electrical interconnect solutions catalogue cleevetech.com

Electrical

Interconnect

Solutions

Catalogue

cleevetech.com

C L E E V E T E C H N O L O G Y I N T E R N A T I O N A L

0-5introduction | CTI |

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Cleeve Technology International (CTI) is a high-tech, innovative company that has developed a substantial profile in the electrical inter-

connect sector of the aerospace and military industries worldwide.

CTI started into business in Oshawa, Ontario, Canada in May of 1998. The company began representing foreign manufacturers of

electrical interconnect parts and components for military and aerospace applications in Canada. In 2005, in order to accommodate the

company’s growth, we moved to our own custom built property on Colonel Sam Drive. Our business continues to expand as the

company continues to focus on providing solutions to customers’ needs and solving difficult problems.

Recognizing the benefits of expanding our operations in the United Kingdom and Europe, we launched into the United Kingdom market

and captured one of the largest contracts for supplying electrical interconnect components to the British Military in support of the

Bowman Communication System Program. CTI now has two locations in the United Kingdom, a shipping and receiving warehouse in

Wigan and a sales centre near Cheltenham. Most recently, CTI has set up business operations in Germany, Holland, Australia and the

United States. CTI has a Global MRP system which allows us full visibility of our world-wide inventories.

CTI has acquired, and continues to acquire, complimentary companies and capabilities allowing us to expand into new markets such as

rail and mass transit, medical, shipboard and marine. As a result, CTI continues to provide products and solutions with better lead times

than our competitors securing our position as a leader in our field.

Even with the company’s international success, CTI continues to foster close relationships within the communities in which we live. The

company is an active participant in Aviation Exhibitions and other local trade shows and recruits graduates and co-op students from local

colleges and high schools. In addition, the company supports local charities, sports organizations, cultural organizations and fosters the

growth of its employees through worldwide experiences.

C l e e v e Te c h n o l o g y I n t e r n a t i o n a l[ ]Innovative. Creative. Resourceful. Challenge us today!


0-2 | CTI | www.cleevetech.com

Our Mission:

Cleeve Technology International (CTI) is a group of companies that together offer a

turnkey, supply and support solution for customers’ electrical interconnect requirements.

CTI empowers its employees to offer quality solutions to customers electrical interconnect

problems and this enables our customers to mitigate risk and focus on their own core

interests and capabilities.

CTI will go above and beyond to exceed our customer and employee expectations through

continuous improvement.

Regards,

Paul Church, President

q u a l i t y s o l u t i o n saccording to the customer’s requirements[ ]


Table of ContentsSection Reference Page(s)

1 Wire and Cable 1-10

2 Connectors, Contacts and Protection Caps 2-30

3 Backshells, Adaptors and Accessories 3-42

4 Heat Shrink Molded Parts 4-56

5 Tubing, Solder Sleeves and Idents. 5-64

6 Kits, Assemblies, Sub-Assemblies and Feedthroughs 6-84

7 Cable Ties and Cable Management Products 7-90

8 Circuit Protection and Control 8-110

9 Tooling and Equipment 9-116

10 Technical Data and Specifications 10-121

For further information please contact us at:

Cleeve Technology International Headquarters

716 Colonel Sam Drive, Oshawa, Ontario, Canada L1H 7Y2

Tel: 001-905-579-9502

Fax: 001-905-579-9991

Email: [email protected]

Web: cleevetech.com


CTI’s strength lies in a highly focused engineering approach to solving customers’ problems.

In addition to off-the-shelf components such as wire, cable, connectors, accessories and

circuit protection devices, we supply completely wired and tested systems to meet specific

project requirements. From standard MIL-spec qualified parts and ‘build to print’ assemblies

through to tested alternatives to sophisticated systems, we have the solution.

We are a high-tech, innovative, international company that has developed a substantial

profile in the electrical interconnect sector of the aerospace and military industry worldwide.

CTI has earned a reputation for taking the design and supply of products above and beyond

our customers’ expectations.

The company’s products and capabilities allow us to support the integration and supply of

electrical interconnect components and assemblies used in an electrical harness

system, panel or box that needs to operate in a harsh environment. Since the company takes

a ‘systems approach’ to design, development, qualification, supply and follow-up on product

support, it allows us to ensure compatibility of many of the products used in a high perform-

ance electrical system, panel or enclosure resulting in very high customer satisfaction. This has

allowed us to grow our business in new markets such as the rail and mass transit, medical,

shipboard and marine, and several other markets where performance in harsh environments

is critical.

CTI has invested in material management software that allows us to service our

customers with detailed reports related to performance and quality. Coupled with the com-

pany’s knowledge of the compatibility of products, CTI provides its customers with access to

a unique market of electrical interconnect components that would not normally be available.

CTI continues to provide better quality products with better lead times than our competitors

securing our position as a leader in our field.

CTI has always been focused on a team approach with our customers, suppliers and staff.

This team approach allows us to develop and maintain strong working relationships and

will ensure the future growth and success of CTI and the customers that we serve.

i n n o v a t i o n[ ]providing solutions to customers’ needs

Research and Development: CTI invests heavily in the development of new products and solutions to solve electrical

interconnect problems and to find solutions for special applications.

Application Technology: Our know-how is characterized by high quality yet economic solutions. We develop special products

according to the customer’s requirements by adapting the material to the corresponding application.

Production: The CTI group of companies is able to build to print, or to offer improvements to existing designs through to newly

engineered solutions.

Crosslinking: The molecular crosslinking of many of our materials intensifies the main properties:

- Optimization of shrinking capacity

- Increase of continuous operation temperature

- Improvement of electrical and mechanical resistance

- Improvement of chemical resistance

Quality Assurance: In accordance with ISO standards, we go above and beyond to demonstrate our commitment to quality.

Cutting and Printing: We offer custom and value added solutions in the field of cutting and marking of wire, tubing and sleeves:

- Cut lengths according to customer request- Marking of sleeves ordered on spools or in cut lengths according to customer’s request- Non-standard delivery units on special request

Logistics: On the basis of an efficient material management system our well-equipped and computer-assisted warehouses ensures

reliable and on time delivery.

An ISO9001:2000 Company: Quality assurance plays an important role in all projects. All materials will be controlled in

accordance to standardized procedures and the quality plan developed specifically for materials used in an electrical interconnect

system or harnessing system.

Control of Purchases: CTI will supply only qualified products from suppliers approved by CTI. The CTI quality group maintains and

issues a company approved suppliers list.

Outgoing Inspection: Shipping documents, test reports and the certificate of compliance are verified by the inspector for

correctness and conformity to the customer’s purchase order. The parts will be shipped in appropriate packaging with all the

documentation enclosed required by the applicable purchase order.


An Introduction to our Products and Services: CTI’s supply

and support products such as wire and cable, connectors, contacts,

backshells, heat shrinkable tubing and heat shrinkable molded parts

are used extensively in the military, aerospace and industrial

industries.

Our products and capabilities allow us to support the integration and

supply of electrical interconnect components, sub-assemblies and wired

and tested harness assemblies to meet specific program requirements.

Since we take a ‘systems approach’ to design, development, qualification,

supply and follow up on product support, it allows us to ensure compat-

ibility of many of the products used in an electrical harness system, panel

or box.

CTI and our manufacturing partners are approved suppliers to most

industries around the world. We are a privately owned Canadian com-

pany centrally located east of Toronto in Oshawa, Ontario. We are con-

fident we can provide qualified and cost effective solutions, products,

and assemblies for your applications and requirements.

CTI Experience: CTI has been involved in the support of the Military

and Aerospace industries for many years, and in most instances from

the risk reduction phase through to the completion of projects. CTI has

supplied much of the material used by harness contractors and also

supplies technical and engineering support when required.

CTI has added additional manufacturing companies to its supply base

over the past years and works closely with our customer’s engineering

staff to ensure only compliant material options are presented and

approved.

CTI has also developed controlled kits of materials specifically for those

industries as required for harness assemblies in order to ensure total

compliance, compatibility of material, configuration management and

reduced costs.

c o m p a t i b i l i t ymaterials, installation, training and ongoing support[ ]

Product Support

Technical Information

Manufacturing Warehouse


Cleeve Technology International: Electrical Interconnect Solutions for High Performance Harnesses and Cable Assemblies

CTI has the worlds best suppliers at their disposal when it comes to design and problem-solving experience with

an unparalleled portfolio of products. The proven quality of support of our supply partners is matched

only by our own ongoing commitment to invest in new technologies to help meet your ‘next-generation’ systems

performance and commercial goals.

CTI is one of the largest distributors and material facilitators supporting the military and aerospace markets.

We can supply cables and material for your electrical harnesses used on existing requirements, or work with you

to develop alternatives or ‘next-generation’ solutions. We support from design prototype to serial production

and have an excellent engineering capability and extensive warehouse and stocking locations around the world.

CTI should be your first choice to contact for harnessing products including wire and cables, connectors,

accessories and all other interconnect parts.

Custom Harness Systems and Cable Connector Assemblies. Custom harnesses built to your

drawings and specifications are available. Pre-tested, factory-built harnesses provide quick, easy installation and

eliminate unnecessary splices and connectors reducing cost and increasing system reliability. Our product groups

also contain an extensive array of compatible components as follows:

• Harness systems and cable assemblies

• Multicore cables, made to customer specifications

• EMI/EMP Screening, optimized with shield termination systems

• Wire and cables, ruggedized for military applications

• Connectors and back shells according to industrial and military requirements

• Zero-halogen cables and components for marine applications

• Heat shrink materials with high performance

• Identifications systems including computerized print service

• Harness design software

• Engineering service and prototypes

• Serial manufacturing to numerous military and industrial standards

“ ”CTI’s expertise in the design and fabrication of complete wiring harnesses, coaxial cable and ribbon cable

assemblies helps us develop the right cable harnessing and custom solutions you require. CTI is the leading

supplier of electrical interconnect systems for military vehicles, aerospace, marine and industrial applications.


Integrated Harness System Design Guide. A typical high perform-

ance sealed harness assembly is shown with its component parts including:

1. Connectors and adaptors (backshells): Section 2 and 32. Heat shrinkable molded parts (boots): Section 4

3. Heat shrinkable tubing: Section 5

4. Heat shrinkable transitions: Section 4

5. Heat shrinkable marker sleeves (non-heat shrink options also available):Section 5

6. Heat shrinkable ‘clear’ protection sleeves: Section 5

7. Primary and shielded wire and cable: Section 1

r e q u i r e m e n t shigh performance materials for complete environmental protection[ ]

1

1

3

6

42

7

7

5

6

1

1

3

3

2

7

5

1

4

4

2


Also available:• A wide range of termination devices for shield terminations and primary wire interconnection;• A selection of electrical shielding options including braids and termination devices;• Multi-conductor cables designed to meet your specific requirements;• Specialty high performance adhesives for complete environmental sealing (also pre-coated to the inside of the molded parts for ease

of assembly).

Innovative. Creative.Resourceful.

Challenge us today!


Electrical InterconnectionWire and cables that are small, lightweight and tough:

CTI wire and cable products are available small and lightweight, yet meet original equipment manufacturers’specifications for operating in hostile environments. These standards include thermal, electrical, and mechanicalperformance characteristics as well as chemical resistance requirements.

A CTI wire insulation system made of a tough, crosslinked fluoropolymer forms the backbone of

aircraft electrical harnesses, from protected avionics applications to harsh SWAMP environments. The CTI wire

products based on this insulation technology (known as M759 wire and cable) comprise consistently high

quality electrical harnessing systems.

Here are some examples:• M759 wire and cable are used as large-gauge power distribution cable and as small-gauge hook-up wire for

avionics systems. Because they are so flexible, CTI’s wire and cable install quickly and route easily around tightbends. This results in minimum-length installations, thus saving space and weight.

• Miniature coaxial cables are lighter and smaller than standard MIL-spec radio-grade coaxial cables, yet provide improved electrical performance for critical connections.

• Organized wiring systems-flat conductor cable and film-bonded cable-yield significant savings in space andweight. They also solve routing problems in many specialized applications.

• Multi-core cable organizes a variety of CTI’s wires and coaxial cable into a controlled geometry of specific applications. For example, a small multi-core cable containing one miniature coaxial cable, two signalwires, and two power wires can connect each passenger seat to the entertainment center aboard the aircraft.

CTI uses a computer aided design system to design multi-core cables to customer specifications. Complete

documentation, including engineering drawings, can be provided quickly. Designs minimize size and weight,

optimize electrical shielding and environmental protection, and provide controlled electrical performance.

Many aircraft applications can benefit from the lightweight, small size, and rugged construction of CTI's

wire and cable products.

wire and cablewire and cableS e c t i o n 1


“ ”From power, control and signal low-smoke, zero-halogen cables designed in accordance with customer specific require-

ments or military specifications such as M24643, CTI offers a wide selection of copper cabling and fibre optic solutions for

military ground support, aerospace, and navy shipboard including ‘application specific’ cable required designs.

CTI is a key supplier of high performance wire and cable to military, aerospace, andindustrial markets.Critical systems require high performing wire and cable that is designed to support demanding environments.As a key supplier to the military, aerospace and industrial markets, CTI has built a reputation of meeting thehighest performance standards in military cable technology.

Breadth of product

CTI offers an expansive line of copper and hybrid application specific cable assemblies and cabling solutions

in the wire and cable industry.

M81044 Military Wire (spec M044)

M22759 Military Wire (spec M759)

M27500 Military Cable (spec M500)

M86878 Military Hook-Up Wire (spec M878)

M3432, M5136, & M5756 Military special purpose cables

M24643 Navy Shipboard LSZH power, control and signal copper cable

M24643 Navy Shipboard LSZH communications cable

NAVSEA/NAVORD Series of power, control, signal, data, triaxial, and copper and fiber optic speciality cable

FRCL Speciality and hybrid cables designed for specific applications

Performance GuaranteedAs a significant cable supplier to the military, CTI is one

of the few wire and cable suppliers that has access to

approved testing facilities. This product assurance

allows CTI to ensure all cables are 100% production

tested prior to shipment, assuring a requisite level

of performance, quality and reliability.

S e c t i o n 1

1-11wire and cable | CTI |



Spec M044 Wire and Cable Features:• Dual wall construction (if selected) • Low smoke and low corrosive gas generation

• 600, 1000 and 2500 voltage rating • Resistant to most chemicals and electrical arc tracking

• Small size, lightweight

Spec M044 wire has a dual wall construction which combines the outstanding physical and electrical characteristics of crosslinked

polyalkene with the excellent mechanical and chemical properties of cross-linked polyvinylidene fluoride (PVDF).

The result is a wire insulation system that offers a 150°C temperature rating, small size, light weight, solder iron resistance, and

resistance to most solvents, fuels and lubricants. Spec M044 wire and cable is highly flame retardant, non-melting, does not cold flow,

and though mechanically very tough, is easy to handle and install using conventional tools.

Originally developed for aerospace and military requirements in applications of high density and complex circuitry, Spec M044 wire and

cable now finds wide use throughout industry, in commercial and military electronics, avionics, on satellites, aircrafts, helicopters, ships,

trains, and offshore platforms where environmental conditions demand consistently reliable performance. In airframe applications, Spec

M044 constructions can offer a modern dimensional replacement for PVC/Nylon/Glass braid type wire and cables. Spec M044 wire is

offered in a wide range of sizes in stranded conductors, standard materials available being tin or silver-plated copper and high strength

copper alloy. Voltage ratings of 600, 1000 and 2500 are available as standard. Shielded and jacketed versions include single and

multi-conductor constructions and flat braid shields where further size and weight savings are achieved.

Reference Specifications/Approvals

MIL-W-81044, MIL-C-27500 (cables)

Def Stan. 61-12 Part 18

Def Stan. 61-12 Part 26

VG 95218 Parts 20, 21, 22, 23, and 1000

NATO Stock Numbers (NSN’s) exist for most standard constructions

Civil Aviation Authority Accessory Approval

Lloyd’s Register of Shipping

NASA Preferred Product List

CTI Specifications M044

Physical Characteristics:

Small Size: Spec M044 equipment wire, 600 volt rated has a 0.19 mm (0.00749”) nominal wall thickness compared to 0.25 mm(0.00984”) and 0.38 mm (0.01496”) for equivalent PTFE and PVC wires in MIL-W-16878, MIL-W-22759 or BS G210.

Primary Insulation - Crosslinked Polyalkene

ConductorM044 Wire Jacket - Crosslinkedmodified PVDF

M044 CableTwisted Pair

S e c t i o n 1


Light weight: Because of the thin wall and low density of the insulation materials considerable weight savings are made over similarly rated PTFE wires. eg: M044AO111-22 AWG equipment wire, 4.62 grams/metre max

22AWG PTFE equipment wire, MIL-W-22759 5.54 grams/metre max

General handling: The flexibility of Spec M044 and the ease with which it takes a 'set' makes it one of the easiest of the ‘high performance' wires to install. Stripping is done with conventional die blade strippers.

For details of appropriate tools see separate wire handling guide. The tin-plated conductor usually specified is easily soldered or crimped.The insulation may be hot stamp marked or printed and does not need etching before potting.

Lengths: Spec M044 is available in long continuous lengths and can be supplied for use on automatic cut and strip wire preparationmachines.

Typical Properties:

Temperature rating -65°C to +150°C

Voltage rating (thin wall) 600 V

Voltage rating (thick wall) 2500 V

Tensile strength and elongation of insulation 30 N/mm2, 230%

Notch propagation, 0.05 mm notch Pass

Solder iron resistance (370°C, 1 minute) Pass

Shrinkage 200°C

Low temperature bend -65°C

Voltage withstand (thin wall) 600 V

Insulation resistance (20°C) 1500 Megaohms for 1 km

Resistance: fuels, oils, solvents Pass

Environmental Performance:

Temperature rating: Spec M044 wire and cable is rated for continuous operation from -65°C to +150°C and for short periods at temperatures as high as 300°C. Heat ageing tests are routinely performed at temperatures of 200°C (168 h) and 300°C (6 h). In addition, Spec M044 insulation will not shrink back under repeated cycling.

Mechanical performance: Spec M044 wire provides better cut through resistance than some wires with much thicker walls.600 volt equipment wire M044AO111 (0.19 mm wall) has 40% greater cut through resistance than 600 volt PTFE insulated wire (0.25 mm wall).

Solder iron/overload resistance: The crosslinking of the materials used in Spec M044 makes them non-melting at high temperature. Asa result, Spec M044 wire is resistant to prolonged contact with solder irons and is resistant to current overloads which would melt mostthermoplastic insulation.

