backshell
2.5 cm
max
 Slide braided shield sleeve over the wire bundle as shown. Tie temporary using
lacing tape on all "pig-tails" (using the boot’s tip groove) around the back-shell.
Clasp the band to the backshell over the shields.
Cut all the extra shields and all the sharp edges.
Cables shield "Pig-tail" End Termination- Method 2

FORM A SHIELD “PIG-TAIL” PROCEDURE
EXPOSE ALL SHIELDED WIRES "PIG-TAILS" AND CONDUCTORS
ASSEMBLE STRAIN RELIEF

TRIM EACH SHIELD "PIG-TAILS" 25 mm LENGTH
AND BEND THEM OVER THE BACKSHELL GROOVE
ASSEMBLE OVER ALL METAL BRAIDED SLEEVE

PULL THE METAL BRAIDED SLEEVE OVER THE BACKSHELL
SQUEEZE "BAND-IT" BAND ON REAR BACKSHELL

TRIM EXCESS BRAIDED SHIELD
SPLICING ALL JUNCTIONS SHIELD BRAIDED SLEEVES BY BRAIDING MACHINE

Soldering “Pig-tail” to overall braided sleeve.-METHOD 3
Raw material
Jacket removed
Pig tails shield preparations
Cable assy. - twisted

Fold after pig tails shield
Fold forward pig tails shield

Covering the cable assy. with glass-cloth tape
Overall metal braiding

Overall braiding pig tail shield
Soldering pig tails around overall braiding
Soldering shiels sleeve around overall braiding

Installing expand sleeve
Shrinking RNF tube
Cable assy. After nomex braiding

“Split Ring" method for EMI backshell
 This method is applicable for all backshell types (straight, 45 and 90).
 The "Split ring" location depends on wire branch length.
 The maximum distance of "Split ring" location shell be up to ~600mm (or 24")
from connector backshell end.
o Expose the wires conductors and “Pig-tail” length according to definitions

length in table.
Signal types [A] [B]

“Pig tail” Conductors max.
Shield max. exposed length
length [mm] [mm]
1 LVDS, ETHERNET 40 40
2 RS422 /RS429 /RS 60 50-60
323 and other
shielded wires
3.2.4.11 Wire & Cable splices
Splices shall be used to connect between wires for termination.

Splices shall be placed in splice area or near connectors (see note /1).
The maximum distance between the splice and the connector
grommet are according to the following table:
Type Maximum Distance

Straight backshell 75 mm
45° or 90° backshell 100 mm
Wire positioner 50 mm
The splices shall be staggered so that the diameter of the wire bundle
will remain equally.
/1 For Lockheed projects only

Splices to be located in the area of expandable sleeves only.
3.2.4.12 Crimp splices
Crimp splices shall be used to connect between wires for termination.
NOTES:
CRIMP SPLICES MUST BE SEALED WITH SEALING SLEEVE.
Butt splice prior to wire insertion
Butt splice prior to crimp properly crimped Butt splice

Butt splice with shrink sleeving
End type splice Parallel type splice
3.2.4.13 Wire wrap splices (PHILIPS METHOD)
Wire wrap splices can be used to terminate wires bigger than 20

AWG. The wire wrap splice shall have 26 AWG solid wire wrap around
the wires for a minimum of 7 rounds, tin soldered and covered with
adhesive shrinkable tube.
0.5 cm 0.5 cm
0.5 cm
TIN SOLDERING
ADHESIVE SHRINKABLE TUBE
1.5 cm
3.2.4.14 Shielded wire splices
 Preferred solution for shielded wire splices use crimp splice for
the wires, and solder shield splice for the shield.
 Another solution for shielded wire spices is a cable-to-cable

splicing kit that used to repair or splice shielded cables.
3.2.4.15 Coax & Triax cable splices
NOTE:
DO NOT USE ANY SPLICE FOR COAX OR OTHER CONTROL

IMPEDANCE CABLE LIKE TRIAX AND HIGH FREQUENCY SIGNAL
CABLES.
3.2.4.16 Mux-Bus cable splices

For MuxBus cable splices use heats shrinkable solder sleeve or crimp
splice for the wires, solder shield splice for the shield and heat
shrinkable tube for sealing sleeve. (see note /1).