Chemical resistance: The dual wall construction of Spec M044 wire is highly resistant to many acids, alkalis, hydrocarbon solvents, fuels,lubricants, water and many missile fuels and oxidizers.

Cold flow: Crosslinking of Spec M044 prevents cold flow of the insulation, a recognized problem of some uncrosslinked materials.



Voltage Ratings Outgassing: Standard available voltage ratings for Spec M044 wire are 600 volts (0.19 mm or 0.00749” wall thickness), 1000 volts (0.28 mm or 0.01102” wall) and 2500 volts (0.48 mm or 0.01890” wall).

Electrical Arc Track Resistance: Spec M044 insulation demonstrates a total resistance to arc tracking under both wet and dry conditions at aircraft system voltages.

Low Outgassing: For use in space applications, special constructions of Spec M044 wire are available with low outgassing characteristics, for use in an environment of high vacuum and high temperature.

Fire Hazard Performance: (for reference only)

Flammability

Smoke/Toxicity Index

BS4066 vertical flammability Pass

S424 14751 (Swedish chimney) Pass

NFC 32070 (2) (French chimney) Pass

IEC 332 part 3 (cable ladder) Pass

Smoke Index, Def Stan 61-12 (18) 6 per metre of wire

Toxicity Index, Def Stan 61-12 (18) 0.8 per metre of wire

Oxygen Index, NES 714 30% Oxygen

Temperature Index, NES 715 >300ºC

Spec M044 Wire and Cable - Nominal Sizes, Strandings, Diameters and Weights

Primary Wires/Twisted PairsM044A011X (600 V) M044A021X (1000 V) M044A031X (2500 V) M044A081X (600 V) M044A012X (600 V)

primary wire primary wire primary wire airframe wire twisted wire

Size Stranding CSA OD Weight OD Weight OD Weight OD Weight OD WeightAWG (mm) (mm2) (mm) (g/m) (mm) (g/m) (mm) (g/m) (mm) (g/m) (mm) (g/m)

30 7/0.10 0.06 0.68 1.00 1.37 2.12

28 7/0.13 0.09 0.76 1.36 1.52 2.90

26* 19/0.10 0.15 0.86 1.98 1.02 2.23 1.73 4.10

24 19/0.13 0.25 1.02 2.97 1.17 3.43 1.44 4.18 1.37 3.73 2.03 6.08

22 19/0.16 0.40 1.19 4.38 1.37 4.92 1.75 6.12 1.57 5.52 2.38 8.91

20 19/0.20 0.60 1.40 6.50 1.57 7.30 1.98 8.65 1.78 7.91 2.79 13.30

18 19/0.25 1.00 1.65 9.90 1.85 10.90 2.23 12.38 2.03 11.49 3.30 20.21

16 19/0.29 1.25 1.83 12.58 2.06 13.88 2.46 15.37 2.26 14.32 3.65 25.73

14 19/0.36 2.00 2.26 19.65 2.49 20.90 2.92 23.13 2.74 22.08 4.52 40.15

12 37/0.32 3.00 2.74 30.68 2.98 31.34 3.32 34.32 3.20 32.23 5.48 62.63

10 37/0.40 5.00 3.28 46.28 3.73 50.4 4.09 54.02 3.94 51.80

8 133/0.29 5.23 87.6 5.56 96.20 5.44 92.94

* For M044A0211-26 the stranding is 7/0.16 mm

S e c t i o n 1


M044A111X (600V) M044A121X (6000 V) M044A181X (600 V) M044A112X (600 V)

1 conductor 1 conductor 1 conductor 2 conductors

Size Stranding OD Weight OD Weight OD Weight OD WeightAWG (mm) (mm) (g/m) (mm) (g/m) (mm) (g/m) (mm) (g/m)

28 7/0.13 1.47 4.92 1.60 5.33 2.38 9.40

26 19/0.10 1.57 5.82 1.73 6.51 2.59 12.05

24 19/0.13 1.83 8.20 1.98 9.18 2.26 11.69 2.99 16.12

22 19/0.16 2.00 10.30 2.24 12.35 2.57 15.39 3.35 21.50

20 19/0.20 2.26 14.02 2.54 17.40 2.77 19.09 3.76 27.97

18 19/0.25 2.62 19.70 2.82 22.61 3.02 23.98 4.32 38.24

16 19/0.29 2.79 23.40 3.02 26.63 3.25 27.97 4.67 44.93

14 19/0.36 3.22 32.50 3.45 36.15 3.73 38.48 5.53 64.28

12 37/0.32 3.70 45.67 4.14 49.55 4.19 52.10 6.50 91.51

Larger sizes are also available in some constructions depending on conductor type and construction required.

Screened and Jacketed Cable



M044 X X X X X- Size- X/X- X

Jacket colour (in accordance with MIL-STD-681, white preferred)

Primary wire insulation colour (in accordance with MIL-STD-681)O=Black 3=Orange 7=Violet 1=Brown 4=Yellow 8=Grey 2=Red 5=Green 9=White 2L=Pink 6=BlueAdditional number after base colour indicates stripe

Conductor size (AWG)

Conductor type1 - Tin-plated copper2 - Silver-plated copper 4 - Silver-plated high strength copper alloy (SPHSCA)

Number of conductors 1 to 9

Class of wire1 - 600 V equipment wire2 - 1000 V equipment wire3 - 2500 V equipment wire4 - Space wire 600 V8 - Airframe wire - medium weight

Constructions0 - Primary wire & unscreened, unjacketed cables1 - Round braid screened & jacketed cable†

2 - Flat braid screened & jacketed cable†

3 - Round braid, screened cable, no jacket†

4 - Jacketed cable, no screen5 - Spiral screened and jacket 7 - 9 Special constructions†Screen material same as conductor material except all flatscreens and screen for conductor types 4 and 6 shall be tin-plated copper (other combinations are available).

TypeA - AWG conductor M - Metric conductorAM - Special CD - Custom design B - Special/ - Space & specialsD - Defense standard 61-12 Part 26

Basic specification number

Ordering Information: Standard equipment wires (M044AO11 1 12 to 30 AWG) in most common AWG’s and colours are kept instock. In addition, many of the most commonly used single/pair and triple screened cables are also stock items, as are some airframeconstructions. Other constructions and custom designed wire and cable are available on request.

PartNumberingSystem

S e c t i o n 1


Spec M759 Wire and Cable Features:• Single or dual wall constructions • Small size, ultra light weight

• Exceptional chemical resistance

Spec M759 wire is insulated with a cross-linked ETFE polymer. It has a temperature rating of -65°C to 200°C continuous, and

combines the easy handling of a flexible wire with excellent scrape abrasion and cut-through characteristics.

The dual wall airframe construction of this type of wire is currently used in numerous aircraft programmes. It has a choice of two total

wall thicknesses, both have a contrasting core colour to act as a damage indicator. Chosen for its balance of properties, Spec M759 wire

has outstanding resistance to chemicals and solvents and is not susceptible to UV and moisture degradation. Single wall equipment wire

constructions are available with reduced wall thicknesses for use inside boxes where flexibility and solder-iron resistance make it a wire

which is very easy to install. Both single and dual wall insulated wires are available in twisted pairs, triples, etc., and as screened and

jacketed cables.

Specifications meet the performance requirement of MIL-W-22759/32-35 and /41 to /46 and MIL-DTL-C-27500 (cables) Defense Standard

61-12 Part 33,VG95218 Part 20, Type D; Part 21, Type A; Part 22, Type A; Part 23, Type A, Part 1001 and Part 1002,VDE 9426, 9427, 9428,

British Standard 3G233, Underwriters Laboratory Style 3467.

Spec M759 Insulation System

Physical characteristics:

Size and weight: Spec M759 wire provides one of the most comprehensive wiring product ranges for aerospace and military users, with

a wide choice of conductor sizes and insulation wall thickness. The dual wall airframe wire has an insulation wall thickness of either

0.2 mm (0.00787”) or 0.25 mm (0.00984”) for robustness in unprotected harnesses and has excellent wire to wire abrasion proper-

ties. The single wall equipment wire has a 0.15 mm (0.00591”) wall thickness for use inside equipment and protected harnesses.

Handling: The excellent flexibility and low resilience makes Spec M759 the ideal wire to install, both in new aircraft and equipment and

for maintenance purposes. The wire is easily stripped with conventional tooling. The insulation is readily marked by hot stamp, ink jet or

laser, and can be potted without pre-etching (for full descriptions of the appropriate tools see wire handling guide).

Environmental Performance:Temperature rating: Spec M759 wire and cable is rated for continuous operation from -65°C to +200°C and for short periods at tem-

peratures as high as 400°C.

Mechanical performance: Crosslinking of the Spec M759 insulation significantly improves the following mechanical characteristics;

scrape (sharp edges), cross wire abrasion, cut-through resistance and creep resistance.

Solder iron/overload resistance crosslinking ensures that the insulation does not melt at a high temperature. As a result, Spec M759 wire

is resistant to hot solder irons and current overloads which would melt most thermoplastic insulation.

Chemical Resistance: Spec M759 is unaffected by all commonly used chemicals, eg. fuels, hydraulic fluids, defluxing agents,

cleaners, coolants and de-icers. It also shows excellent resistance to weathering (UV, ozone, pollutants, water).

Space Wire: Spec M759 is available in special versions suitable for use in outer space meeting both ESA and NASA requirements

for outgassing.

InsulationCrosslinked ETFEOver Conductor

Conductor

Spec M759Standard constructions, nominal sizes, strandings, diameters and weights

• Conductor • Primary Wire

• Twisted Pair • Screened & Jacket

M759-AWG conductor: Equipment/interconnect wires & cables



Typical Properties:

Temperature rating (tin plated conductor)

Temperature rating (silver or nickel plated conductor)

Thermal endurance

Scrape abrasion (BS 3G233)

Flexing endurance (Boeing BSS 7324)

Voltage rating

Tensile strength + core elongation tensile strength + total elongationNotch propagation BS 3G230 0.05 mm notch

Solder iron resistance (370°C, 1 minute)

Solderability - Tin plated copper conductor BS 3G233 conditions

Shrinkage:

Long term water resistance

Permittivity 1 KHz (ASTM D150)

Dissipation factor (ASTM D150)

-65°C to +150°C

-65°C to +200°C

200°C, 10000 h

> 100 cycles at 150°C

> 1000 cycles

600 V

(Airframe wire only) 35 N/mm2, 125% (All primary wire) 35 N/mm2, 75% Pass

Pass

<0.8 seconds to wet

Will not hydrolyze

2.7

0.001

Size Stranding M759AO11X Weight M759A012X Weight M759A111X Weight M759A112X WeightAWG (mm) OD (g/m) OD (g/m) OD (g/m) OD (g/m)

(mm) (mm) (mm) (mm)

30 7/0.102 0.61 0.98 1.27 1.94 1.51 5.10 2.12 7.74

28 7/127 0.68 1.35 1.42 2.68 1.59 5.80 2.27 8.90

26 19/102 0.81 2.10 1.67 4.20 1.71 6.85 2.53 11.32

24 19/127 0.94 2.98 1.93 5.96 1.84 8.20 2.80 13.86

22 19/0.16 1.09 4.20 2.23 8.60 1.99 10.30 3.07 17.90

20 19/0.203 1.27 6.40 2.66 13.26 2.20 13.40 3.50 23.80

18 19/0.25 1.52 9.70 3.20 19.57 2.45 17.88 4.10 32.60

16 19/287 1.73 12.40 3.58 25.80 2.67 21.75 4.43 39.70

14 19/0.36 2.20 19.40 4.47 39.60 3.10 30.40 5.30 57.00

12 37/0.32 2.62 29.35 5.38 60.00 3.55 42.46 6.30 81.20

10 37/0.403 3.25 47.40 6.65 96.70 4.20 62.70

8 133/0.287 4.77 87.60 9.80 178.8 5.80 110.50

Single

Pair

S e c t i o n 1


Size Stranding M759AO81X Weight M759A082X Weight M759A111X Weight M759A112X WeightAWG (mm) OD (g/m) OD (g/m) OD (g/m) OD (g/m)

(mm) (mm) (mm) (mm)

26 19/102 1.01 2.50 2.10 5.10 1.71 6.85 2.63 11.32

24 19/127 1.14 3.40 2.33 6.84 1.84 8.20 2.80 13.86

22 19/0.16 1.27 4.80 2.64 9.98 1.99 10.30 3.07 17.90

20 19/0.203 1.47 7.00 3.07 14.75 2.20 13.40 3.50 23.80

18 19/0.25 1.78 10.70 3.63 21.90 2.45 17.88 4.10 32.60

16 19/287 1.95 13.40 4.06 27.50 2.67 21.75 4.43 39.70

14 37/0.36 2.40 20.50 4.90 42.30 3.10 30.40 6.30 57.00

12 37/0.32 2.82 30.50 5.80 63.00 3.55 42.46 6.30 81.20

10 37/0.403 3.40 48.30 7.10 99.10 4.20 62.70

M759-AWG conductor: Airframe wires & cables

CTI Wire and Cable ApplicationsCTI wire and cable products are used extensively in harsh environments such as in military vehicles, ships, aircrafts and applications

that demand the highest performance while exposed to corrosive fluids, high temperatures and physical abuse.

CTI wire and cable products optimize size and weight while still delivering the highest performance and electrical characteristics.



M759 X X X X X- Size- X/X- X

Jacket colour (in accordance with MIL-STD-681, white preferred)

Primary wire insulation colour (in accordance with MIL-STD-681)O=Black 3=Orange 7=Violet 1=Brown 4=Yellow 8=Grey 2=Red 5=Green 9=White 2L=Pink 6=BlueAdditional number after base colour indicates stripe

Conductor size (AWG)

Conductor type1 - Tin-plated copper2 - Silver-plated copper 3 - Nickel-plated copper 4 - Silver-plated high strength copper alloy 6 - Nickel-plated high strength copper alloy

Number of conductors 1 to 9

Class of wire1 - 600 V equipment wire, light weight 2 - 600 V airframe wire, light weight 4 - 450 V equipment wire 8 - 600 V airframe wire, normal weight

Constructions0 - Primary wire & unscreened, unjacketed cable

1 - Round braid screened & jacketed cable†

2 - Flat braid screened & jacketed cable†

3 - Round braid, screened cable, no jacket†

4 - Jacketed cable, no shield

5 - Spiral-screened and jacketed cable†

8 - Special constructions (part numbers not coded)

9 - Special constructions including lightweight†Screen material same as conductor material except all flatscreens and screen for conductor types 4 and 6 shall be tin-plated copper (other combinations are special, refer to wireand cable division).

TypeA - AWG conductor M - Metric conductor/ - Space wire

Basic specification number

Typical ordering example:3 conductors, red, yellow, blue, 600 volt equipment wire with overall round braid, 20 AWG tinned conductor and white jacket:

total Part Number is M759A1 131-20-2/4/6-9

PartNumberingSystem

S e c t i o n 1


Spec M500 Cable DesignationAll M500 cables are designated by a combination of digits and letters (not to exceed 16) which indicates the exact construction

of each cable. Please note the following example of a M500 cable.

Cable Description: M500A 22 SB 3 T 23

(1) (2) (3) (4) (5) (6) (7)

Classification: The cable will be of the following types and will be furnished in the basic wire size, type, number of wires, and

shield and jacket styles, as specified.

Unjacketed: 2 to 15 colour coded wires, spirally laid without an overall outer jacket.

Jacketed: 2 to 15 colour coded wires, spirally laid with an overall outer jacket.

Shielded: A single wire, or 2 to 15 colour coded wires spirally laid, with one or two overall shields.

Shielded and jacketed: A single wire, or 2 to 15 colour coded wires spirally laid, with one or two shields and one or two jackets.

(1) Specification Number: All cables will carry this prefix.

(2) Identification Method: When 85% minimum shield coverage is required:

‘-’ designates the preferred identification method using Table IIIA;

‘F’ designates the preferred identification method using Table IIIB;

‘A’ designates optional identification method A using Table IIIA;

‘G’ designates optional identification method A using Table IIIB;

‘B’ designates optional identification method B using Table IIIC;

‘K’ designates optional identification method C;

‘L’ designates optional identification method D (see MIL spec for band marking specification).

When 90% minimum shield coverage is required:

‘C’ designates the preferred identification method using Table IIIA;

‘H’ designates the preferred identification method using Table IIIB;

‘D’ designates optional identification method A using Table IIIA;

‘J’ designates optional identification method A using Table IIIB;

‘E’ designates optional identification method B using Table IIIC;

‘M’ designates optional identification method C;

‘N’ designates optional identification method D (see MIL spec band for marking specification).

(3) Conductor Size: Designates the wire size. Wire size depends upon the basic wire specification (see 4).

(4) Basic Wire Specification: The component wires are identified by a one or two letter code. A listing of the basic wire

specifications can be found in Table I.

(5) Number of Conductors: M500 currently specifies from 1 to 15 conductors for shielded or shielded and jacketed cables,

and from 2 to 15 for unshielded unjacketed or unshielded jacketed cables. Cables with 10 to 15 conductors are limited to 12 AWG

and smaller.

(6) Shield: The specific shield style and material are designated by a single letter code and are detailed in Table IA.

(7) Jacket: Cable jacketing materials are specified by a two digit code and are detailed in Table IB.

Table I - Basic Wire Specifications



A MIL-W-5086/11 CA MIL-W-22759/13 SP MIL-W-22759/43 MF MIL-W-81044/7

B MIL-W-5086/21, 2 CB MIL-W-22759/14 SR MIL-W-22759/44 MG MIL-W-81044/83

C MIL-W-5086/31, 2 CC MIL-W-22759/15 SS MIL-W-22759/45 MH MIL-W-81044/9

P MIL-W-5086/41 TE MIL-W-22759/16 ST MIL-W-22759/46 MJ MIL-W-81044/10

AA MIL-W-5086/51 TF MIL-W-22759/17 WB MIL-W-22759/803 MK MIL-W-81044/113

AB MIL-W-5086/61 TG MIL-W-22759/18 WC MIL-W-22759/813 ML MIL-W-81044/12

AD MIL-W-5086/71 TH MIL-W-22759/19 WE MIL-W-22759/823 MM MIL-W-81044/13

H MIL-W-8777, MS25471 TK MIL-W-22759/20 WF MIL-W-22759/833 MR MIL-W-81381/73

F MIL-W-8777, MS 27110 TL MIL-W-22759/21 WG MIL-W-22759/843 MS MIL-W-81381/83

EA MIL-W-22759/1 TM MIL-W-22759/22 WH MIL-W-22759/853 MT MIL-W-81381/93

E MIL-W-22759/2 TN MIL-W-22759/23 WJ MIL-W-22759/863 MV MIL-W-81381/103

RA MIL-W-22759/3 JB MIL-W-22759/28 WK MIL-W-22759/873 MW MIL-W-81381/113

RB MIL-W-22759/4 JC MIL-W-22759/29 WL MIL-W-22759/883 MY MIL-W-81381/123

VA MIL-W-22759/5 JD MIL-W-22759/30 WM MIL-W-22759/893 NA MIL-W-81381/133

WA MIL-W-22759/6 JE MIL-W-22759/31 WN MIL-W-22759/903 NB MIL-W-81381/143

SA MIL-W-22759/7 SB MIL-W-22759/32 WP MIL-W-22759/913 NE MIL-W-81381/173

TA MIL-W-22759/8 SC MIL-W-22759/33 WR MIL-W-22759/923 NF MIL-W-81381/183

LE MIL-W-22759/9 SD MIL-W-22759/34 JA MIL-W-25038/1 NG MIL-W-81381/193

LH MIL-W-22759/10 SE MIL-W-22759/35 JF MIL-W-25038/3 NH MIL-W-81381/203

RC MIL-W-22759/11 SM MIL-W-22759/41 MD MIL-W-81044/52 NK MIL-W-81381/213

RE MIL-W-22759/12 SN MIL-W-22759/42 ME MIL-W-81044/6 NL MIL-W-81381/223

1Not for use in aerospace applications. 2Inactive for new design. 3Not for Naval Air Systems Command usage.

Table IA - Shield MaterialLetter Code Maximum temperature

Single Double Description limit for shield materialShield Shield °C °F

U --- No shield N/A N/A

T V Round, tin-coated copper 150 302

S W Round, silver-coated copper 200 392

N Y Round, nickel-coated copper 260 500

F Z Round, stainless steel 400 752

C R Round, heavy nickel-coated copper 400 752

M K Round, silver-coated high strength copper alloy 200 392

P L Round, nickel-coated high strength copper alloy 260 500

G A Flat, silver-coated copper 200 392

H B Flat, silver-coated high strength copper alloy 200 392

* # Flat, nickel-coated copper 260 500

J D Flat, tin-coated copper 150 302

E X Flat, nickel-coated high strength copper alloy 260 500

I Q Flat, nickel-chromium alloy 400 752

S e c t i o n 1


Table IB - Jacket Material and ColourNumeric Code Temperature limit

Single Double Description for jacket materialJacket Jacket °C °F

00 00 No jacket N/A N/A

01 511 Extruded white polyvinylchloride (PVC) 90 194

022 522 Extruded clear polyamide in accordance with ASTM-D-4066 105 221

03 53 White polyamide braid impregnated with clear polyamide finisher over a polyester tape 105 221

04 54 Polyester braid impregnated with high temperature finishers over polyester tape 150 302

05 55 Extruded clear fluorinated ethylene propylene (FEP) 200 392

06 56 Extruded or taped and heat sealed white polytetrafluoroethylene (PTFE) 260 500

07 57 White polytetrafluoroethylene (PTFE) treated glass braid impregnated and coated 260 500

with polytetrafluoroethylene finisher over presintered polytetrafluoroethylene tape

083 583 Cross-linked white extruded polyvinylidene fluoride (PVDF) 150 302

09 59 Extruded white fluorinated ethylene propylene (FEP) 200 392

103 603 Extruded clear polyvinylidene fluoride (PVDF) 125 257

114 614 Tape of natural polyimide combined with clear fluorinated ethylene 200 392

propylene (FEP) wrapped and heat sealed with (FEP) outer surface

124 624 Tape of natural polyimide combined with fluorinated 200 392

ethylene propylene (FEP) wrapped and heat sealed with polyimide outer surface

14 64 Extruded white ethylene-tetrafluoroethylene copolymer (ETFE) 150 302

15 65 Extruded clear ethylene-tetrafluoroethylene copolymer (ETFE) 150 302

16 66 Braid of aromatic polyamide with high temperature finisher over presintered 200 392

polytetrafluoroethylene (PTFE) tape

175 675 Extruded white ethylene chlorotrifluoroethylene (ECTFE) 150 302

185 685 Extruded clear ethylene chlorotrifluoroethylene (ECTFE) 150 302

20 70 Extruded white perfluoroalkoxy (PFA) 260 500

21 71 Extruded clear perfluoroalkoxy (PFA) 260 500

22 72 Tape of polyimide combined with clear fluorinated ethylene propylene (FEP) wrapped 200 392

and heat sealed with opaque polyimide outer surface

23 73 Extruded white cross-linked modified ethylene-tetrafluoroethylene copolymer (XLETFE) 200 392

24 74 Tape layer of white polytetrafluoroethylene (PTFE) wrapped over 200 392

a tape layer of natural polyimide combined with FEP and heat sealed

1 Polyvinylchloride (PVC) materials shall not beused for aerospace applications

2 Jacket material 02/52 is not to be used forcables having a diameter of 0.251 in (6.38mm) or greater

3 Jacket materials 08, 10, 58, and 60 are not tobe used for cables having a diameter of 0.401in (10.19 mm) or greater.

4 Not for Naval Air Systems Command usage5 Inactive for new design.



See Table I A and Table I B for jacket material cross-reference.1T = Tin, S = Silver, N = Nickel, F = Stainless steel, C = Heavy coated nickel

126 AWG is inactive for new design.2For MIL-W-81381 basic wire, the insulation colour may be dark yellow or unpigmented polyimide resin colour.

Table II - Allowable Shield and Jacket Materials for Each Basic Type Wire

Table IIIC - Colour of Insulation for Identification of WireSizes in accordance with MIL-STD-686

MIL-W-5086

MIL-W-8777

MIL-W-22759

slash sheets

1-12,20-23, 28-31

MIL-W-22759

slash sheets

13-19

MIL-W-22759

slash sheets

32-35, 41-46

MIL-W-22759

slash sheets

80-92

MIL-W-25038/1 &

/3

MIL-W-81044

MIL-W-81381

Wire Size 261 24 22 20 18 16 14 12 10 8 6 4 2 1 1/0 2/0

Insulation

Colour Black Blue Green Red White 2 Blue Green Yellow Brown Red Blue Yellow Red White Blue Green

Solid

T

S

T, S, N

T, S, N

T, S, N

T, S, N

F, C

T ,S ,S

T, S, N

00

00

00

00

00

00

00

00

00

Unshielded

Unshielded

Unshielded

Unshielded

Unshielded

Unshielded

Unshielded

Unshielded

Unshielded

01, 02, 03, 10

04

04, 05, 06, 07, 09,

14-18, 20, 21

04, 05, 09, 14-18,

20,21

04, 05, 08, 09,

14-18, 20, 21,

23, 24

04, 05, 06, 07, 09,

11, 12,14-18, 20,

21, 22, 24

06,07

04, 08, 09,14,

16, 23

05, 09, 11, 12, 22

T

S

T, S, N

T, S, N

T, S, N

T, S, N

F, C

T ,S ,S

T, S, N

01, 02, 03, 10

04

04, 05, 06, 07, 09,

14-18, 20, 21

04, 05, 09, 14-18,

20,21

04, 05, 08, 09,

14-18, 20, 21,

23, 24

04, 05, 06, 07, 09,

11, 12,14-18, 20,

21, 22, 24

06,07

08, 09, 14,

16, 23

05, 09, 11, 12, 22

Cable TypeShielded Jacketed Shielded and Jacketed

Basic Wire Shield Jacket Shield Jacket Shield JacketSpecifications Material1 Material Material Material Material1 Material

S e c t i o n 1


Table IIIA - Circuit Identification Colours for Basic Wires in Cablein accordance with MIL-W-22759, MIL-W-25038, MIL-W-81044, or MIL-W-81381

1 Except where preferred colour on basic wire specification sheet is not white.2 Where basic wire is MIL-W-81381, a brown helical stripe shall be used.3 Where basic wire is MIL-W-81381, a brown and white helical stripes shall be used.4 For cables having more than 10 conductors, the wires shall be a white base identified by double colour tracers as indicated.5 Inactive for new design

Table IIIB - Circuit Identification Colours for Basic Wires in Cablein accordance with MIL-W-5086', MIL-W-8777, MIL-W-22759, MIL-W-25038, MIL-W-81044, or MIL-W-81381

1 Inactive for new design MIL-W-5086.2 Colour designation indicated a solid colour with stripe, e.g., red/white - solid red insulation with a white stripe.

No. ofWires Wire Number

inCable 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 Basic

(white)

2 White Blue

3 White Blue Orange

4 White Blue Orange Green

5 White Blue Orange Green Red

6 White Blue Orange Green Red Black

7 White Blue Orange Green Red Black Yellow2

8 White Blue Orange Green Red Black Yellow2 Violet

9 White Blue Orange Green Red Black Yellow2 Violet Gray

10 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3

114 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3 Blue/Blue

124 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3 Blue/Blue Orange/Orange

134 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3 Blue/Blue Orange/Orange Green/Green

144 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3 Blue/Blue Orange/Orange Green/Green Red/Red

154 White Blue Orange Green Red Black Yellow2 Violet Gray Brown3 Blue/Blue Orange/Orange Green/Green Red/Red Black/Black

No. ofWires Identification Colours for Respective Wires in Cable

inCable 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 Basic

(white)

2 Red, blue

3 Red, blue, yellow

4 Red, blue, yellow, green

5 Red, blue, yellow, green, basic

6 Red, blue, yellow, green, basic, black

7 Red, blue, yellow, green, basic, black, brown

8 Red, blue, yellow, green, basic, black, brown, orange

9 Red, blue, yellow, green, basic, black, brown, orange, violet

10 Red, blue, yellow, green, basic, black, brown, orange, violet, gray

11 Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2

12 Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2

13 Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2

14 Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2, green/white2

15 Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2, green/white2, black/white2

FRCL Multi-Conductor Cable

CTI has been recognized as a leading manufacturer of electrical and electronic wire and cable. We offer a broad

and complete line of instrumentation, thermocouple, communications, control, and other types of wire and cable.

Our specialty is in ‘custom cable constructions’.

CTI can manufacture and/or supply a broad spectrum of special cables for OEM equipment or replacement

applications. We can work from your specifications or design custom cables according to your needs.

Cables are available with or without shielding; shields can be conventional braids, spiral braids, aluminum foil

or conductive plastics. Taped, served and wrapped shields are also available. Cable jacketing options include

extruded cross-linked compounds as well as vinyl, nylons, polyethylenes, polyurethanes and fluorocarbons,

elastomers and vitons.

For further information about special cables, please contact CTI. We want to work with you to develop the right

features and functions for your application, within a unique custom package.

Short runs are another specialty, with minimum order quantities as low as any in the industry.

By definition, off-the-shelf cable products do not give end-users the chance to decide on many critical features of

the finished product. Large cable companies have already decided upon the design, materials, tolerances, and

manufacturing techniques to be used for their products before the customer has an opportunity to define

their needs.

CTI’s custom cable products are designed and manufactured to suit the specific needs of our customers' appli-

cations. They are an integral part of the system and its performance.

Advantages of a custom-engineered cable:• Determine physical and electrical tolerances;

• Define the components (insulation, shield, jacket, etc.) that best fit your application;

• Combine various functions, such as power, signal, coaxial, shielded sub-assemblies, and optical fiber

into one cable;

• Optimize the conductor count, stranding, size, and colour-code.

Our extensive engineering and manufacturing capabilities allow us to be able to meet the needs of virtually any

electrical wire and cable application. Our products can be found everywhere from the wiring in electrical devices,

aircraft, ships and military vehicles, through to automotive and industrial applications.



Standards and specifications for cable insulation have

been developed by ASTM, ICEA, CSA, UL, NEC and

others. We advise consulting these organizations for

complete, current, and accurate data.

Local code requirements often exist regulating wire and

cable specification and installation. Always check code

requirements before specifying or installing your wire

and cable.

Jacketing insulation

Jackets: Includes many of the primary insulating

materials, containing nylon, neoprene, hypalon,

ethylene propylene rubber, polyurethane, elastomers,

vitons or zero halogen etc. Jackets cover and protect the

enclosed wires or core against damage, chemical attack,

fire and other harmful elements which may be present in

the operating environment.

Our conductor offering includes (all can be specified in solid or stranded constructions):• Bare copper • Tinned copper • Plated copper • All major thermocouple alloys

We offer numerous insulating and jacketing materials:• Polyethylene • Elastomers • Polypropylene • Vitons®

• Polyurethane • Zero Halogen • Nylons • Teflon (TFE, FEP, PFA, Tefzel)

• TPE • All heat shrinkable tubing options

Our shielding capabilities include a variety of foil shields and metal braids. We can cross reference competitor part numbers and

manufacture cables of equal or higher quality with greater flexibility in design.

The most important part of any cable is the insulation of the conductors. When choosing materials to insulate conductors or cables,

many factors should be taken into consideration. These include electrical properties, mechanical properties, chemical properties, thermal

properties, and more.

S e c t i o n 1


Electric Properties:

- dielectric strength

- insulation resistance

- insulation power factors

- charging current

- arc resistance

- tracking susceptibility

Chemical Properties:

- moisture absorption

- resistance to oil, gas, acids and alkalis

- stability when exposed to sunlight, ozone, or flames

Mechanical Properties:

- toughness and flexibility

- tensile, elongation and crushing strengths

- resistance to abrasion or moisture

- brittleness

Thermal Properties:

- expansion and contraction

- softening and flow temperature

- compatibility with operating, ambient, or emergency overload

and short circuit conditions

Example:FRCL-602006B

Primary Wire For Commercial ApplicationsGeneral Purpose Primary Wire: Plastic primary single conductor wire, with durable thermoplastic PVC

compound that resists chemical attack, abrasion and heat to 90˚C (194˚F). Clean stripping for easy use. Type GPT

to SAE specification J1128.

SXL Heat Resistant Primary Wire: General purpose, low tension cable, crosslinked polyethylene insulated jackets providetoughness combined with outstanding heat, grease, oil, gasoline and chemical resistance. Clean stripping for easy use. Ideally suited for heavy-duty applications. 125˚C (257˚F) temp rating, 50 volt, chemical attack, abrasion and heat to 90˚C (194˚F). Type GPT to SAEspecification J1128.

TEW 600 Volt Rated Primary Wire: For use in internal wiring of electrical equipment. Applications include electric ranges, heat-

ing equipment, lighting fixtures, panels and meters. Stranded copper conductor, PVC insulation, 600 volts, -40˚C (-40˚F) to 105˚C (221˚F)

temp rating. Meets CSA and UL requirements.

Gauge Length Outside Stranding Part Numbers(ft) Diameter (in) (in) Black Blue Brown Green Orange Red White Yellow

Mini Spools

18 50 0.091 16 x 0.010 CTI68051 CTI68052 CTI68053 CTI68054 CTI68056 CTI65057 CTI68059





50’ (15.2m) Spool


100’ (30.5m) Spool


16 100 0.104 19 x 0.0113 CTI68010 CTI68011 CTI68012 CTI68013 CTI68014 CTI68015 CTI68016 CTI68017



8 100 0.239 7 x 12 x 0.0142 CTI68050 CTI68155

6 100 0.285 7 x 7 x 0.0226 CTI68060 CTI68165

4 100 0.354 7 x 27 x 0.0142 CTI68175

1000’ (305m) Spool






Gauge Outside Stranding Part NumbersDiameter (ft) (in) Black Blue Brown Green Orange Red White Yellow

100’ (30.5m) Spool

16 0.129 19 x 0.0113 CTI68840 CTI68841 CTI68842 CTI68843 CTI68847 CTI68844 CTI68845 CTI6884614 0.151 19 x 0.0142 CTI68850 CTI68851 CTI68852 CTI68853 CTI68857 CTI68854 CTI68855 CTI6885612 0.172 19 x 0.0179 CTI68860 CTI68861 CTI68862 CTI68863 CTI68867 CTI68864 CTI68865 CTI6886610 0.203 19 x 0.0234 CTI68770 CTI68773 CTI68774 CTI68775 CTI687768 0.226 7 x 12 x 0.0142 CTI68780 CTI68784 CTI68785

Gauge Outside Stranding Part NumbersDiameter (ft) (in) Black Blue Brown Green Orange Red White Yellow Grey

100’ (30.5m) Spool

16 0.122 26 x 0.010 CTI68609 CTI68610 CTI68611 CTI68612 CTI68613 CTI68614 CTI68615 CTI68616 CTI6861714 0.136 41 x 0.010 CTI68618 CTI68619 CTI68620 CTI68621 CTI68622 CTI68623 CTI68624 CTI68625 CTI6862612 0.159 65 x 0.010 CTI68627 CTI68628 CTI68629 CTI68630 CTI68631 CTI68632 CTI68633 CTI68634



S e c t i o n 1


Cable For Commercial ApplicationsType GPT 2, 3 & 4 Conductor: General purpose, low-tension plastic, insulated cable withgrey PVC outer jacket. SAE specification J1128.

Type GPT 2 Conductor, Parallel Jacketed PVC Cable: General purpose low-tension, plastic

insulated cable with PVC compound

insulation. Bonded parallel red and brown

conductor SAE specification J1128.

Type GPT Parallel Jacketed, 3 & 4 Conductor PVC Cable: General purpose, low-tension, plastic

insulated cable with bonded parallel 3

and 4 conductor. SAE specification J1128.

Speaker Wire,Clear Two-Tone Vinyl Jacketed Cable:Bonded parallel conductors. Wire is polarized using

bare copper stranding on one side and tin plated copper

stranding on the other side.