Splices for MUX-BUS wires shall not be used.
3.2.4.17 Terminal Lug
The table below specifies the maximum number of wires in one (1)
terminal lug.
Wire gauge QTY PER LUG BY WIRE BARREL AWG

# 6 8 10 12 14 16 18 20 22
26 3 3 3 2
24 3 3 3 2 1 1
22 3 3 2 1 1
20 3 3 3 2 1 1
18 3 3 3 2 1 1 1
16 3 3 2 1 1 1
12 3 2 1 1
NOTES:
MAXIMUM FOUR (4) WIRES MAY BE TERMINATED IN ANY ONE
TERMINAL LUG
3.2.5 Harness jacketing

If harness jacketing is required, branches shall be covered with the
jacket specified on the harness drawing. Each individual harness
branch shall be completely covered with one option only. Jacketing
shall extend into the boot or transition as specified in figure 1 to figure
5, depending on the application.
3.2.6 Heat shrinkable tubing
The heat shrinkable tubing shall be uniformly shrunk to minimum

diameters, determined by the bundle’s size, with no evidence of
cracks, splits, or abrasions. Multiple section of tubing may be used on
long harness branches, provided each individual length, no less than
1000 mm long and an overlap of no less than 50 mm is maintained.
All joints including overlap shall be sealed watertight using adhesive
specified on the applicable harness or cable drawing. Excessive
adhesive on the outside of the harness jacketing shall be removed.
3.2.7 Braiding of synthetic fibers
Where applicable,
The cover shall be fabricated (weave) by braiding machine (in
accordance with Elbit spec. 34786593P) of synthetic fibers according
the drawing.
The braiding cover distance from the connector grommet shall be no
less than 150 mm. The harness in this section shall be cover with
expandable braiding sleeve.
The expendable braiding sleeve shall be terminated to the braiding
cover with lacing tape and over it the identification label of the
connector.
3.2.8 Harness transitions

3.2.8.1 Shielded harness transitions
When overall shielded branches meet in a transition the overall shield
shall be connected together according to 3 methods:
(Unless a specified method is defined in the drawing, any of the

following methods are permitted)
Method 1 – Use the overall shield of one of the branches to cover the
transition point.
Method 2 – Use a flat shield to cover the transition point.
Method 3 – Use a braiding machine to weave the braid and

cover the transition point. There shall be at least 25mm of
overlapping in between the woven braid and the braid
sleeve of each branch. See IPC-WHMA-A-620A(L)
(16.1.1)
Braids Meeting
point
25mm 25 mm
3.2.8.2 Heat shrinkable transitions
The heat shrinkable harness transitions shall be positioned only after

the harness jacketing has been installed over the branches.
The transitions shall be uniformly shrunk to minimum diameters,
determined by the bundle's size, with no evidence of cracks, splits, or
abrasions. All joints shall be sealed watertight using adhesive
specified on the applicable harness or cable drawing. All transitions
shall be free of cracks, splits or abrasions. Excessive adhesive on the
outside of the harness jacketing shall be removed.
3.2.9 Adjustment of harness thickens to the boot entry size
When the boot or harness transitions minimum dimension (after

shrunk - by calculation) is bigger than the harness or cable dimension,
a suitable material (per drawing) shall be placed under the heat
shrinkable tube of the harness near the boot or harness transitions
and shall be bonded to the mating parts with adhesive. The maximum
length of the shrink tube shall be approx. 50 mm.
Multiple tubing may be used to increase the cable diameter. Each
individual overlaps length shall be approx. 50 mm.
3.2.10 Airframe harnesses
Airframe harnesses (without overall jacketing) shall be twisted and tied

with Polyester lacing tape( MIL-T-43435), or Cable ties(MS3667-X) in
intervals of no more than 300 mm(12 in) ,(see note /1).

Airframe harnesses (without jacket) shall not be used.
Acceptable
Unacceptable
3.2.11 Adhesive
The adhesive application processes shall conform to the adhesive

manufacturer specification.
Excessive adhesive on the outside of the harness jacketing shall be
removed
3.2.12 Crimp contacts
3.2.12.1 Connector crimp contacts
Unless otherwise specified in the drawing,
When a connector with crimp contacts is used, all contact positions
shall be filled with new contacts and contact sealing (in according with
3.2.15) (see note /1).
NOTE:
ONLY ONE WIRE WILL BE PLACED IN CRIMP CONTACT.

Spare contacts and sealing plugs will be used only in size 20 contact
cavities. All other contact cavities are to be filled w/sealing plug only.
3.2.13 Solder contacts/hooks
When solder contacts/hooks are used no sign of excess heat

(discoloration or scorching) of the insert face surface will appear. The
visible side of the contact /hook shall be covered with heat shrinkable
tube.
NOTES:
ONLY ONE WIRE WILL BE PLACED IN A CONNECTOR SOLDER
CUP AND UP TO THREE WIRES WILL BE PLACED IN SOLDER
HOOK.
3.2.14 Solder Sleeve contacts
Solder sleeve contacts are used for coaxial, triaxial, shielded wires
and twisted pairs. When triaxial or twisted shielded cables are
connected to the solder sleeve contact, the outer shield shall be
connected to the connector backshell or to ground contact.
3.2.15 Sealing plugs
Sealing plugs shall be inserted in the grommet holes of unused

contacts after inserting other contact into the unused contact position.
When installing sealing plugs in connector or module grommets, the head
of the sealing plug shall be inserted first. The sealing plug shall than be
pushed into the grommet until the head is positioned against the end of the
unwired contact or empty grommet cavity (In accordance with MS27488M).
SEALING PLUG CONTACT

POSITION
3.2.16 Spare wires
Unless otherwise specified in the electrical cable drawing,
The harness and cable branches shall not contain spare wires. Spare
wire shall be assembled in Harness/Cable by engineering drawing
definitions. Spare wires shall be ended with end caps or insulation.
(See note /1).

Spare wires shall not be used.
3.2.17 RF connectors and cables

RF connectors shall be used to connect Coaxial RF cables. Add a self
adhesive shrink tube of approx. 40 mm length on the connector rear
end accordance to the following figure. Refer to IPC-WHMA-A-620A
(L) paragraph 13
3.2.18 Electronic Component in Cable
In case that an electronic component shall be implemented in a cable,

follow the set forth comment.
NOTE:
USE SHORT WIRE TO CONNECT THE ELECTRONIC
COMPONENT TO THE CONNECTOR.
 The component shall be located near the connectors and under

the backshell.
 The component shall be soldered to the wire using solder iron.
 A service loop of the wire shall be left on both side of the
component.
 A shrinkable tube shall be covered the component and the
solder points.
 The component lug shall be band backward (both lugs near the
connector).
3.2.19 Bend radius
The bend radius data shall be applied for bending that occurs in the
interconnecting harness or cable.
Wire type Optimum Bend Minimum Bend

Radius Radius
Individual coaxial cable 10 X OD (*) 6 X OD

Overall harness (with 10 X OD 6 X OD
coaxial cable or AWG
size 8 or larger).
Overall harness (with 10 X OD 3 X OD

AWG size 10 or smaller
without coax cable).
(*) Outside Diameter
3.2.20 Securing connectors backshells

3.2.20.1 Connector backshells, assembly nuts and cable clamps adapters shall be
secured from undesired relief.
3.2.20.2 Clean thread surface with cleaning solvent and wipe dry with absorbent
wiper.
3.2.20.3 Apply two (2) drops of thread locking compound Vibratite or loctite a minimum
of two (2) threads approximately 180 apart to the external threads of all parts (except
connector coupling nuts).
3.2.20.4 Assemble the components immediately after application of the locking

compound.
3.2.20.5 Ensure that no thread locking compound contacts the edge of the serrations
(teeth).
3.2.20.6 To proper engagement, wiggle the backshell back and forth by hand until the
teeth are fully seated securely.
3.2.20.7 Tighten the backshell by hand force and then tighten finally, applying a torque
wrench to the recommended torque required according to table No.-2.
3.2.20.8 Tighten the backshell clamping bars screws according to figures in

para.3.2.4.2.2; tighten finally applying recommended torque according to table No.-3.
3.3 Test procedures
3.3.1 Crimp tensile strength.

The crimp type connector contacts shall be crimped and tested
according to MIL-DTL-22520G section 4.7 (also see 40391020P_E
section 3.6.1, 3.6.2).
A sample shall consist of an identified contact and a 50 mm (2")
minimum conductor crimped together. An axial force shall be exerted
at a speed of 25.4+ 6.4 mm per minute (1" + 1/4 " per minute)
separating contact and conductor.
The crimp tensile strength shall be as specified in the following table:
Minimum tensile strength (lb.)