Part # Conductors/ Stranding Red Green Black WhiteGauge (in)

100’ (30.5 m) SpoolCTI68430 2/16 19 x .0113 • •CTI68431 2/14 19 x .0142 • •CTI68432 2/12 19 x .0179 • •CTI68570 3/16 19 x .0113 • • •CTI68571 3/14 19 x .0142 • • •CTI68580 4/16 19 x .0113 • • • •CTI68581 4/14 19 x .0142 • • • •1000’ (305 m) SpoolCTI68435 2/16 19 x .0113 • •CTI68436 2/14 19 x .0142 • •CTI68437 2/12 19 x .0179 • •CTI68475 3/16 19 x .0113 • • •CTI68576 3/14 19 x .0142 • • •CTI68585 4/16 19 x .0113 • • • •CTI68586 4/14 19 x .0142 • • • •

Part # Conductors/ Stranding Green Brown Yellow WhiteGauge (in)

100’ (30.5 m) SpoolCTI68089 3/16 19 x .0113 • • •CTI68091 3/14 19 x .0142 • • •CTI68090 4/16 19 x .0113 • • • •CTI68092 4/14 19 x .0142 • • • •

250’ (76 m) SpoolCTI68481 4/16 19 x .0113 • • • •

1000’ (305 m) SpoolCTI68093 4/14 19 x .0142 • • • •

Part # Conductors/ Stranding LengthGauge (in) (ft)

CTI68401 2/16 19 x .0113 100 (30.5m) spoolCTI68405 2/16 19 x .0113 250 (76.2m) spoolCTI68416 2/16 19 x .0113 2500 (762m) spool

Part # Conductors/ Stranding LengthGauge (in) (ft)

CTI68500 2/22 19 x .0113 100 (30.5m) spool

connectors, contacts and protection capsconnectors, contacts and protection capsS e c t i o n 2

Selection Guide for CTI Connectors, Contacts and Connector Protection Caps. CTI carries an extensive inventory of military, industrial and commercial connectors. These products are managed

in our MRP system via the military or commercial part number as well as by a CTI spec number which allows us

to offer our customers the most competitive pricing and available stock, while only supplying the very highest

quality parts manufactured by some of the best electrical interconnect companies in the world.

Connectors can be ordered by the military part numbers and, certificates of compliance and test reports can be

provided. Connectors can also be ordered by the manufacturer’s part numbers with the same level of supporting

documentation available as required.

Alternatively, connectors can be ordered by the CTI part number, which allows us the option of suppling the best

suited product for each specific need. All parts supplied under the CTI part number are form fit and functionally

equivalent and will be based on the specific needs of the end user.

Some of the approved specifications and performance criteria as it relates to the military, aerospace and

industrial industries are as follows

CTI Connector part numbers. Cleeve has allocated a prefix to standard military part numbers in order to

differentiate between specific manufacturer’s products and also to allow for multiple supply options.

Examples: D38999/26-WC35PN would be replaced with FAE26-WC-35PN

and MS3475W14-4SN would be replaced with FAE-3475-W14-4SN

All variations such as plating, contact style arctic coupling rings etc. are available upon request and will be

allocated specific part numbers as required

MIL-C-26482 Series I and II Military specification, connectors

MIL-C-38999 Series I, II, III and IV Military specification, connectors

MIL-C-5015 Military specification, connectors

FAE347* series Circular connectors

D38999 (FAE 2* series) Circular connectors

MIL-C-28840 Circular connectors

SCC-3181 series Circular protection caps

SCC-8993 series Circular protection caps

SCC-4841 Circular protection caps


Connector Part Number for FAE-347 series: FAE - 347 5 - Z 10 - 07 P N

Connector prefix

Connector type and

Class (specification number)

Shell style Insert rotation or clocking

Service class Contact configuration

Shell size Insert arrangement

Connector Part Number for FAE-20 through 27 series: FAE - 26 W Z 35 P N

Connector prefix

Shell style Insert rotation or clocking

Service class Contact configuration

Shell size (A through J) Insert arrangement

Connector Kits: Also available and in which CTI will

include all the parts required for a specific application.

FRCK ****

Project prefix

(if applicable)

Sequential number

Depicts kit contents (see kit list for details)

Kit Content Options:

• Contacts

• Backshells

• Protection caps

• Heat shrinkable molded parts

S e c t i o n 2

Product Number Description Performance Specifications

FAE-3475-XXX-XXXX Plug: aluminum alloy, specified finish over MIL-C-26482 Series IIelectroless nickel, arctic coupling ring option.

FAE-3474-XXX-XXXX Jam nut receptacle: aluminum alloy, MIL-C-26482 Series IIspecified finish over electroless nickel.

FAE-3470-XXX-XXXX Wall mount receptacle: aluminum alloy, MIL-C-26482 Series IIspecified finish over electroless nickel.

FAE-3472-XXX-XXXX Wide flange: wall mount receptacle, aluminum alloy, MIL-C-26482 Series IIspecified finish over electroless nickel.

FAE-26-XXXXXX Plug: aluminum or composite. Technical spec ref. MIL-C-38999

FAE-24-XXXXXX Jam nut receptacle: aluminum or composite. Technical spec ref. MIL-C-38999

FAE-20-XXXXXX Square flange receptacle: aluminum or composite Technical spec ref. MIL-C-38999

SCC-8993 Protection cap MIL-C-38999 Series III connectors

SCC-8992 Protection cap MIL-C-38999 Series II connectors

SCC-3181 Protection cap FAE-347X Series receptacle connectors

SCC-3180 Protection cap FAE-347X Series plug connectors


An Overview of Connectors

This section of the CTI catalogue is intended to be used as a ready reference to typical standard, miniature and subminiature cylindri-

cal connector part numbers and terminology. This section should guide you in becoming familiar with the product, in order to better

allow you to determine how your needs can be supported.

Cylindrical Connectors

Basic Components

1. Shell (houses inserts & contacts)

2. Insert (dielectric contact insulator) pin or socket

3. Contact (wire end termination) (electrical engagement)

4. Coupling nut

5. Accessories (wire seals, cable seals, wire support, etc.)


Connector Terms and Definitions Solder Contact: A contact to which wire is joined by soldering

Crimp Contact: A contact to which wire is joined by mechanical ‘squeeze’

Plug: The cable/coupling half of a mating pair

Receptacle: The panel/receiving half of a mating pair

Mating Pair: Two connectors that couple together. Shell size insert arrangement and rotation must be compatible

Plating: The metal finish applied to contacts and or shell components (protective) to resist corrosion and wear

Grommet: Resilient part at back of insert (attached or separate); gives wire moisture seal

Gland: Resilient ring in rear accessory, provides seal on jacketed cable

Sealing Plug: Plastic type slug, placed in unused grommet holes to seal

Grounding Fingers: A metal strap around plug shell for positive shell-to-shell conductivity/shielding

Hermetic: A connector with a fused glass insert for air tightness

Mating/Unmating Forces: Torque required to couple/uncouple a mating pair of connectors or contacts

Rear Termination: An accessory which threads to back of shell (see section 3)

Strain Relief: A type of accessory which clamps wires for support (see section 3)

Potting Boot: A type of accessory which forms a mold for potting compound (see section 4)

EMI or RFI Backshell: A type of accessory to terminate wire shielding (see section 3)

Interface Seal: A resilient part on the face of pin inserts which provides moisture seal

Shell Sizes

Contact Size 22D 22M 22 20 16

Wire Size (AWG) 22-28 24-28 22-26 20-24 16-22

Contact Size

American Wire Gauge 12 8 4 0

Wire Size (AWG) 12-14 8-10 4-6 0-2

| CTI | www.cleevetech.com 2-32

S e c t i o n 2

Example:Wall Mount Receptacle

Example:Plug

Contact Size 6 8 10 12 14 16 18 20 22/22D

Wire Size (AWG) 6 8 10 12-14 14-16 16-20 18-20 20-24 22-26

Note: Contacts available to accommodate other wire sizes upon request. Extended length and PC tail contacts also available

connectors, contacts and protection caps | CTI | 2-33

Major MIL-Specifications by Type:• Miniature, MIL-C-26482

• Widely used small style and size of connectors. Extensive use on military equipment including aircraft as well as commercial applications.

• 3 point bayonet coupling available with either crimp or solder type contacts.

MIL-C-26482 Military Part Number can be replaced by CTI’s ‘FAE’ Series part number.

For example: MS 347 0 L 18 -32 P W can be replaced with FAE 3470L18-32PW

1. ‘MS’ or ‘FAE’ designates Military or commercial standard

2. Specification Number: ‘347’ designates basic family number for MIL-C-26482, Series 2 crimp type

3. Shell Style: ‘0’ designates narrow flange wall mounting receptacle;

‘1’ designates cable connecting receptacle;

‘2’ designates wide flange wall mounting receptacle;

‘4’ designates jam nut receptacle;

‘5’ designates plug with grounding fingers;

‘6’ designates straight plug.

4. Service Class: ‘A" designates grommet seal, 200°C, non-conductive anodic coating;

‘L' designate fluid resistant, 200°C, conductive electroless nickel finish;

‘W’ designates fluid resistant, 175°C, olive drab cadmium over nickel, conductive finish, 500/hr. salt spray;

‘Z designates a zinc cobalt finish.

Note: absence of a letter to designate will result in CTI ‘best available’ option being supplied.

5. Shell Size: ‘18’ designates shell size. Shell sizes 8 through 24 available.

6. Insert Arrangement: ‘18-32’ designates insert arrangement.

7. Contact Configuration: ‘P’ designates pin contacts ‘S’ designates socket contacts.

8. Insert Rotation: ‘W’, ‘X’, ‘Y’, 'T' designate that insert is rotated in its shell from ‘normal’ position. No letter required for normal (no

rotation) position.



MIL-C-38999 Military Part Number can be replaced by FAE 2* Series part number.

Widely used small style and size of connectors. Extensive use on military equipment including aircraft as

well as commercial applications. Available with crimp type contacts and threaded bayonet style coupling.

To more easily illustrate ordering procedure by military designation, part number D38999/20FA35PB is

shown as follows:

For example: CTI alternative part number FAE20-FA35PB, D38999/20-FA35PB designates MIL-C-38999 Series III Connector.

Shell Style: ‘20’ designates wall mount receptacle

‘21’ designates box mount receptacle, hermetic

‘23’ designates jam nut receptacle, hermetic

‘24’ designates jam nut receptacle

‘25’ designates solder mount receptacle, hermetic

‘26’ designates straight plug

‘27’ designates weld mount receptacle, hermetic

Service Class: ‘C’ non-conductive, anodic coated aluminum, 500 hour salt spray, 200°C (environmental resisting);

‘F’ electroless nickel plated aluminum, optimum EMI shielding effectiveness -65dB Ca 10GHz specification min.,

48 hour salt spray, 200°C (conductive, environmental resisting);

‘K’ corrosion resistant stainless steel, firewall capability, plus 500 hour salt spray resistance, EMI -45 dB Ca 10GHz

specification min., 200°C;

‘W’ corrosion resistant olive drab cadmium plate aluminum, 500 hour extended salt spray, EMI -50 dB Ca 10GHz

specification min., 175°C;

‘Y’ hermetic seal, passivated stainless steel, 200°C S (non-hermetic connectors), nickel plated stainless steel,

optimum EMI shielding effectiveness -65 dB Ca 10GHz specification min., 48 hour salt spray, 200°C;

‘N’ (hermetic connectors), nickel plated stainless steel, 200°C;

‘J’ olive drab cadmium plate (175°C) composite, environmental resisting, corrosion resistant;

‘M’ electroless nickel plate (200°C) composite, environmental resisting, corrosion resistant.

Shell Size: MIL-C-38999, sizes 9 - 25

A B C D E F G H J

9 11 13 15 17 19 21 23 25

Specifications • MIL-C-38999, Series III

- 100% scoop-proof;

- High density contact arrangements;

- Contact sizes 12 through 22D plus size 8, 12, 16 coaxial, and size 8 twinaxial removable crimp, PCB, wire wrap, coaxial, triaxial,

twinaxial and fiber optic contact styles available. Options include hermetics, filters and thermocouples;

- Self-locking, quick disconnect threaded coupling;

- Corrosion resistant: shells of stainless steel or cadmium plate over nickel withstand a 500 hour salt spray exposure;

- Moisture resistance: improved interfacial seal design prevents electrolytic erosion of contacts;

- EMI shielding: designed to obtain metal-to-metal coupling, the FAE connector provides a superior EMI shielding capability;

- Vibration/shock: operates under severe, high temperature shock and vibration testing through 200°C;

- Firewall capability: available in stainless steel shell, Class K;

- Locksmith keying: 5 keyway polarization provides 5 alternate rotations

S e c t i o n 2



Contact RatingContact Test Current Maximum Millivolt Drop*

Size Crimp Hermetic Crimp** Hermetic**22D 5 3 73 8520 7.5 5 55 6016 13 10 49 8512 23 17 42 85

10 (Power) 33 N/A 33 N/A

*Maximum millivolt drop data is determined by measuring resistance of mated contacts from end to end** When using silver plated wire

Finishing DataService Class

Finish MilitaryAnodic coating (non-conductive) CElectroless nickel FOlive drab cadmium plate nickel base WStainless steel with nickel plate SStainless steel KOlive drab cadmium plate, composite JElectroless nickel plate, composite M

Hermetic ConnectorsMaterial/Finish MilitaryStainless steel YStainless steel, nickel plate N

Service Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage(Sea Level)

Rating AC (RMS) DC (Sea Level) 50,000 ft. 70,000 ft. 110,000 ft.M 400 550 1300 VRMS 550 VRMS 350 VRMS 200 VRMSN 300 450 1000 VRMS 400 VRMS 260 VRMS 200 VRMS1 600 850 1800 VRMS 600 VRMS 400 VRMS 200 VRMS

11 I 900 I 1250 I 2300 VRMS I 800 VRMS I 500 VRMS I 200 VRMSThe establishment of electrical safety factors is left entirely in the designer’s hands, since they are in the best position to know what peak voltages, switching surges, transients,

etc. can be expected in a particular circuit.

Service Rating

Crimp Well Data Hermetic Well DataContact Well Nominal Well Minimum

Size Diameter Well Depth Diameter Well Depth

22D 0.0345 ± 0.001 0.141 0.036 ± 0.004 0.094

20 0.047 ± 0.001 0.209 0.044 ± 0.004 0.125

16 0.067 ± 0.001 0.209 0.078 ± 0.004 0.141

12 0.100 ± 0.002 0.209 0.116 ± 0.004 0.141

10 (Power) 0.137 ± 0.002 0.355 N/A N/A- Shell grounding fingers are standard on all plugs triple-web grommet seal- DOD preferred


S e c t i o n 2MIL-SPEC Cross Reference Data and General Information

Contact Contact Sizes in Coupling OtherMIL-Spec Description Termination and Series Method Notes

Removal Wire GaugeMIL-C-5015 Power type connectors, large contacts, Solder or crimp, 16 thru 0 Threaded 31OX solder,

older series had solder contacts; front or rear removal 340X crimp F. R.,newer has crimp 345X crimp R. R.,

GT series reverseBayonet coupling

MIL-C-26482 Miniature connector. Contacts are Solder or crimp, 20, 16, 12 Bayonet thread, 311X solder,medium size, both power and front or rear removal version 312X crimp F. R.

Series I crimp signal currents, solder or crimp non-military 347X crimp R. R.MIL-C-22992 Power type connector, heavy duty. Solder for MS1734X, 16 thru 0 Threaded (quick Class ‘L’ Series is

MIL-C-5015 insert patterns, rugged. crimp for military thread), double for heavy power.Solder or crimp contacts class ‘L' stub MS9055X class ‘L'

MIL-C-83723 Series I mates with MIL-C-26482, 2 Crimp, rear removal 20, 16, 12, 8, 0 Threaded and 83723/1 thru 14,Series II mates with MIL-C-5015 bayonet, 36 thru 49 Series I,

Series I, II & III Series III mates with MIL-C-26500 depending 17 thru 27 -29 -30on Series -33-34-35-50-52

-53 Series II,7X -8X -9X Series III

MIL-C-38999 Subminiature-medium and high Crimp, rear removal 22D, 20, 16, 12, Bayonet Intermates withcontact density, crimp contacts. and coax sizes 8, Series I of

Series I-scoop-proof 12,16 MIL-C-27599Series II-lightweight, low profile Crimp, rear removal 22D, 20, 16, 12, Bayonet Intermates with

and coax sizes Series II of 12,16 MIL-C-27599

Series III-High performance, but Crimp, rear removal 22D, 20, 16, 12, Threaded Available in Class ‘K’suited for general duty and coax sizes 8, firewall and lanyard

12,16 release breakawaySeries IV Breech-Lok, Crimp, rear release 22D, 20, 16, 12, Breech-Lok Does not meet total

expensive design, and coax sizes 8, performance can be difficult to mate 12,16 requirements

of series IIIMIL-C-26500 Miniature connector. Contacts are Crimp, front removal 20, 16, 12 Bayonet and Intermates with

medium size, both power and threaded Series III of signal, solder or crimp MIL-C-83723

MIL-C-81511* Subminiature-medium and high Crimp, front release 22, 20, 16, 12 Bayonet M81511/OX F. R.contact density, crimp contacts. and rear removal M81511/4X R. R.

Series I & II-front release contactsSeries III & IV-rear release contacts

MIL-C-27599 Subminiature, similar to Solder 22, 20, 16 Bayonet Intermates withMIL-C-38999 except has Series I and II of

non-removable solder contacts. MIL-C-38999Fully mateable with

MIL-C-38999

*Denotes inactive


TT4 PLACES

NOTES, UNLESS OTHERWISE SPECIFIED

SPECIFICATION CONTROL DRAWING

PART NUMBER DESIGNATIONEXAMPLE - FAE20 - WCX - 35SN

BASIC PART NUMBER

FINISH & SHELL SIZE(SEE NOTE 3)

MATL. IF REQUD(SEE NOTE 2)

INSERT ARRANGEMENT& POLARIZATION

(SEE NOTE 1)

TECHNICAL SPEC REF MIL-DTL-38999 SERIES III1.

MATL: ALUMINUM ALLOY (UNLESS OTHERWISE SPECIFIED WHERE X IN PART NUMBER = S - STAINLESS,2. B - BRONZE, C - COMPOSITE)

FINISH: N - ELECTROLESS NICKEL, W - CADMIUM OVER NICKEL, Z - ZINC COBALT, SHELL SIZE - A THRU J3.