Wire Size (AWG) Silver Or Tin-Plated Nickel-Plated
Copper Wires Copper Wires
26 5 3
24 8 6
22 12 8
20 20 19
16 50 37
14 70 60
12 110 100
10 150 135
8 220 200
6 300 270
4 400 360
2 550 495
1 650 585
0 700 630
00 750 675
0000 875 785
3.3.2 Contact retention test.
The test shall be performed in accordance with Elbit document
40391020P_E (Para.5.3.2)
Each rear insatiable removable crimp contact (pin or socket) of the
harness connectors should be subjected to a retention push test,
following insertion of the contact in the connector insert. The force
should be applied at the mating face of the connector to check the
retention of the contact in the insert by the retention mechanism.
The test shall be performed on100 percent of the contacts.
The contact retention testing can be handled by two testers as follows:
 "HT250" series tester- adjustable tool.
 "HT210" series tester- fixed tool.
HT250- ADJUSTABLE RETENTION TOOL HT210- FIX RETENTION TOOL

Inspect the position of the contacts in a connector.
Hold the connector stationary and mate with tester tip each contact individually.
CONTACT RETENTION TESTING RETENTION TEST TOOL FOR CONNECTOR SERIES
 Use pin end with socket and socket end with pin. Mach the tip size to the
contact size correctly.
 Apply a pushing force in-line with the contact.
 Observe, when the indicator band reaches the body of the tools, the test force
has been obtained.
 If contact is still firmly retained, the retention is satisfactory.
 If any have moved out of the correct position, this indicates a failure, and
rework is necessary.
HT250- HANDLES AND REPLACEMENT TIPS
HT210- FIXED RETENTION TEST TOOL AND ACCESSORIES

3.3.3 Conductor Continuity & Resistance
Each circuit of each assembly shall be tested for continuity and correct
connections between its terminations in accordance with applicable
wiring diagrams or wiring lists.
Using a potential of no more than 10 volts DC and a current not
exceed 2 Amperes.
NOTE:
THE RESISTANCE MEASUREMENT IS FOR THE ENTIRE LENGTH
OF THE WIRE
When testing automatically with calibration ability the measured

resistance of each circuit shall not exceed the limits in the following
table:
Wire Size Resistance in ohms at 20°C

AWG. L< 1 m 1m< L< 2 m 2m< L< 5 m L> 5 m
Coax&Traix 2Ω 2+ {1.217 x (L-1)}
36# 2Ω 2+ {1.217 x (L-1)}
34# 1 .5Ω 1.5+ {0.777 x (L-1)}
32# 1Ω 1+ {0.538 x (L-1)}
30# 1Ω 1Ω 1+ {0.338 x (L-2)}
28# 1Ω 1Ω 1+ {0.213 x (L-2)}
26# 1Ω 1Ω 1Ω 1+ {0.136 x (L-5)}
24# 1Ω 1Ω 1Ω 1+ {0.076 x (L-5)}
22# 1Ω 1Ω 1Ω 1+ {0.048 x (L-5)}
20# 1Ω 1Ω 1Ω 1+ {0.033 x (L-5)}
18# 1Ω 1Ω 1Ω 1+ {0.019 x (L-5)}
16# and Up 1Ω 1Ω 1Ω 1+ {0.012 x (L-5)}
3.3.4 Overall shield continuity test
IMPORTANT
BEFORE PERFORMING THE EMI SHIELD CONTINUITY TEST
REFER TO PARAGRAPH 3.3.7.
When EMI backshell are terminated at the connector backshells, the

resistance between any two connectors’ backshells of the assembly
shall not exceed 2.5 milliohm between the overall shield [1] and the
connector body [2]. The measurement shall be performed at a
distance of 1 inch [25.4mm] from the rear end of the connector.
The resistance between any two connectors on the harness shall be

according to the following table. In case of two types of overall shield
between the connectors under test the resistance shall be according
to the smallest diameter overall shield.
Whenever there are different diameters of overall shield along the
measuring branch the resistance shall be in accordance to the
smallest diameter.
Military part number Description Approx. Resistance of Max. overall resistance in
(diameter at AWG braid** mΩ (L=length in m)/1
inch) equiv. mΩ / 1m
Tin Silver Tin Coated Silver Coated
Coated Coated
A-A-59569R36T*0031 Braid tube 1/32 22 51 49 L*51 L*49
A-A-59569R36T*0062 Braid tube 1/16 19 25.5 25 L*25.5 L*25
A-A-59569R36T*0125 Braid tube 1/8 15 12.5 12.5 L*12.5 L*12.5
A-A-59569R30T*1000 Braid tube 1.0 4 0.9 0.9 L*0.9 L*0.9
* T=Tin-copper S= Silver-copper
** according to CID A-A59569C (latest REV.)
/1 Tolerance is + 10% unless otherwise specified.