4. CONDUCTIVE SHELL WITH EMI FINGERS

5. DIMENSIONS IN BRACKETS ARE IN MILLIMETERS

REVISIONS

ZONE REV. DESCRIPTION DATE APPROVED

- PRELIMINARY RELEASE NOV 30 06 CS

R2

SR1

T 4 PLACES

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFCLEEVE TECHNOLOGY INCORPORATED ANY REPRODUCTION IN PART OR AS AWHOLE WITHOUT THE WRITTEN PERMISSIONOF CLEEVE TECHNOLOGY INCORPORATEDIS PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL NAANGULAR: MACH NA BEND NATWO PLACE DECIMAL NATHREE PLACE DECIMAL NA

INTERPRET GEOMETRICTOLERANCING PER: NA

MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME CLEEVE TECHNOLOGY INCORPORATED

TITLE:

SIZE

BDWG. NO. REV

SCALE: NA

UNLESS OTHERWISE SPECIFIED:

-

CS NOV 30 06

CIRCULAR CONNECTOR, SQUARE

FLANGE RECEPTACLE

SHEET 1 OF 1

FAE20 SERIESDO NOT SCALE DRAWING CAGE: 3AN64

BTHREAD

VTHREADVIEW DETAIL B

M

Z

WMAX.

DETAIL B SCALE 3 : 1


Contact Installation InstructionsCrimping Contacts

1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used.

2. Cycle the tool to be sure the indentors are open.

3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match.

4. Place the contact, mating end first, into the tool.

5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go.

6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact.

7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted.

Insertion of Contacts

1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adaptors) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted.

2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leavea conductive film. Caution: Never use any lubricant other than isopropyl alcohol.

3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool (tool tip will butt against the shoul-der). Hold the plug or receptacle body firmly.

4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position.Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet couldbe damaged.

4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, removethe contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity.

5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pullingback lightly on the wire to make sure the contact is properly seated.

Completion

1. After all the cavities have been filled, slide the hardware back into position on the connector and tighten.

Extraction of Contacts (rework)

1. Slide the hardware back over the wire bundle.

2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket.

3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expandingthe clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator.

Example of aCTI Connector:


Examples of CTI Connectors:

S e c t i o n 2



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


-

CS NOV 30 06

CIRCULAR CONNECTOR, WIDE FLANGE

WALL MOUNT RECEPTACLE

SHEET 1 OF 1


SHELL 8 THRU 181.465 MAX

C

SHELL 20, 22 &24

D MAX

EF

GROMMET

.130 GROMMET EXTENSION.190

1.405 MAX

THREAD.290 MIN FULLMASTER KEYWAY

T MOUNTINGHOLES TYP. 4 PL

A MAX TYP.

B TYP.



PART NUMBER DESIGNATIONEXAMPLE - FAE3472 - W14X - 05SN

BASIC PART NUMBER




(SEE NOTE 1)

MATES WITH MIL-C-26482 SERIES I AND II CONNECTORS1.


FINISH: N - ELECTROLESS NICKEL, W - CADMIUM OVER NICKEL, Z - ZINC COBALT, SHELL SIZE - 08 THRU 24 3.


REVISIONS



(FLAT)B

MASTER KEYWAYTYP.

B

A MAX

TYP.K MAXH ACCESSORY

THREAD J MOUNTING THREAD

EXTENSION

0.130 (3.30mm)

E

0.190 (4.83mm)GROMMET

C

FSHELL 20,22 &24

1.405 MAXSHELL 8 THRU 18

1.465 MAX



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


-

CS NOV 30 06

CIRCULAR CONNECTOR, JAM NUT RECEPTACLE

SHEET 1 OF 1




BASIC PART NUMBER




(SEE NOTE 1)

EXAMPLE - FAE3474 - W14X - 05SNPART NUMBER DESIGNATION





REVISIONS



CFLAT



TECHNICAL SPEC REF MIL-DTL-38999 SERIES III1.


FINISH: N - ELECTROLESS NICKEL, W - CADMIUM OVER NICKEL, Z - ZINC COBALT, SHELL SIZE - A THRU J3.


5. DIMENSIONS IN BRACKETS ARE IN MILLIMETERS

BASIC PART NUMBER




(SEE NOTE 1)

EXAMPLE - FAE24 - WCX - 35SNPART NUMBER DESIGNATION

REVISIONS





NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


-

CS NOV 30 06

CIRCULAR CONNECTOR, JAM NUT RECEPTACLE

SHEET 1 OF 1


BTHREAD V

THREAD

RTHREAD .062 (1.57MM) TO .125 (3.18MM)

MZ

P

MAX PANEL THICKNESS

AS

FULL THREAD.290 MIN

HACCESSORY THREAD

GROMMET

1.230MAX

MAX

0.1300.190

B

KNURL

AMAX OVER



BASIC PART NUMBER




(SEE NOTE 1)

EXAMPLE - FAE3475 - W14X - 05SNPART NUMBER DESIGNATION





REVISIONS





NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


-

CS NOV 30 06

CIRCULAR CONNECTOR, PLUG

SHEET 1 OF 1




Insert Arrangements for Series FAE 20 thru 27


Insert Arrangements for Series FAE 20 thru 27

S e c t i o n 2


Insert Arrangements for Series FAE 347*

Insert Arrangements for Series FAE 347*

C

BTYP

D

E

TYP.G

PROFILE 0 - STRAIGHT PROFILE 1 - 45 PROFILE 2 - 90


NOTES UNLESS OTHERWISE SPECIFIED:FOR ALL CIRCULAR CONNECTORS1.

PER GENERAL NOTES, MATERIAL AND FINISH CHARACTERISTCS2.DETERMINED BY DESIGNATION IN PART NUMBER

TO BE USED IN CONJUNCTION WITH SHRINKABLE MOLDED PARTS 3.

PART NUMBER DESIGNATION

SYSTEM PREFIX

CONNECTOR TYPE AND CLASS

MATERIAL

FINISH

BACKSHELL ADAPTOR PROFILE

SHELL SIZE

BACKSHELL ENTRY SIZE

SB - XXXX - XX XX - XXXX

SPACER

TERMINATION

DRAIN HOLES

COATING

J/24/25

H/22/23

G/20/21

F/18/19

E/16/17

D/14/15

C/12/13

B/10/11

A/08/09

REF

1.65(41.91)

1.59(40.39)

1.53(38.86)

1.46(37.08)

1.40(35.56)

1.34(34.04)

1.28(32.51)

1.21(30.73)

(29.21)1.15

E

DIMREF

(43.69)1.72

(22.61).89 1.11

(28.19) 18 04

(40.64)1.60

(22.10).87 1.08

(27.43) 16 04

(37.34)1.47

(21.34).84 1.06

(26.92) 16 04

(34.29)1.35

(20.57).81 1.03

(26.16) 14 04

(30.99)1.22

(20.07).79 1.00

(25.40) 12 04

(27.94)1.10

(19.30).76 .98

(24.89) 10 04

(24.64).97

(18.80).74 .96

(24.38) 10 04

(21.59).85

(18.29).72 .93

(23.62) 10 04

0304(18.29).72

(17.53).69

(23.11).91

D

DIM

CREFDIM

BREFDIA

MINREF

MAXREF

ENTRY SIZEAVAILABILITY

CLASS - 2B

ATHREAD

SHELL SIZE

PER

CO

NN

ECTO

R IN

TERF

AC

E

1.98(50.29)

1.91(48.51)

1.85(46.99)

(31.75)1.250

(30.18)1.188

(28.58)1.125

20

19

18

17 (26.97)1.062

(25.40)1.000

(23.83).938

(22.23).875

(20.62).812

(19.05).750

(17.48).688

(15.88).625

(14.27).562

(12.70).500

(11.13).438

(9.53).375

(7.92).312

(6.35).250

(4.78).188

G

±.015 DIA REF

16

15

14

13

12

11

10

09

08

07

06

05

04

03

SIZEENTRY

REF

1.79(45.47)

1.73(43.94)

1.66(42.16)

1.60(40.64)

1.54(39.12)

1.48(37.59)

1.41(35.81)

1.35(34.29)

1.35(34.29)

1.23(31.24)

1.16(29.46)

1.10(27.94)

1.04(26.42)

.98(24.89)

(23.37).92

FDIM

REVISIONS


- PRELIMINARY RELEASE FEB 21 07 CS

A THREAD(INTERNAL)

TYP.

F



NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL


MATERIAL

FINISH

NA

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: X:X


-

CS FEB 21 07

BACKSHELL, CIRCULAR,EMI (IF REQUD.)STRAIN RELIEF

SHEET 1 OF 1

SB-XXXX-XX XX-XXXX

DO NOT SCALE DRAWING CAGE: 3AN64

backshells, adaptors and accessoriesbackshells, adaptors and accessoriesS e c t i o n 3


Design Guide and Product Selection for Connector Backshells (adaptors) Product options for environmental sealing, strain relief and cable shield termination.

Product OptionsMaterial: Aluminum alloy, bronze, stainless steel, cadmium, olive drab, over electroless nickel, composite,

cadmium, olive drab, or zinc cobalt over electroless nickel.

Corrosion resistance (adaptor and shield termination ring or band), 500 hour salt spray finish.

Style: Spin coupling, straight, unless otherwise stipulated to allow connector keying and re-entry for connector

pin repair.

Environmental: Proper (matched) connector seat with O ring interfacial seal (if required)

- Anti-rotation teeth

- Grove for Heat-shrinkable boot (if required)

- Land for shield termination (if required)

- Immersion resistant

- Torque values (see table on page 3-45)

Shield Termination: 360º shield termination

- DC resistance: < 10 milliohm

- Pull out force: 100 lbs or braid break failure

- Operating temperature range: -65°C to 150°C

- Vibration: MIL-STD-167B, para 5.1.3.3.3

S e c t i o n 3

backshells, adaptors and accessories | CTI | 3-43

PartNumberingSystem

Finish

N Environmental, electroless nickel

B Environmental, olive drab cadmium, 500 hr. salt spray

T Environmental, nonmetallic, MIL-I-817651/1 performance

Z Zinc cobalt

Shell Size

Code letter A B C D E F G H J K L M N

Shell size (mm) 9 11 13 15 17 19 21 23 25

Shell size (1/16”) 8 10 12 14 16 18 20 22 24 26 28 30 32

Feedthrough (mm) 12 16 20 24 30 36 48 60

*check connector code designation letter on backshell selection chart, all others see chart following

SB - XXXX - XX XX - XXXX

System prefix Spacer

Connector type Terminationand class

Drain holesMaterial

CoatingFinish

Backshell adaptor profile

Shell size

Backshell entry size

Connector Type Code

D38999 Series I or II A

D38999 Series III or IV B

MS3475 Series II C

Transitions and breakouts D

FAE and AC347x Series C

MS3106 Series M

MS3456 C

FAE20, FAE24, FAE26 B

Connector Type Code

M28840 Series F

Feedthroughs K

MIL-C-81511 T*

MIL-C-83723 C or S*

MIL-C-22992 V*

M26482 Series 1 J*

M26482 Series 2 C*

All others See chart

Material Profile

A Aluminum 0 Straight

S Stainless steel 1 45° angle

B Navy bronze 2 90° angle (right angle)

C Composite



Entry Size Max Cable

Diameter (in)

04 0.250

05 0.312

06 0.375

07 0.437

08 0.500

10 0.625

Entry Size Max Cable

Diameter (in)

12 0.750

14 0.875

16 1.000

18 1.125

20 1.250

22 1.375

Backshell Entry Size

Options:Lining

P Protective coating

U Unlined

Termination

0 No Termination

1 A size termination ring

2 B size termination ring

3 C size termination ring

4 EMI band termination

Drain Holes

D Drain Holes

N No Drain Holes

Spacer Option

O No Spacer required

S Spacer required of appropriate size

Boot Selection Chart

Entry Size Boot Size

04 FMP-XXXX121

05/06 FMP-XXXX132

07/08 FMP-XXXX142

10/12 FMP-XXXX153

14/16 FMP-XXXX163

18/22 FMP-XXXX174


Accessory Coupling Nut Torque Values Shell Size Accessory Thread Torque (+/- 5 in-lbs)

Heavy Duty Medium & Light DutyNon-locking Self-locking Non-locking Self-locking

8, 9 75 60 50 403, 10, 10SL, 11 100 80 50 407, 12, 12S, 13 140 112 50 4014, 14S, 15 150 120 50 4016, 16S, 17 150 120 50 4018, 19, 27 150 120 100 8020, 21, 37 170 140 100 80

22, 23 170 140 100 8024, 25, 26 175 140 100 80

28 190 152 N/A N/A32 190 152 N/A N/A36 190 152 N/A N/A40 210 168 N/A N/A44 210 168 N/A N/A48 210 168 N/A N/A

1 CLEEVE ST SERIES TERMINATION BANDS - (SIMPLE, REALIABLE AND EASY TO INSTALL AND REMOVE)

2 USED TO TERMINATE CABLE SHIELDS TO CONNECTOR BACKSHELLS WITH A DIAMETER OF FROM 0.25 INCH UP TO 2 INCHES.

3 MATL: SST QQ-S-766, 300 SERIES

4 BANDS AVAILABLE IN A RANGE OF OPTIONS BASED ON THE TERMINATION REQUIREMENTS. SOME BANDS CAN BE SUPPLIED "FLAT" OR PRE-COILED (SEE PART NUMBER EXAMPLE)

5 HAND AND PNEUMATIC INSTALLION TOOLS ARE AVAILABLE TO ENSURE CORRECT INSTALLATION.

CONTACT CLEEVE FOR TOOLING AND INSTALLTION PROCEEDURES.

6 CORRECTLY INSTALLED PRODUCTS WILL PROVIDE GREATER THAN 6000 PSI FORCE AND EXCEED 140 LBS PULL OUT FORCE AND LESS THAN 1 MILI-OHM DC RESISTANCE SHIELD TO BACKSHELL.



EXAMPLE PART NUMBER:ST3175-2 - SUPPLIED PRE COILEDST3175F2 - SUPPLIED FLAT

REVISIONS


- FULL RELEASE 05/08/07 CS



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

SEE NOTES

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


-

C.SAVILLE 05/08/07

CLEEVE ST SERIESTERMINATION

BAND

SHEET 1 OF 1

ST 3175-XDO NOT SCALE DRAWING CAGE: 3AN64

B

LENGTH A

7 PARTS SUPPLIED MAY NOT BE EXACTLY AS SHOWN. MATERIAL AND PERFORMANCE MAY VARY BASED ON PART NUMBER SELECTED AND TOOLING USED. PLEASE CONTACT CLEEVE FOR SPECIFIC INFORMATION RELATED TO YOUR SELECTION IF REQUIRED.

C

1 CLEEVE ST SERIES TERMINATION BANDS - (SIMPLE, REALIABLE AND EASY TO INSTALL AND REMOVE)

2 USED TO TERMINATE CABLE SHIELDS TO CONNECTOR BACKSHELLS WITH A DIAMETER OF FROM 0.25 INCH UP TO 2 INCHES.

3 MATL: SST QQ-S-766, 300 SERIES

4 BANDS AVAILABLE IN A RANGE OF OPTIONS BASED ON THE TERMINATION REQUIREMENTS. SOME BANDS CAN BE SUPPLIED "FLAT" OR PRE-COILED (SEE PART NUMBER EXAMPLE)

5 HAND AND PNEUMATIC INSTALLION TOOLS ARE AVAILABLE TO ENSURE CORRECT INSTALLATION.

CONTACT CLEEVE FOR TOOLING AND INSTALLTION PROCEEDURES.

6 CORRECTLY INSTALLED PRODUCTS WILL PROVIDE GREATER THAN 6000 PSI FORCE AND EXCEED 140 LBS PULL OUT FORCE AND LESS THAN 1 MILI-OHM DC RESISTANCE SHIELD TO BACKSHELL.

Part Number Length Width ThicknessA B C

ST3175-2 14 inches 0.25 inch 0.02 inchST3175-3 9.5 inches 0.12 inch 0.015 inchST3175-4 14.25 inches 0.12 inch 0.015 inch

ST6052-1 14 inches 0.24 inch 0.02 inchST6057-1 8.1 inches 0.12 inch 0.015 inchSTAXCL-5 12 inches 0.25 inch 0.02 inch

S e c t i o n 3

ST SERIES



Series Part Number

D38999/20

D38999/24

D38999/26

D38999/40

D38999/42

D38999/44

D38999/46

D38999/47

M28840/10

M28840/11

M28840/14

M28840/16

M81511/01

M81511/03

M81511/05

M81511/06

M81511/21

M81511/23

M81511/25

M81511/26

M81511/31

M81511/32

M81511/33

M81511/34

M81511/35

M81511/36

M81511/37

M81511/38

M81511 /41

M81511/45

M81511/46

M81511/49

M81511/51

M81511/53

M81511/55

M81511/56

M83723/01

M83723/02

M83723/03

M83723/04

M83723/05

M83723/06

Connector Specification

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-28840

MIL-C-28840

MIL-C-28840

MIL-C-28840

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-81511

MIL-C-82723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

Series/Class

Series III: C, F, K, W

Series III: Class C, F, K, W

Series III: Class C, F, K, W

Series IV: C, F, W

Series IV: Class C, F, W

Series IV: Class C, F, W

Series IV: Class F, W

Series IV: Class C, W

Class D, DS

Class D, DS

Class D, DS

Class D, DS

Series 2: Class A, E, F








Series 2: Class C, P, T
















Series I: Class A, G, R






CTI Connector Code

B

B

B

B

B

Contact Cleeve

B

B

F

F

F

F

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

C

C

C

C

C

C

CTI Connector Code by Military Part Number

* denotes a variable that has no impact on the backshell selection

S e c t i o n 3


Series Part Number

M83723/07

M83723/08

M83723/13

M83723/14

M83723/17

M83723/18

M83723/19

M83723/20

M83723/23

M83723/24

M83723/36

M83723/37

M83723/38

M83723/39

M83723/40

M83723/41

M83723/42

M83723/43

M83723/48

M83723/49

M83723/52

M83723/53

M83723/65

M83723/66

M83723/67

M83723/68

M83723/69

M83723/71

M83723/72

M83723/73

M83723/74

M83723/75

M83723/76

M83723/77

M83723/78

M83723/82

M83723/83

M83723/84

M83723/85

M83723/86

M83723/87

M83723/91

M83723/92

M83723/95

M83723/96


MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

MIL-C-83723

Series/Class





Series II: Class A, G, R












Series I: Class G, R




Series II: Class K

Series II: Class K

Series III: Class H

Series III: Class A, G, R










Series III: Class G, R

Series III: Class G, R

Series III: Class A, G, K, R, S




Series III: Class A, G, K, R


Series III: Class G, R, W

Series III: Class G, R, W



CTI Connector Code

C

C

C

C

S

S

S

S

S

S

C

C

C

C

C

C

C

C

C

CS

S

C

C

C

C

C

C

C

C

C

CC

C

CC

C

C

C

C

C

C

C

C

C* denotes a variable that has no impact on the backshell selection



CTI Connector Code by Military Part Number

Series Part Number

M83723/97

M83723/98

MS17343

MS17344

MS17345

MS17346

MS17347

MS17348

MS24264

MS24264

MS24265

MS24265

MS24266

MS24266

MS27466

MS27467

MS27468

MS27469

MS27472

MS27473

MS27474

MS27475

MS27479

MS27480

MS27481

MS27482

MS27484

MS27497

MS27515

MS27613

MS27614

MS27615

MS27652

MS27653

MS27654

MS27656

MS27661

MS27665

MS3100

MS3101

MS3106

MS3107


MIL-C-83723

MIL-C-83723

MIL-C-22992

MIL-C-22992

MIL-C-22992

MIL-C-22992

MIL-C-22992

MIL-C-22992

MIL-C-26500 (AL)