3.3.5 Insulation Resistance
WARNING
DO NOT PERFORM THIS TEST ON CABLES WITH ELECTRONIC
COMPONENTS INSIDE.
Unless otherwise specified on the harness or cable assembly drawing,

the insulation resistance shall not be less than 100 Megohm when
measured at 500 ±50 Volts DC applied at least for one (1) second for
Automatic or Manualy testing. The potential shall be applied between
each conductor and the remaining conductors connected together to
the metallic adapter or to the shield(s), when present.
The harness and cable assembly shall be tested in accordance with
MIL-STD-202, method 302, test condition B.
The test shall be performed before and after sealing the boots.
3.3.5.1 Special Cables
Special cables (see paragraph 7.7) shall be measured at 100 ± 10

volts DC applied for at least half (0.5) second for Automatic testing
and one to two (1-2) second for Manual testing.
The special cables Coax/Triax and thermocouple wires shall be tested

as follow:
a. Coaxial/Triaxial cables:
1. Continuity
2. Insulation Resistance
3. Impedance and/or Attenuation (if required by engineering drawing).
Note: Coaxial/Triaxial cables shall not be High Voltage Withstand

tested.
b. Thermocouple wires:
1. Continuity
2. Insulation Resistance
c. Measure resistance: 20 Megaohms minimum for Coaxial/Triaxial cables

1 Megaohm minimum for Thermocouple
wiring.
3.3.6 Dielectric Withstanding Voltage (High potential withstand)
WARNING
THIS TEST IS FOR QUALIFICATION TEST ONLY!!!
DO NOT PERFORM THIS TEST ON SPECIAL CABLES (SEE
PARAGRAPH 7.7) AND CABLES WITH ELECTRONIC
COMPONENTS INSIDE.
The dielectric-strength test shall be performed between each

conductor and the remaining conductors, connected together to the
metallic adapter or to the shield(s), when present.
an AC or a DC potential shall be applied for 60 seconds for
qualification testing.
The harness and cable assembly shall be tested in accordance with
MIL-STD-202, method 301.
the wires resistance shall be no less than as specified in the following
table:
Wire length Resistance

(Megohm)
Up to 30 meters 100
Up to 100 meters 75
Up to 200 meters 50
When shielded wire is measured, the resistance shall be no less than

30 Megohm.
The dielectric withstand test voltages shall be performed per

connector series and types as specified in the following table:
Dielectric Withstand test voltages

Connector (lowest service rating)
series & types AC RMS 50-60Hz. DC
MIL-C-24308 355 500
MIL-C- 83513 425 600
MIL-C-83723 (II) 710 1000
MIL-C-38999 920 1300
MIL-C-83723 (III) 1060 1500
MIL-C-26482 1060 1500
3.3.6.1 Wires and Cable test
Wires which are terminated into connectors the voltage specified in