MIL-C-26500 (SST)

MIL-C-26500 (AL)

MIL-C-26500 (SST)

MIL-C-26500 (SST)

MIL-C-26500 (AL)

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-26500 (SST)

MIL-C-26500 (SST)

MIL-C-26500 (SST)

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

Series/Class

Series III: Class S

Series III: Class S

Class C, J, R

Class C, J, R

Class C, J, R

Class C, R

Class C, J, R

Class C, R

Class F, G, R Type B&T aluminum shell

Class E Type B&T stainless steel shell





Series I: Class E, P, T



Series I: Class Y

Series II: Class T

Series II: Class E, P, T

Series II: Class T

Series II: Class Y

Series II: Class T

Series II: Class E, T

Series II: Class T

Series II: Class Y

Series II: Class E, T

Series II: Class T

Series I: Class E

Class K Type B&T stainless steel shell



Series I: Class E, T




Series I

Series I

Class A, E, F, R less endbell; solder contact




CTI Connector Code

C

C

V

V

V

V

V

V

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

A

A

A

Contact Cleeve

A

A

A

Contact Cleeve

A

A

A

Contact Cleeve

A

A

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

A

A

Contact Cleeve

A

A

A

M

M

M

M* denotes a variable that has no impact on the backshell selection

S e c t i o n 3


Series Part Number

MS3110

MS3111

MS3114

MS3116

MS3120

MS3121

MS3124

MS3126

MS3128

MS3130

MS3132

MS3134

MS3137

MS3138

MS3140

MS3144

MS3147

MS3148

MS3400

MS3401

MS3404

MS3406

MS3408

MS3409

MS3412

MS3424

MS3445

MS3446

MS3450

MS3451

MS3454

MS3456

MS3459

MS3464

MS3467

MS3468

MS3470

MS3471

MS3472

MS3474

MS3475

MS3476


MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-5015

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

Series/Class

Series 1: Class E, F, J, P


Series 1: Class E, F, P




Series 1: Class E, F, P



Series 1: Class E, P, J

Series 1: Class E




Series 1: Class E, J




Class D, L, U, W crimp contact





Crimp contact

Class D, L, U, W crimp contact less endbell

Series 3: Class E, L

Series 2: Class E






Class L, W crimp contact




Series 2: Class A, L






CTI Connector Code

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

W

W

W

W

W

W

W

W

W

C

C

C

C

C

C

C

C

W

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C




CTI Connector Code by Manufacturer’s Prefix

Series Part Number

10-214

10-475

10-720

118

149

162GB

164GB

165

172

179

182

246

251

2PPN

2PPN-07

2PSN

2PSN-07

348

381

418

45/PT

450

451

460

48

486

518

5MS

602*

602GB

62AB-14

62GB

650

652

652

674

675

679

69

71

711

801


MIL-C-5015

40M38277

MIL-C-5015

MIL-C-26482

MIL-C-81703

MIL-C-26482

BS9522 F0023

None

MIL-C-5015

MIL-C-5015

None

MIL-C-5015

MIL-C-26482

MIL-C-26482

MIL-C-26482

BS9522 F0017

MIL-C-26482

MIL-C-81511

40M39569

MIL-C-38999

MIL-C-26482

MIL-C-26482

PRL 54125

MIL-C-26482

MIL-C-26500

MIL-C-26482

MIL-C-83723

Def Stan 59-35

Def Stan 59-56

Def Stan 59-56

MIL-C-26482

Def Stan 59-35

VG 95329

LN 29504

PRL 54125

VG 95328

VG 95328

VG 95329

MIL-C-5015

MIL-C-5015

BS9522 F0042

None

Series/Class

MS3100 Class A, E, R


Series 2

Series 1

Series 1

MS3100 Class E, F, R

Series 1

Series 1

Series 1

Patt 105

Series 1

Series 1 and 2

Series I and II

Series 1

Series 1

Series 1

Alum Class F, G, R

Series 2

Series III

Patt 121A

Patt 602

Patt 602

Series 1

Patt 105

MS3100 Class E, F, R


Manufacturer

Bendix

Bendix

Bendix

Amphenol

Deutsch

Amphenol

Amphenol

Amphenol

Amphenol

Amphenol

Amphenol

Amphenol

Cannon

Plessey

Plessey

Plessey

Plessey

Amphenol

Deutsch

Amphenol

Socapex

Deutsch

Socapex

Deutsch

Amphenol

Amphenol

Amphenol

FKI

Amphenol

Amphenol

Amphenol

Amphenol

Schaltbau

Amphenol

UMD

Schaltbau

Schaltbau

Schaltbau

Amphenol

Bendix

Amphenol

Amphenol

CTI Connector Code

M

A

M

C

W

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

M

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

T

C

A

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

C

C

X

C

C

Contact Cleeve

E

T

C

Contact Cleeve

Contact Cleeve

Contact Cleeve

T

M

M

C

C


S e c t i o n 3


Series Part Number

837

83723

83730

845

847

850

851

8520

8525

8526

853

857

89

891

892

8LT

8ST

8T

9-815

91-483

944

951

97

981

A815

AA70

AB05

AB06

ABB

ABJ

ADS

AFD

AFD5

B815

BE

BG

BL

BL

BT

BT*

BTK

BY*

C48

CA (Bayonet)

CA310*


MIL-C-83723

MIL-C-83723

MIL-C-83723

NFL 54120

NFL 54120

MIL-C-26482

MIL-C-26482

MIL-C-26482

NAS 1599

PAN 6432-1

MIL-C-83723

LN 29728

NFL 54140

MIL-C-5015

MIL-C-5015

MIL-C-38999

VG 96912

MIL-C-38999

MIL-C-81511

MIL-C-26482

MIL-C-5015

LN 29500

MIL-C-5015

MIL-C-5015

MIL-C-81511

Not known

Def Stan 59-35

Def Stan 59-35

BS9522 F0032

MIL-C-38999

MIL-C-81703

MIL-C-83723

MIL-C-26482

MIL-C-81511

MIL-C-83723

MIL-C-26482

MIL-C-38999

MIL-C-38999

MIL-C-26482

MIL-C-83723

MIL-C-26482

MIL-C-83723

MIL-C-26500

VG 95234

MIL-C-5015

Series/Class

Series III

Series III

Series III

Series 1

Series 1

Series 2

Series III

Class K

Class K

Series I

Series 1

Series II

Series 3 and 4

Series 2

MS3400 Class L, U, W

MS3100 Class A

MS3400

Series 3

Patt 105

Patt 105

Series I and II

Series 1

Series 2

Series 4

Series III

Series I

Series IV

Series IV

Series 1

Series III

Series 1

Series III

aluminum

MS3100 Class E, F R

Manufacturer

Deutsch

Souriau

Deutsch

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Souriau

Deutsch

Bendix

Matrix

Deutsch

Amphenol

Matrix

Deutsch

Deutsch

AB Elec

AB Elec

AB Elec

AB Elec

Deutsch

Deutsch

Deutsch

Deutsch

Pyle

Bendix

G&H Tech

TRW

Burndy

Pyle

Deutsch

Pyle

TRW

Cannon

Cannon

CTI Connector Code

C

C

C

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

C

C

C

C

C

C

Contact Cleeve

Contact Cleeve

A

Contact Cleeve

A

T

C

C

Contact Cleeve

M

C

T

W

Contact Cleeve

Contact Cleeve

Contact Cleeve

A

W

C

C

T

C

Contact Cleeve

B

B

Contact Cleeve

C

Contact Cleeve

C

Contact Cleeve

Contact Cleeve

M





Series Part Number

CA310*

CA310*KE

CIR

CN0930

CT

CT

CV-R

CV34

CVA

CWL

CWLD

D817

DA

DBAD

DBAS

DD

DFE

DKM

DL

DM

DPX

DS

DTS

EA

EB

EEG

ES

ES0004

ET

FAE3470

FAE3474

FAE3475

FAE20

FAE24

FAE26

FC

FDBA

FF

FH

FPK

FP5K

FYL


MIL-C-5015

MIL-C-5015

VG 95234

MIL-C-83723

MIL-C-38999

MIL-C-38999

MIL-C-83723

MIL-C-5015

MIL-C-83723

None

MIL-C-22992

MIL-C-81703

None

MIL-C-81703

MIL-C-81703

MIL-C-81703

MIL-C-26482

VG 95328

MIL-C-83723

MIL-C-81703

None

MIL-C-38999

None

NAS 1599

MIL-C-83723

None

MIL-C-5015

NAS1599

M26482

M26482

M26482

D38999

D38999

D38999

MIL-C-5015

LN 29504

MIL-C-5015

MIL-C-83723

MIL-C-26500

MIL-C-26500

MIL-C-26500

Series/Class

MS3100 Class A

Class K

Series III

Series II

Series II

Series II

MS3400 Class L, U, W

Series II

Class C, J, R

Series 3

Series 3

Series 2

Series 2

Series III

Series 1

Series III

Series I

Class K

Series 2

Series 2

Series 2

Series III

Series III

Series III

Rev E only

MS3400 Class D, L, U, W

Series III

Class K

Class K

Class K

Manufacturer

Cannon

Cannon

VEAM

TRW

Burndy

Plessey

Cannon

Cannon

Cannon

Cannon

Cannon

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Cannon

Deutsch

Deutsch

Pyle

Pyle

Pyle

Pyle

Various

Pyle

CTI

CTI

CTI

CTI

CTI

CTI

Flight

Deutsch

Flight

Flight

Pyle

Pyle

Pyle

CTI Connector Code

M

Contact Cleeve

Contact Cleeve

C

A

A

S

C

S

Contact Cleeve

Contact Cleeve

C

W

Contact Cleeve

C

W

C

Contact Cleeve

C

W

Contact Cleeve

W

B

C

C

C

C

Contact Cleeve

C

C

C

C

B

B

B

Contact Cleeve

C

C

C

Contact Cleeve

Contact Cleeve

Contact Cleeve


S e c t i o n 3


Series Part Number

G

GC-E

GTA

HAN

HD

HTMAS

HTMF

HTMS

JT

JT

JT

JT-R

JT-R

KFS

KJ

KJA

KJJ

KJJL

KJL

KPSE

KPT

KV-R

L

LJT

LJT

LL3

LL5/6

LMB

LPT

LS

LTT

M-T

M723

MB1

MB3

MB9

MD

MDR

MF

MK12

MK18

MK38

MK25

MK7

MK8


None

MIL-C-26482

MIL-C-28840/*

MIL-C-5015

MIL-C-28840

MIL-C-5015

MIL-C-83723

MVEE 695

MIL-C-38999

MIL-C-38999

MIL-C-38999

PAN 6433-1

PAN 6433-1

MIL-C-28840

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-26482

MIL-C-26482

NAS 1599

MIL-C-26482

MIL-C-38999

MIL-C-38999

MIL-C-81511

BS9540 F0001

Def Stan 59-35

MIL-C-26482

None

BS9522 F0029

MIL-C-26482

MIL-C-83723

MIL-C-26482

MIL-C-83723

MIL-C-38999

MIL-C-26482

None

MIL-C-83723

Def Stan 59-35

Def Stan 59-35

MIL-C-38999

MIL-C-38999

DEF 5325-2

Def Stan 59-35

Series/Class

Series 1

MS3100 Class E, KE

Class K

Series Ill: Class K

Series II

Series II

Series II

Series II

Series III

Series II

Series I

Series I

Series 1

Series 1

Series 1

Series 1

Series I

Patt 602

Patt 121A

Series 1

Patt 616

Series 1

Series II

Series 2

Series III

Series I and II

Series 2

Series III

Patt 603

Patt 608

Series I

Series II

Patt 104

Patt 105

Manufacturer

Burndy

General

Hughes

Deutsch

SAE

Cannon

Cannon

AB Elec

Amphenol

Bendix/FKI

Socapex

FKI

Teldix

Cannon

Cannon

Cannon

Cannon

Cannon

Cannon

Cannon

Cannon

Cannon

Burndy

Bendix

Socapex

Deutsch

Deutsch

Litton-Veam

Deutsch

Pyle

FKI

Burndy

Matrix

Matrix

Matrix

Matrix

Matrix

Deutsch

Cannon

Plessey

Plessey

Plessey

Plessey

Plessey

Plessey

CTI Connector Code

Contact Cleeve

Contact Cleeve

F

Contact Cleeve

F

Contact Cleeve

C

X

A

A

A

A

A

F

A

B

Contact Cleeve

Contact Cleeve

A

Contact Cleeve

Contact Cleeve

C

Contact Cleeve

A

A

T

Contact Cleeve

X

Contact Cleeve

C

A

Contact Cleeve

S

C

C

A

C

W

C

Contact Cleeve

Contact Cleeve

A

A

Contact Cleeve

Contact Cleeve* denotes a variable that has no impact on the backshell selection




Series Part Number

ML94

MQ3

MT3

MT93

P5

PAT104D

PT

PT

PT-CE

PT-G

PT-SE

PT-SE

PT07

PT07SE

PT33

PT33SE

PT44

PT44SE

PT55

PT55SE

PT77

PT77SE

PTG55

PTG55SE

PTS-DR

PV7*

PVJ

PVW

PVX

QDP

QRP

QWL

QWLD

RD1

RR

RR20

RR50

RR70

RSM

RTK

SA

SB


MIL-C-38999

MIL-C-83723

MIL-C-83723

MIL-C-38999

NFL 54 125

Def Stan 59-35

MIL-C-26482

MIL-C-26482

None

VG 95328

MIL-C-26482

MIL-C-26482

MIL-C-26482

MIL-C-26482

BS9522 F0017

BS9522 N0001

BS9522 F0017

BS9522 N0001

BS9522 F0017

BS9522 N0001

BS9522 F0017

BS9522 N0001

BS9522 F0017

BS9522 N0001

MIL-C-26482

MIL-C-26482

MIL-C-26482

Def Stan 59-56

None

None

MIL-C-22992

MIS-20065

Def Stan 59-56

PAN 6432-2

PAN 6432-1

PAN 6432-2

None

None

MIL-C-5015

MIL-C-5015

Series/Class

Series IV

Series III

Series III

Series III

Patt 104

Series 1

Series 1

Series 1

Series 1

Series 1

Series 1

Patt 105

Patt 603

Patt 105

Patt 603

Patt 105

Patt 603

Patt 105

Patt 603

Patt 105

Patt 603

Series 2

Series 2

Series 2

Patt 602

Class C, J, R

Patt 602

MS3400

Class E

Manufacturer

Matrix

Matrix

Matrix

Matrix

Plessey

AB Elec

Socapex

Teldix

Bendix

Teldix

Socapex

Teldix

Bendix

FKI

FKI

FKI

FKI

FKI

FKI

FKI

FKI

FKI

FKI

FKI

Bendix

Cannon

Cannon

Cannon

Cannon

Bendix

AB Elec

Bendix

Bendix

Raychem

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

Deutsch

SAE

Bendix

CTI Connector Code

B

C

C

B

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

Contact Cleeve

C

C

C

C

C

V

Contact Cleeve

Contact Cleeve

V

C

C

C

C

C

W

W

C

M


S e c t i o n 3



Series Part Number

SB104

SB-M4

SB-MS

SC

SCB

SF

SG

SJT

SJT07

SLPT

SM

SPT

SPT

SPT07

STK

STT

STT07

T3*

TRIM TRIO

TT

TV

TV-O-R

TVP

TVPS

TVS

Tri-Start

VPT

VTT

ZZY/ZZW

ZZY/ZZW


Def Stan 59-35

Def Stan 59-35

BS9522 F0030

MIL-C-5015

VG 95234

MIL-C-5015

MIL-C-5015

PAN 6433-2

PAN 6433-2

MIL-C-26482

MIL-C-5015

MIL-C-26482

MIL-C-26482

MIL-C-26482

None

BS9522 F0012

BS9522 F0012

MIL-C-38999

None

BS9522 N0003

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-38999

MIL-C-26482

MIL-C-38999

MIL-C-26500

MIL-C-26500

Series/Class

Patt 104

Patt 104

MS3100 Class A

MS3100 Class E

MS3100 Class E

Series 1


Series 1

Series 1

Series 1

Patt 615

Patt 615

Series III

Patt 614

Series III

Series III and IV

Series III

Series III

Series III

Series III and IV

Series 1

Series III

Class R, G (AL)

Class E (SST)

Manufacturer

AB Elec

AB Elec

AB Elec

Bendix

SICEM

Bendix

Bendix

Various

Various

Deutsch

Bendix

Bendix

Socapex

Various

Deutsch

FKI

FKI

Pyle

Burndy

FKI

FKI/Bendix

Bendix

FKI/Bendix

FKI/Bendix

FKI/Bendix

Bendix

VEAM

FKI

Pyle

Pyle

CTI Connector Code

Contact Cleeve

Contact Cleeve

X

M

Contact Cleeve

M

M

Contact Cleeve

Contact Cleeve

Contact Cleeve

M

Contact Cleeve

Contact Cleeve

Contact Cleeve

W

Contact Cleeve

Contact Cleeve

B

Contact Cleeve

A

B

B

B

Contact Cleeve

Contact Cleeve

B

Contact Cleeve

B

Contact Cleeve

Contact Cleeve

heat shrink molded partsheat shrink molded partsS e c t i o n 4


CTI’s Heat Shrinkable Molded Partsprovide dependable strain relief and mechanical and electrical protection for a wide

range of applications and environmental conditions.

Performance advantages include the following:

• Abrasion and crush resistance

• Excellent performance at high and low temperatures

• Superior mechanical protection

• Sealing and strain relief

• Compliance with MIL-I-81765, the American Bureau of Shipping (ABS), Lloyd’sRegistry of Shipping, and Det Norske Veritas (DNV) standards.