the above table shall be applied. These voltages shall be ramped up
at approximately of 500 V per (1) second.
3.3.7 Shield - Connector Bonding Conductivity
IMPORTANT
ATTACH TESTER TO THE CONNECTOR BODY AND NOT TO THE
COUPLING NUT.
When EMI adapter are used, the resistance between the harness
overall shield (near the connector) and the body of the connector
(after adapter are assembled) shall be less than:
 For metallic components 2.5 milliohm.
 For non-metallic components (Composite or Plastic) 5.0
milliohm.
3.3.8 First Article Inspection (FAI)
When the customer requires First Article Inspection (FAI), the test
shall be performed in accordance with Elbit specification 20398A-00.
3.4 Marking
3.4.1 Harness and Cable Marking
Marking on the outer surface shall identify harness and cable
assemblies. The marking shall be on heat shrinkable tubing, in
accordance with MIL-STD-130 (4.3 - b) using characters 3 mm high
(preferred), at least 2 mm high (after shrinking),
In cases, that bundle exceeds 15 mm (diameter), marking shall be
duplicated 180° on both side of marker.
Unless otherwise specified in the drawing, the identification marking
will be placed as follows:
 Ends identification will be placed 100 mm from the end of
the harness on open ends and 50 mm from backshell or
boot.
 Harness identification will be placed as follows:
Harness Length Recommended Identification
place*
Up to 2 meter At the middle
Up to 4 meter At the ends and in the middle of the
cable
More than 4 meter At the ends of the cable and at
interval of 1.75 meter
(*Or as specified in the drawing)
3.4.2 Wire and Cable Marking (When wire marking is required)
To make maintenance and production easier, each interconnecting
wire and cable shall be marked with a combination of letters and
numbers that identified the wire, the circuit it belong to, its gage size,
and other information relate to the wire to a wiring diagram.
When wire marking is required each individual wire and cable in the
harness shall be marked directly or indirect using heat shrinkable
tube.
Wires in close harness (with outer jacket) shall be marked only at last
380 mm of both ends at interval of 75 mm.
Mark wires and cables at intervals of no more than 380 mm along their
entire lengths. In addition, the last 380 mm, of both ends, shall be
marked at interval of 75 mm.
 Wire less than 75 mm long shall not be marked.
 Wire between 75 mm to 180 mm long shall be marked at
the middle.
 Wire between 180 mm to 380 mm long shall be marked at
interval of 75 mm.
3.4.2.1 Direct Marking
The identification number shall be marked directly on the wires or
cable either horizontally or vertically.
3.4.2.2 Indirect Marking

When wire or cable cannot be marked directly, mark the identification
number on a heat shrinkable tube and place it on the wire or cable.
The identification number can mark either horizontally or vertically.
The following types of wires and cables shall be identified by heat

shrinkable tube and not by printing:
 Multi conductor cable.
 Coaxial cable.
 Traixial cable.
 LVDS cable.
 Ethernet cable.
 Thermocouple.
 Fiber Optic cable.
 Wires with insulation difficult to mark (high temperature wire,
TFE, fiberglass, etc.).
In a multi conductor cable the marking shall be as follows:

 The heat shrinkable tube(s) shall include the identification of
each wire of the cable.
 When the basic wire of the cable is not identified by color
add the color identification to the heat shrinkable tube.
3.4.3 Keyway marking

NOTE:
DO NOT MARK THE BOOT WHEN A 90º OR 45º BACKSHELL IS
ATTACHED TO THE CONNECTOR. THE MARKING SHALL BE ON
THE BACKSHELL.
When a heat shrinkable boot is used in the harness, a line (or a

sticker) shall be marked on the boot in the direction of the keyway.
The line shall be white color, approximately 8mm length and 3mm
width.
The white color material (50-100 R + CATALYST No.20 or alternative)
shall be dried by according the manufacturer's orders (approximately
40 min at 150 °C).
On special cases when it is forbidden to heat the cable, use a white
color sticker (TMS-PMT-540-9 or alternative) instead.
3.4.4 Cable mode marking
Unless otherwise specified in the drawing, Instead of the generic mode
marking XX, the manufacturer shall fill the relevant mode of the cable as
appear in the "DWG NO." line, on the drawing.
For example:
3.5 Workmanship
3.5.1 Wiring
Wires and cables shall be positioned or protected to avoid contact
with rough or irregular surfaces and sharp edges and to avoid damage
to conductors or adjacent parts.
3.5.2 Shielding
Shielding on wires and cables shall be secured in a manner that will
prevent it from contacting or shorting exposed current-carrying parts.
The ends of the shielding or braid shall be secured to prevent fraying.
3.5.3 Containment
The harness and cable from containment means should be neat in
appearance, uniformly applied, and positioned to retain critical form
factors and breakout locations. The containment means (lacing, ties,
tie-down, straps, etc.) should not cause the wire or cable insulation to
deform so that performance characteristics are adversely affected.
3.5.4 Insulation
There should be no evidence of burns, abrading, or pinch marks in the
insulation that could cause short circuits or leakage.
3.5.5 Clearance
The clearance between wires or cable and heat generating parts
should be sufficient to minimize deterioration of the wires or cable.
3.5.6 Soldering
All electrical connections shall be soldered in accordance with
IPC-J-STD-001.
4. WIRING LIST
4.1 Wiring list tables
Wiring list tables (Table 6) is required in order to manufacture the

harness in all stages the table will include the following columns:
4.1.1 Serial number
This column contains the serial number for each line in the table.
4.1.2 Wire number / Signal Name
This column contains the wire number in case of harness or the signal
name in case of boxes.
4.1.3 Wire type and AWG
This column contains the wire type in code, according to the following
table (table 4a,4b) and the wire AWG.
For example:
Wire type Wire code