Broad range of configurations. CTI’s molded parts, boots, cable breakouts,

transitions, covers, caps, and feedthroughs come in a variety of configurations

and sizes.

They are also available in a variety of materials:• Semirigid and flexible polyolefin (PL and PF)

• Modified elastomer (EL)

• Zero Halogen (ZH)

• Viton® polymer blend (VL)

Applications: CTI molded parts are versatile and can offer cost-effective

solutions in many application areas, including military, aerospace, rail, mass transit,

automotive and truck, heavy equipment, and marine.

Heat shrinkable transitions for breakouts and junctions. Heat

shrinkable transitions together with adhesives are used to provide strain relief,

environmental sealing and mechanical protection wherever there is a junction or

breakout in a cable harness. Transitions are available for forming multiple breakout

configurations. They are supplied in an expanded form which easily allows cable

bundles to be fed through the transitions prior to shrinking. For mechanical strength

and sealing, transitions need to be installed with an adhesive at each interface.

Adhesive options available are pre-coated to molded parts or as separate adhesives

in hot melt or epoxy systems.

Transition selection guide:

1. Select the transition series from the table;

2. Determine the diameter of the harness at each leg of the junction breakout. The

cable bundle may be calculated from information the following pages;

3. Select the transition size from the information sheets to follow. The largest tran-

sition for a particular application should be chosen as this will give the largest

wall thickness providing the optimum mechanical protection and strain relief.

Transition series:

Name Series Part Number

T Transition FMP301A0XX

FMP322A1XX

45° side breakout FMP342A0XX

Y transition FMP382A0XX

1 into 3 breakout FMP462A0XX

1 into 4 breakout FMP562A0XX

These transitions can be supplied pre-coated with adhesive. The adhesive designator is detailed in the pages following.

Undersized cable. When choosing a transition it may be that, having determined the optimum transition, one of the legs is

slightly undersize. This can be built up to the correct diameter by using a packing sleeve. A packing sleeve is a cut piece of tubing

that is installed underneath the cable jacket. Adhesive should also be used in order to ensure a sealed assembly.

Example: A harness requires a breakout to be installed. From the table the relevant series is FMP382A0XX. The three cable legs

are (over the braid) 14 mm, 4 mm, and 6 mm. The choice of tubing to be installed on each leg would be as follows (the wall

thickness calculated as the example below):

The optimum part is FMP382A023 which in the main branch recovers from 27 mm to 12.4 mm and has two legs of 13 mm

recovering to 6.1 mm. Cable 2 is too small to fit the 6.1 mm leg. By installing a 25 mm piece of tubing 1/4” as a package piece

at the transition and then installing the tubing 1/4” over the whole cable length the final cable OD will be:

5.34 + 2(0.53) = 6.4 mm (this will then provide a diameter large enough for the FMP382A023)

S e c t i o n 4

heat shrink molded parts | CTI | 4-57

Cable Wire bundle Tubing size Wall thickness Finished

(mm) (in) (mm) (in)

1 14 1 1.5 17.0

2 4 1/4 0.67 5.34

3 6 3/8 0.75 7.50

FMP301A011 to 048 Transition TMaterials available:

• EL Fluid resistant modified elastomer

• VL Modified fluoroelastomer

• ZH Low fire hazard material

• PL Semi-rigid modified polyolefin

• PF Flexible modified polyolefin

Coatings: See chart at bottom of page



Table of Dimensions apply to all materials unless otherwise indicated

dimensions (mm): Expanded as supplied (min) Recovered after heating (max)

H J K H J K P R

FMP301A011 7 7 7 3.6 3.6 3.6 30 15

FMP301A022 13 13 13 6.9 6.9 6.9 59 30

FMP301A034 27 27 27 13.5 13.5 13.5 120 60

FMP301A048 56 56 56 30.2 30.2 30.2 246 123



H J K H J K P R S

FMP322A112 13 13 7 5.8 5.8 3.0 52 26 19

FMP322A123 27 27 7 12.4 12.4 3.0 83 42 27

FMP322A134 27 27 13 12.7 12.7 5.8 108 54 39

FMP322A148 56 56 13 25.4 25.4 5.8 181 90 57

FMP322A158 56 56 27 25.4 25.4 12.4 222 111 78

FMP322A112 to 158 90° Side Breakout TransitionMaterials available:







Coatings: Material Available coatings:

EL WA High performance

WA Curing adhesive

ZH WA High performance hot melt adhesive

PL WA High performance hot melt adhesive

PF WA General purpose hot melt adhesive

VL Not available adhesive coated

S e c t i o n 4


FMP342A012 to 058 45° Side Breakout TransitionMaterials available:









H J K H J K P R S

FMP342A012 13 13 7 6.9 6.9 3.6 49 23 23

FMP342A024 27 27 7 12.7 12.7 3.6 93 41 36

FMP342A034 27 27 13 13.7 3.7 7.4 145 70 54

FMP342A048 56 56 13 26.9 26.9 6.9 185 83 72

FMP342A058 56 56 27 26.9 26.9 13.7 204 96 93



H J K H J K P R

FMP382A012 13 7 7 6.1 3.3 3.3 22 19

FMP382A024 27 13 13 12.4 6.1 6.1 38 43

FMP382A034 39 27 27 18.0 12.4 12.4 66 82

FMP382A046 56 27 27 25.9 12.7 12.7 85 94

FMP382A012 to 046 Transition YMaterials available:









WA Curing adhesive







FMP562A011 to 067 Transition 1 into 4 CablesMaterials available:









WA Curing adhesive







H J K L N H J K L N P R S C° D°

FMP562A011 13 7 7 7 7 6.9 3.6 3.6 3.6 3.6 24 38 24 45 15

FMP562A022 19 9 9 9 9 9.7 5.3 5.3 5.3 5.3 36 36 32 45 15

FMP562A032 19 13 13 13 13 9.7 6.9 6.9 6.9 6.9 49 36 45 45 15

FMP562A043 27 13 13 13 13 13.0 6.9 6.9 6.9 6.9 49 52 45 45 15

FMP562A054 39 19 19 19 19 18.5 9.7 9.7 9.7 9.7 72 75 65 45 15

FMP562A067 56 27 27 27 27 26.7 13.0 13.0 13.0 13.0 102 109 93 45 15

FMP462A011 to 60 Transition 1 into 3 CablesMaterials available:









H J K L H J K L P R S C

FMP462A011 13 7 7 7 6.6 3.6 3.6 3.6 46 25 21 30

FMP462A023 27 13 13 13 13.2 6.9 6.9 6.9 93 50 43 30

FMP462A034 39 19 19 19 18.8 9.7 9.7 9.7 135 74 62 30

FMP462A046 56 27 27 27 25.4 12.4 12.4 12.4 192 103 89 30

FMP462A060 91 46 46 46 54.6 27.4 27.4 27.4 390 211 179 30

S e c t i o n 4


CTI’s Heat Shrinkable Molded Parts Shapes and Boots provide mechanical and electrical protection, strain relief and

dependable environmental sealing for a wide range of applications and environmental conditions.

Available in a wide range of material options for your specific application and pre-coated with a high performance adhesive system (if

required). CTI heat shrinkable molded parts offer:

• Abrasion and crush resistance;

• Sealing and strain relief;

• Compliance with numerous military, defence and industrial standards and specifications;

• Wide range of shapes and configurations including boots, cable breakouts, transitions, covers, caps, and feedthroughs;

• All in a wide variety of configurations and sizes.

CTI molded parts are versatile and can offer cost-effective solutions in many application areas, including military, aerospace, rail and

mass transit, automotive and truck, heavy equipment, and marine.



Connector BootsCTI heat shrinkable boots are used to provide strain relief, mechanical protection and environmental sealing from the cable

jacket to connector. CTI offers many types of Molded shapes. The choice depends on the application, repair considerations

and the screening required. For more detailed information on the Molded parts discussed here refer to the ‘Molded Parts Product

Guide’.

Boot Selection Chart: In the table on page 3-44 the recommend-ed boots are detailed for each adaptor for a particular connector code.The boots are recommended for the entry size of the adaptor. Once thepart number has been determined the material suffix must be added.

The cable range stated in the table refers to the fully recovered bootdimensions.

Molded Part Type Description Typical Part NumberingChoice Table Application Straight Right Angle

Standard K boots

Uni-boots

Low profile boots

The most commonly used heatshrinkable boot to terminate cablesat connectors. This boot providessufficient room for repair loops. Byreheating, the boot can be rolledback allowing access for repair

- Military ground vehicles - Communications equipment

FMP222K1XXFMP202K1XX

FMP222D1XXFMP202D1XX

FMP202C6XX

- Open wire bundles in aircraft application

- Military ground vehicles - Communication equipment- Marine

A flexible boot which can beformed to the desired angle. Thepart can be equipment compressedto effect repair

These boots conform closely to theadaptor shape. They are normallyused on open-wire cable bundles

PartNumberingSystem

FMP202K1 32 - EL - 01 / WA

Adhesive coating selected for compatibility with molded part materialGeneral purpose hot melt High performance hot melt Pre-coated curing adhesive

Modification code

Material selectionEL Fluid resistance elastomer ZH Low fire hazard material VL Modified fluoroelastomerPL Semi-rigid polyolefin PF Flexible polyolefinPS Low outgassing polyolefinEB Fluid resistant elastomer (uni-boots only) PB Semi-rigid polyolefin (uni-boots only)

Comparative size

Product family

S e c t i o n 4


Sample Drawings: Heat Shrink Molded Parts

What is Heat Shrink Tubing?

Heat shrink tubing is commonly referred to by several different names, including: shrink wrap, shrink band, shrink tubing, heat

shrink sleeve and heat shrinkable tubing.

Typical applications include: electrical insulation, termination, splicing, cable bundling, colour coding, strain relief, wire marking,

identification, mechanical protection, corrosion protection, abrasion protection, strain relief, wire and cable management and

moisture and weather sealing.

Heat shrinkable tubing is manufactured in one size and then supplied in the ‘expanded’ state. Upon the application of heat, it will

shrink down to its originally manufactured size (usually the size it is supplied in, which would make it a 2 to 1 shrink ratio) but

in some cases the expansion may be greater. Common types include 3 to1 and 4 to 1 but ratios as large as 6 to 1 are also avail-

able. Some options are supplied with an adhesive inner lining which will flow and seal like an adhesive as part of the

installation process (also know as dual wall heat shrink tubing).

When the heat shrink tube is supplied in an expanded state, it has ‘memory’. This means that when it is exposed to high heat

(commonly referred to as the shrink temperature or activation temperature), it will ‘shrink’ back to its original diameter. This is

called the recovered state. Unless stated otherwise, the diameter listed and ordered is the expanded diameter. Also, the diameter

is measured as a tube, not the flat width.

There are many ways to shrink heat shrink tubing. Usually a hair dryer will not work. A cigarette lighter will work, but may cause

charring to the tubing. In most cases a hot air oven or a heat shrink gun (available from CTI) is the ideal heat source. In special

cases a blow torch may be used.

CTI offers many varieties of heat shrink tubing, such as: polyolefin, fluoropolymer, elastomers and neoprenes (like rubber) each

selected based on the performance needs and application.

CTI tubing conforms to all major commercial and military specifications and is available to specific manufacturer’s part

numbers, to the applicable military specification part number or to a CTI part number.

Materials are available in thin wall, medium wall or heavy wall configurations, with melt-and-flow adhesives, weather proofing

encapsulants, and in many different colours, lengths and packaging options.

Custom cutting and printing services are also available upon request.

tubing, EMI shielding, conduit & protective sleevingtubing, EMI shielding, conduit & protective sleevingS e c t i o n 5


CTI Heat Shrink Tubing Heat Shrink PVC

S e c t i o n 5

tubing, EMI shielding, conduit & protective sleeving | CTI | 5-65

Description CTI Specifications Approvals

Standard wall M053-2C2 (Class 2) UL VW-1 & CSA OFT

1/32" wall UL VW-1 & CSA OFT

Irradiated M053-2C1 (Class 1) UL VW-1 & CSA OFT

Lay flat

Heat Shrink Polyolefin (with and without inner adhesive or meltable lining)


Standard wall M053-5C1 (Class 1) also Class 2 and Class 3 UL VW-1 & CSA OFT

Very flexible R46846 Type 5 UL & CSA

Thin wall M053-5TW UL VW-1 & CSA OFT

Semi-rigid M053-6C1 (Class 1) also Class 2 UL

Meltable inner wall M053-4C1 (Class 1)

Adhesive lined M053-4C2 (Class 2) also Class 3

Heavy wall adhesive lined M053-15C1 (Class 1) also Class 2

Heat Shrink Teflon


TFE M053-12C1, also Class 2, Class 3, Class 4 and Class 5

FEP M053-11C1 (Class 1) also Class 2

Heat Shrink Kynar®


Kynar® M053-8 UL VW-1 & CSA OFT

Heat Shrink Mylar®


Mylar® M23053-7C2 (Class 2)

Heat Shrink Neoprene and Elastomer


Neoprene M053-1C1 (Class 1) also Class 2

Elastomer M053-16

Heat Shrink Viton® and Silicon Rubber


Viton® M053-13

Silicon Rubber M053-10



Other Shrinkable Tubing Available Upon Request Non-Shrink Tubing Teflon


TFE M22129C

FEP

Non-Shrink Tubing PVC


Standard wall M631D Grade C UL VW-1 & CSA OFT

1/32" wall UL VW-1 & CSA OFT

Fractional wall FDA Grade

Low temperature M7444 Type 1 & 3

Non-Shrink Tubing Sleeving


Heat treated fiberglass UL

Vinyl coated fiberglass M3190 UL

Acrylic coated fiberglass M3190 UL

Silicone coated fiberglass M3190 UL

Expandable polyester

Non-Shrink Tubing Special Services

Description CTI Specifications

Hot stamp marking MIL-M-81531

Cutting to length

Special packaging/kitting

Example of full part number: M053-5C1 - 1/2 - 9

Material description

Size

Colour

CTI Protective Sleeving

CTI protective sleeving, tubing and conduits are available in many options, from material types and constructions, sizes, lengths, colours

and operating performance through to qualification and approval levels, and are most often used for:

• Thermal protection • Electrical protection/sleeving • General purpose • Heat shrink

• Packaging • Identification • Mechanical-abrasion protection

Overview of product options available:

ProtectaSleeve F: High temperature fire sleeves protect hoses, lines, cables and wires in areas of extreme heat, guard personnel

from burns, and cut costly energy losses. Under the heavy coating of silicone rubber is a braided interior layer.

ReflectaSleeve: Performance tested at 3000°F (1650°C) for 1 minute, ReflectaSleeve reflects at least 90% of radiant heat energy.

ProtectaSleeve W: Heavy-wall braided fiberglass sleeve offers economical hose and cable protection where exposure to moisture,

oils or molten splash is not a factor.

ProtectaGuard: Nylon woven design provides ultimate abrasion protection. Treated with heat and flame resistant coating, acts as a

protective barrier/shield ensuring operator safety. Expandable braided sleeving is very similar a woven ‘stocking’ and when you push the

end back, the sleeving expands to go over wires or other substrates easily, and then when you let go, the sleeving comes back to its

original diameter (or the diameter of your wire harness or bundle, whichever is larger).

Polyethylene Terephthalate (PET) braided sleeving is the most widely used expandable braided sleeve. It is commonly referred to

as ‘General Purpose’ (GP). In many cases, sleeving referred to as Nylon is actually polyester. While Nylon monofilaments do provide

better abrasion resistance in some cases, it also costs 40-60% more than PET, and may be of a higher performance than required in

many applications.

While the braiding process can be controlled to regulate the expandability of the final braid, most expandable PET braided sleeving

supplied today is made in a standard construction that before further processing, varies very little between manufacturers. Standard

braids can expand up to 2 times their nominal size, allowing for easy installation in complex wiring harnesses, and a high degree of

flexibility in the size used.

There are a few different types of fray resistant braided sleeves also available. One type has a resin applied to the braid causing the

individual filaments to stick to each other. Other types consist of a tighter braid, causing the braid to fray less than normal when cut

with scissors.

S e c t i o n 5




General Installation Instructions for CTI Heat Shrink Products: Select the largest sizeof tubing that will still fit snugly after shrinking, according to the shrink ratio of the product beingused (e.g. for 2:1 products select approximately twice the diameter). Cut tubing to the exact lengthrequired (i.e. no shrinkage in length) with a clean, square cut to avoid splitting.

Position tubing over object and heat evenly until tubing shrinks into place or will shrink no further.Products containing pre-installed adhesive may need extra heat to melt and flow the adhesive forproper application.

Keep the heat source or product moving, so the heat is not concentrated in one spot. Keep the heatsource at least one inch away from tubing, using a low-intensity heat source such as a hot air gun,oven, infrared heat source, or soft (yellow) flame.

Thermafix® 2:1 3/64 to 4 No -30˚C to 125˚C CSA (LR31929) Black, Very flexibleSingle Wall -22˚F to 257˚F MIL-I-23053/5 White,Polyolefin Tubing (Class 1) Red,

UL (E35586) Yellow,Blue,

Green,Orange,Violet,Grey

Thermafix® 2:1 3/64 to 4 No -55˚C to 135˚C MIL-I-23053/5 Clear FlexibleSingle Wall -67˚F to 275˚F (Class 2)Polyolefin (Clear)

Thermafix Plus™ Dual 4:1 1/4 to 3/4 Yes -40˚C to 130˚C UL (E85381) Black, Semi-rigidWall Polyolefin Tubing -40˚F to 266˚F Clear

Thermafix ST™ Heavy 3:1 0.4 to 4 As Required -55˚C to 90˚C UL(E15664) Black, RigidWall Polyolefin Tubing -67˚F to 194˚F Red

Thermafix DWP™ Dual 3:1 1/8 to 1.5 Yes -40˚C to 110˚C UL (E35586) Black, FlexibleWall Polyolefin Tubing -40˚F to 230˚F CSA (LR31929) Red

Thermafix 3X™ Single 3:1 3/16to 1.5 No -30˚C to 125˚C CSA (LR31929) Black, Very flexibleWall Polyolefin Tubing -22˚F to 257˚F MIL-I-23053/5 White

(Class 1)UL (E35586)

Thermafix DC™ Dual 2:1 1/8 to 1 No -55˚C to 135˚C CSA (LR31929) Yellow/Green FlexibleColour Polyolefin Tubing -67˚F to 275˚F UL (E35586) (Dual Colour)

Thermafix Kynar® 2:1 1/16 to 3/4 No -55˚C to 175˚C CSA (LR31929) Clear Semi-rigidPolyvinylidene Fluoride -67F to 347˚F UL (E35586 VW-1)Tubing MIL-I-23053/8

Thermafix Crimp™ as per 10 to 22 AWG Yes -55˚C to 125˚C UL Red, RigidShrinkable Nylon specified -67˚F to 257˚F C-UL Blue,Terminals and Splices wire gauge (E87681) Yellow

Thermafix SolderSplice™ as per 10 to 22 AWG Partial -30˚C to 125˚C UL (E87681) Red, Semi-rigidShrinkable Polyolefin specified -22˚F to 257˚F Blue,Wire-to-wire wire gauge YellowSplices with Solder

Product Shrink Ratio Sizes (in) Adhesive lined Temp. Range Agency Approval Colours Rigidity

A Quick Guide to CTI Heat Shrink Tubing and Complimentary Products:

S e c t i o n 5


Braid EMI Pull on Shield SelectionBraids can be supplied on formers to facilitate easy removal and installation on to primary wire that has been laid into a bundle. Four

braid sizes are supplied to cover from 4.5 mm to 39 mm diameter bundles. This product is based on 36 AWG braid and is compatible

with Tinel-lock spin coupling adaptors.