Unshielded twisted 2 Wires 22 AWG U2W22
Shielded twisted 5 Wires 16 AWG S5W16
Table 4a - Wire type codes
Wire type Wire code

Single Wire 1W
Unshielded twisted 2 Wires U2W
Shielded Wire S1W
Shielded twisted 2 Wires S2W
Coax Cable Coax
Triax Cable Triax
Mux-Bus Cable Mux-Bus
Ethernet Ethernet
Twinax Twinax
Table 4b - Wire type codes (Aerospace Div.)
Wire type Wire code

Single wire regular WXX
Unshielded twisted 2 wires U2WXX
Unshielded twisted 3 wires U3WXX
Shielded singal Wire S1WXX
Shielded twisted 2 Wires S2WXX
Shielded twisted 3 Wires S3WXX
Coax Cable Coax-XX
Triax Cable Triax-XX
Mux-Bus Cable Mux-Bus
Ethernet ETH
Twinax Twinax
LVDS LVDS
4.1.4 Wire length
This column contains the wire length in Millimeters.
4.1.5 From/To
This group of columns contains the wire source.
4.1.6 Component
This column contains the reference designator of the From/To

component.
4.1.7 Contact
This column contains the contact number of the From/To component.
4.1.8 Termination code
This column contains the termination code of the From/To component

according to the following table (table 5).
Table 5 - Termination Code /3
Termination type Termination

code
Contact Coax CA
Contact Crimp CC
Contact Solder CS
Contact Triax TR
Cup Wire CUP
Not Connected NA
Splice SP
Terminal Lug – Crimp TC
Terminal Lug – Solder TS
Wire Wrap WW
/3 For Land systems only.

4.1.9 Shielded groups
This column contains the Shielded group’s wires according to

engineering drawing specification and definitions.
4.1.10 Wire Group
This column contains the wire groups. In case the wires are under
overall shield the group number will be marked in this column.
4.1.11 Notes
This column contains all the notes referring this wire.
Table 6 – Wiring List
From To
S/N Wire number / Wire Wire Lg. Comp. Cont. Term. Comp. Cont. Term. Shld. Wire Notes
Signal Name Type (mm) code code group Group
4.1.1 4.1.2 4.1.3 4.1.4 4.1.6 4.1.7 4.1.8 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11
5. QUALITY ASSURANCE INSTRUCTIONS
5.1 Responsibility for inspection
The manufacturer will be responsible for the product, its assembly and its
fabrication in compliance with the applicable documents, as well as for
the conformance of materials and processes. He will also be responsible
for inspection and final testing.
The manufacturer will hand over a COC testifying the compliance of the
product with the specification.
5.2 Quality conformance inspection
Quality conformance inspection shall be as specified in the table:
Inspection Paragraph Notes

Conductor Continuity & Resistance 3.3.3
Overall shield continuity test 3.3.4
Insulation Resistance 3.3.5
Dielectric Withstanding Voltage 3.3.6
Shield – Connector Bonding 3.3.7 For overall shielded
Conductivity cable
First Article Inspection 3.3.8 If required
6. PACKAGING
6.1 Packaging requirements
Each harness assembly shall be wound uniformly into a coil. The

connectors shall be inserted into the eye of the coil, when not practicable,
secured to the coil. The diameter of the coil eye shall be no less than 14
times the diameter of the harness. All connectors shall be protected with
plastic caps.
Place the wound harness into a bubble polyethylene bag. Materials for
further work of the harness shall be placed into a polyethylene bag and
placed in the eye of the harness.
The inspection tag shall be put into the bag. Close the bag using a self
adhesive tape.
The harness/es shall be packed within a close-fitting cardboard carton
box.
Close the box using a self adhesive tape.
7. DEFINITIONS
7.1 Wire
A single metallic conductor of solid, stranded, or tinsel construction

designed to carry current in an electrical circuit. It may be bare or
insulated, but does not have a metallic covering, or shield.
7.2 Cable
Two or more insulated conductors, solid or stranded, contained in a

common covering (shield, or jacket); two or more insulated conductor
twisted or molded together without common covering; or one or more
insulated conductor with a metallic covering shield or outer conductor
(insulated or uninstalled).
7.3 Coaxial cable
Cable used for transmission of radio frequencies (RF), assembled or not,

with two RF (coaxial) termination devices.
7.4 Harness
One or more insulated wires and/or cables with or without helical twist,
with or without common covering jacket, or braid; with or without
breakouts; assembled with two or more electrical termination devices and
so arranged that as a unit, can be assembled and handled as one
assembly.
7.5 Shield
Metallic cover over an insulated conductor or conductors
7.6 Harness and Cable Jacketing
Harness and cable jacketing is the exterior elastomeric harness cover

that accounts for the assembly's water resistance capability. This
elastomeric jacketing includes, heat sealable tape, boots and transitions,
but is not limited to heat shrinkable tubing.
7.7 Special cables
Under this definition there are the following cables:

 Coaxial cable.
 Traixial cable.
 LVDS cable.
 Thermocouple cable.
 Ethernet cable.

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REVISION HISTORY

REV CHG NO DESCRIPTION DATE APPROVED

ALL SHEETS ARE THE SAME REVISION

FCTN NAME SIGNATURE DATE

PREP M. Benuel cy03623 28-Sep-22 TITLE

2.1 Military standards

2.2 General standards

2.3 Elbit standard

34786593P Braiding of Harnesses and cables

3.2 Assembly and Fabrication requirements

The harnesses and cable assemblies shall be assembled according to

3.2.1 Harness layout

3.2.1.2 Twisting of wires and cables rule and method

3.2.1.3.2 Twisted wire lay pattern

The lay pattern arranges the conductors to obtain uniformity,

1/: for Lockheed projects only.

The following factors should be considered in assembly harnesses

3.2.1.3.3 Cable lay length

2/: for Lockheed projects only.

2 Cond. 3 Cond. 4 Cond. 5 Cond. 6 Cond. 7 Cond. 8 Cond.

3.2.1.3.4 Parallel wire lay.

3.2.2.2 Connector and boot angular tolerances

Length (mm)/[in.] Tolerances (mm))/[in.]

0 to 299 [0 to 11.8] +12.7 [+0.5]

3.2.3.4 Internal Shield & Double Overall Layer

The backshell shall be tightened to the connector as specified in Table

The EMI backshell coating shall be conductive and compatible to the

A suitable heat shrinkable boot shall be installed on the EMI adapter

There are several types of EMI adapters:

Those adapters connect the individual (inner) shields and/or the

 Disadvantage s(for tinel lock method only)

Those adapters connect the individual (inner) shields and/or the

Those adapters connect the shielded wires in to a ring method of

Shell size Group 1 Group 2

Screw size Recommended

Note: Torque Requirements in Inch-pounds for Corrosion-Resistant

3.2.4.2 Non EMI adapter

There are several types of non EMI adapters:

3.2.4.2.1 Shrink boot adapter

POSITION OF TAPE IN THE CABLE CLAMP

3.2.4.2.3 Quick tie adapter

The heat shrinkable boot shall be uniformly shrunk to minimum

3.2.4.4 Overall shield

Unless otherwise specified in the drawing, when an EMI shield is

Unless otherwise specified in the drawing, when two layers of overall

METHOD 1–SPLICING METAL BRAIDED SLEEVES BY SOLDERING

METHOD 2–SPLICING METAL BRAIDED SLEEVES BY BRAIDING MACHINE (/3)

/3 Preferable method for Land system projects

3.2.4.5 Ground termination of shielded group

A shielded group is a group of wires with overall shield within harness

3.2.4.6 Ground termination of shielded individual wire/s

The individual shield termination shall be used to connect wire shield

Mfg. Part E-Max F-Min G-Min

There are three methods to connect the individual shielded cable to

One of the three methods or a combination of them can be used in

3.2.4.8 Solder sleeve at the mid of the cable (window)

SHRINK TUBE (IF REQUIRED)

Shield tail preparation

Prepare 0.5 cm of shield tail shield.

Open a "window" of approx. 5 mm in the cable jacket. Unless otherwise specified in