Part number FRB101 Tin-plated copper

FRB103 Nickel-plated copper

Construction Description Cable range Former diameter

(mm) (mm)

7.5 4.5-15.0 7.5

10.0 8.0-22.5 10.0

12.5 10.0-25.0 12.5

20.0 16.0-39.0 20.0

Example: FRB-101-10.0

Tin-plated copper braid with cable range of 8-22.5 mm

Features of PET Braided Sleeving• Excellent cut through and abrasion resistance • Melt temperature of 230°C (446°F)

• Continuous use temperature of -70°C to 125°C (-103°F to 257°F) • Halogen free, ROHS compliant

• Braided from 10 MIL polyethylene terepthalate (PET) monofilament yarns • Self-extinguishing

• Resists gasoline, engine chemicals & cleaning solvents • Expands up to three times its resting diameter

• Registered in the NASA database for low outgassing (under CS technical manufacturer)

• Many colours available

FRRB Pull On EMI Shield (‘Pull On Braid’)

FRRB was developed in an effort to improve the shielding efficiency of ‘pull on’ braids that previously had been dependent on optical

coverage as the major means of specification.

It was found through testing and analysis that a degradation in performance could result from increased optical coverage, due to an

increase in surface transfer impedance.

It was also found that significant improvements in shielding performance could be achieved if the shield was ‘optimized’ so as to best

accommodate a pre-determined cable bundle diameter.

Optimized shields are manufactured by correct choice of shield parameters such as wire size, number of carriers, number of wires and

the braid angle.

Optimized shields are best achieved when machined directly onto a cable bundle, however this is often an impossible option.

FRRB gives the highest levels of shielding performance when used on the range of cable bundle sizes specified in the technical data

included.

Part number for ordering

FRRB-size-material (see part numbering breakdown)

• Available in tin plated copper or nickel plated copper;

• 93% minimum optical coverage;

• Supplied in a range of sizes from 0.125” to 0.750” diameter, to cover a range of cable bundle diameters form 0.125” to 1.500”;

• Higher level of screening performance;

• Compatible with shielded backshell systems;

• Low Braid angle provides high usable expansion ratio.



PartNumberingSystem

FRRB- XXXX XPC

Size T - Tin N - Nickel

0125 (0.125”)

0160 (0.160”)

0250 (0.250”)

0300 (0.300”)

0400 (0.400”)

0500 (0.500”)

0750 (0.750”) Example: FRRB-0300-TPC

‘Example of a Tubing Data Sheet’

S e c t i o n 5


Examples of CTI specification control data sheets available in support of all M053 series heat shrinkable tubing.

Typical Features:

• M053-5V is a very flexible, low recovery temperature, flame-retardant, heat shrinkable polyolefin tubing that is recognized by Underwriters' Laboratories (UL) under Subject 224as UL VW-1, and the Canadian Standards Association (CSA) at 125ºC;

• Low recovery temperature benefits the user in more rapid installation, with less potential damage to heat sensitive component insulation systems;

• Shrink temperature is 90º C, with an indefinite storage life;

• Operating temperature range is -55ºC to +125ºC;

• M053-5V is recommended for all general purpose applications such as insulating, colour coding, bundling and light harness jacketing or environmental protection where UL orCSA recognition as VW-1 rated material is desirable.

Ordering Information:

• Standard colours: Black, white, red, yellow, blue (other colors are available upon request) • How to order: (type of material) (size) (colour)

• Standard package: Spooled (S) or 4 feet (4') Example: M053-5V 1/4” Black

Standard Sizes

Size Inside Diameter Inside Diameter Wall Thickness

As Supplied After Recovery After Recovery

(min) (max) (nom)

(in) (mm) (in) (mm) (in) (mm)

3/64 0.046 1.20 0.023 0.60 0.016 0.40

1/16 0.063 1.60 0.031 0.80 0.017 0.43

3/32 0.093 2.40 0.046 1.20 0.020 0.51

1/8 0.125 3.20 0.062 1.60 0.020 0.51

3/16 0.187 4.80 0.093 2.40 0.020 0.51

1/4 0.250 6.40 0.125 3.20 0.025 0.64

3/8 0.375 9.50 0.187 4.80 0.025 0.64

Standard Sizes



(min) (max) (nom)


1/2 0.500 12.70 0.250 6.40 0.025 0.64

3/4 0.750 19.10 0.375 9.50 0.030 0.76

1 1.000 25.40 0.500 12.70 0.035 0.89

1 1/2 1.500 38.10 0.750 19.10 0.040 1.02

2 2.000 50.80 1.000 25.40 0.045 1.14

3 3.000 76.20 1.500 38.10 0.050 1.27

4 4.000 101.60 2.000 50.80 0.055 1.40

M053-5V Heat Shrinkable Polyolefin TubingFlexible Polyolefin, UL/CSA recognized 125°C and 600V (VW-1)

Data Sheet

For further information or additional data sheets please contact us at: Cleeve Technology International Headquarters • [email protected] • www.cleevetech.com

Specification Reference: UL 224 125°C, 600V, VW-1 CSA-C22.2 125°C, 600V

Physical:

Tensile strength (psi)

Elongation (%)

Specific gravity

Low temperature flex (-550°C)

Heat resistance (1580°C, 168 hrs)

Elongation (%)

Secant modulus (psi)

Deformation (125°C, 1 hr) (%)

Longitudinal change (%)

Electrical:

Dielectric withstand (volts)

Volume resistivity (ohm-cm)

Chemical:

Corrosion

Copper stability (158°C 168 hrs)

Elongation (%)

Water absorption (%)

Fluid resistance (230°C, 24 hrs)


Flammability

Shrink temperature, nominal

UL 224

UL 224

ASTM D792

AMS-DTL-23053

UL 224

ASTM D882

UL 224

AMS-DTL-23053

UL 224

UL 224

UL 224

UL 224

ASTM D570

AMS-DTL-23053

UL 224 VW-1

1500 min

200 min

1.35 max

No cracking

100 min

25000 min

50 max

+5

2500 min

1.0 X 1014 min

No corrosion

100 min

0.5 max

1000 min

pass

90°C

Cleeve cage code is 3AN64




Typical Features:

• M053-5TW is a very flexible, flame retardant, heat shrinkable polyolefin tubing;

• M053-5TW is available in multiple colours and sizes with white and black being most common;

• Shrink temperature is 90°C. Storage life is indefinite;

• Operating temperature range is -55°C to +135°C;

• M053-5TW is recommended for many applications where protection, colour coding, identification or ‘packaging’ is required.


• Standard colours: Black, white, yellow, blue • How to order: (type of material) (size) (colour)

• Standard package: Spooled (S) Example: M053-5TW 1/4” Black

M053-5TW Data SheetFlexible polyolefin, low recovery temperatures.

Data Sheet

Physical:


Elongation (%)

Specific gravity


Heat resistance (1580°C, 168 hrs.)

Elongation (%)



Electrical:



Chemical:

Heavy metals content

Water absorption


ASTM D638

ASTM D638

ASTM D792

AMS-DTL-23053E

ASTM D638

ASTM D882

AMS-DTL-23053E

ASTM D876

ASTM D876

ASTM D570

1500 min

200 min

1.0 max

No cracking

100 min

25000 min

+5, -15

500 min

1.0 X 1015 min

<1 ppm

0.2 max

115°C

Standard Sizes

Normal Inside Diameter Inside Diameter Wall Thickness

Size As Supplied (min) After Recovery (max) After Recovery (nom)

(in) (mm) Inch (mm) Inch (mm)

3/64 0.046 1.20 0.023 0.60 0.016 0.40

1/16 0.063 1.60 0.031 0.80 0.017 0.43

3/32 0.093 2.40 0.046 1.20 0.020 0.51

1/8 0.125 3.20 0.062 1.60 0.020 0.51

3/16 0.187 4.80 0.093 2.40 0.020 0.51

1/4 0.250 6.40 0.125 3.20 0.025 0.64

3/8 0.375 9.50 0.187 4.80 0.025 0.64

1/2 0.500 12.70 0.250 6.40 0.025 0.64



S e c t i o n 5



Examples of CTI specification control data sheets available in support of all M053 series heat shrinkable tubing.

Typical Features:

• M053-1C1 is a rubber-like, flame retarded chlorinated polyolefin heat-shrinkable tubing which meets or exceeds all the requirements of Military Specifications AMS-DTL-23053/1CClasses 1 and 2.

• Shrink temperature is 150°C.

• Operating temperature range is -75°C to +120°C and up to 200°C for short durations.

• M053-1C1 is recommended for general purpose applications which require excellent abrasion and chemical resistance, such as the protection of wire bundles in diesel fuel environments. M053-1C1 has excellent properties at low temperatures.


• Standard colours: Black • How to order: (type of material) (size) (colour)

• Standard package: Spooled (S) Example: M053-1C1 1/4” 0 (Black)

Standard Sizes



(min) (max) (nom)


1/8 0.125 3.2 0.062 1.6 0.027 0.70

3/16 0.187 4.8 0.093 2.4 0.033 0.84

1/4 0.250 6.4 0.125 3.2 0.035 0.90

3/8 0.375 9.5 0.187 4.8 0.040 1.00

1/2 0.500 12.7 0.250 6.4 0.048 1.20

5/8 0.625 15.9 0.315 8.0 0.051 1.30

3/4 0.750 19.1 0.375 9.5 0.057 1.40

Standard Sizes



(min) (max) (nom)


7/8 0.875 22.2 0.433 11.0 0.065 1.65

1 1.000 25.4 0.500 12.7 0.070 1.80

1-1/4 1.250 31.8 0.625 15.9 0.080 2.00

1-1/2 1.500 38.1 0.750 19.1 0.080 2.00

1-3/4 1.750 44.5 0.875 22.2 0.095 2.40

2 2.000 50.8 1.000 25.4 0.095 2.40

M053-1C1 Flexible Chlorinated Polyolefin Heat shrinkable Harnessing Tubing

Data Sheet


Specification Reference: AMS-DTL-23053/1C, Class 1 and Class 2

Physical:


Elongation (%)

Specific gravity


Heat shock (200°C, 4 hrs)

Heat resistance (150°C, 168 hrs)

Elongation (%)


(200% elongation)

Deformation (125°C, 1 hr) (%)


Electrical:



Chemical:

Corrosion (150°C, 16 hrs)

Water absorption (%)

Fluid resistance (23°C, 24 hrs)


Flammability


ASTM D 638

ASTM D 638

ASTM D 792

AMS-DTL-23053

AMS-DTL-23053

ASTM D 638

ASTM D 412

AMS-DTL-23053

ASTM D 876

ASTM D 876

AMS-DTL-23053

ASTM D570

AMS-DTL-23053

AMS-DTL-23053

1500 min

250 min

1.3 max

no cracking

no cracking

200 min

2500 max

+5, -10

300 min

1.0 X 1014 min

no corrosion

1.0 max

1000 min

pass

150°C




Orig. Diam. Length Colour and Part NumbersInches Feet Black White Red Orange Yellow Green Blue Violet Grey Clear*

Single Wall Heat Shrinkable Tubing• Cost effective, single wall polyolefin

• Excellent flexibility and high flame-retardance

• Low shrink temperature—shrinks 2:1 at 90°C (194°F)

• MIL-I-23053/5, class 1 and 3

• UL recognized and CSA certified at 125°C (257°F), 600V

• Wide range of sizes and colours

Small and Medium Spools (also available in larger spools see next page)

CTI13000 Series

Small Spools

3/64 25 CTI12100 CTI12190 CTI12110

1/16 25 CTI12009 CTI12099 CTI12029 CTI12039 CTI12049 CTI12059 CTI12069 CTI12079 CTI12089 CTI12019

3/32 25 CTI12200 CTI12290 CTI12210






Medium Spools

3/64 100 CTI13100 CTI13110


3/32 100 CTI13200 CTI13290 CTI13210







1 10 CTI13006 CTI13096 CTI13026 CTI13036 CTI13046 CTI13056 CTI13066 CTI13076 CTI13086 CTI13016

1-1/2** 8 CTI13007 CTI13097 CTI13027 CTI13037 CTI13047 CTI13057 CTI13067 CTI13077 CTI13087 CTI13017

2** 6 CTI13008 CTI13098 CTI13028 CTI13038 CTI13048 CTI13058 CTI13068 CTI13078 CTI13088 CTI13018

*Clear is not CSA/UL rated as flame retardant.

**1-1/2” and 2” are packaged in a poly bag.

S e c t i o n 5


Bulk ProgramNote: Some sizes and colours are available by special order only. Contact CTI Customer Service with your requirements.

4 ft. lengths in poly bags

Large Spools

CTI19000 Series

Orig. Diam. Pieces Colour and Part NumbersInches Per Bag Black White Red Yellow Green Blue Clear*

1/16 25 CTI91009 CTI91099 CTI91029 CTI91049 CTI91059 CTI91069 CTI91019








1 10 CTI91006 CTI91096 CTI91026 CTI91046 CTI91056 CTI91066 CTI91016

1-1/2 5 CTI91007 CTI91097 CTI91027 CTI91047 CTI91057 CTI91067 CTI91017




Orig. Diam. Length Colour and Part NumbersInches Feet Black White Red Orange Yellow Green Blue Violet Grey Clear*













1-1/2 125 CTI19007 CTI19097 CTI19027 CTI19037 CTI19047 CTI19057 CTI19067 CTI19077 CTI19087 CTI19017





Cutting ServiceCustom cutting is available. Select the part number from the “Large Spools” table.(Minimum order must be the equivalent of one spool). Contact customer service for details.



Part # by Blister Card Polybag PolybagColour & Pack Size (3” lengths) (6” lengths) (4 ‘ lengths)Size Original Diam. # Pcs Black # Pcs Black Clear # Pcs Black Clear

Assorted (Sizes) 5 CTI14000 7 CTI15000 CTI15010 n/a n/a n/a

#1 0.225” 10 CTI14001 14 CTI15001 CTI15011 25 CTI54801 CTI54811




Clear tubing allows

for easy inspection

Dual Wall Heat Shrinkable Tubing• Semi-rigid, flame-retardant polyolefin jacket

• Inner layer of specially formulated adhesive

• High shrink ratio of 4:1

• Extended temperature range of -40°C to 130°C (-40°F to 266°F)

• Markings for size

• UL 224 600V, 125°C

Thermafix Plus™ is a semi-rigid, ‘dual wall’ tubing, designed to meet automotive industry

requirements for environmental sealing. As the tubing is heated, an inner wall of adhesive

melts and flows to form an effective barrier against automotive fluids and moisture. This

helps to protect the harness from the effects of corrosion and water wicking.

OEM Approved

Adhesive lined, seals and protects

Thermafix DWP™ (Flexible)• Flexible, flame-retardant polyolefin jacket

• Available from 1/8” to 1” original diameter

• High shrink ratio of 3:1

• Adhesive lining

• Meets UL 224 600V, 125°C and MIL-I-23053/4

Thermafix DWP™ is a flexible, ‘dual wall’ tubing, used for sealing

and protecting mechanical and electrical systems (including splices,

breakouts, and connector-to-cable transitions).

Original Poly bag (12” lengths) Poly bag (4 ‘ lengths)Diameter (in) Pcs Black Red Pcs Black Red

1/8 8 CTI31100 CTI31120 50 CTI31400 CTI31420

3/16 8 CTI31101 CTI31121 50 CTI31401 CTI31421

1/4 8 CTI31102 CTI31122 25 CTI31402 CTI31422

3/8 8 CTI31103 CTI31123 25 CTI31403 CTI31423

1/2 8 CTI31104 CTI31124 25 CTI31404 CTI31424

3/4 4 CTI31105 CTI31125 25 CTI31405 CTI31425

1 4 CTI31106 CTI31126 15 CTI31406 CTI31426

1-1/2 4 CTI31107 CTI31127 15 CTI31407 CTI31427

Thermafix DWP™ is now available in other colours by special order only (minimum quantities apply)

S e c t i o n 5


Heavy Duty & Self-SealingHeat Shrinkable Tubing• Provides excellent strain relief and abrasion protection

• Shrink ratio as high as 3:1

• Meltable lining provides protection underwater and underground

(for without meltable lining, see Thermafix ST™ Non-Adhesive below)

• Rated for up to 600 volts, 90°C (194°F) continuous

• Meets UL Standard

Available in various lengths as follows:

Thermafix ST™ Non-Adhesive

Thermafix ST™in popular sizesfor automotiveapplications.General purpose sealant lining

provides an environmental seal and

will adhere to non-oily substances. The

tubing can be removed where re-entry

is necessary.

Diameter For Cable Range (8” pcs)* (12” pcs)* (4 ‘ pcs)*

(original)(final) (AWG/MCM) Pcs Part # Pcs Part # Pcs Part #

in. in. /bag Black Red /bag Black Red /bag Black Red

0.40 0.15 #14 - #10 4 CTI80604* CTI70604* 4 CTI81004* CTI71004* 10 CTI83004* CTI73004*

0.75 0.22 #8 - #1 4 CTI80807 CTI70807 4 CTI81207 CTI71207 10 CTI84807 CTI74807

1.10 0.38 #2 - #4/0 2 CTI80811 CTI70811 2 CTI81211 CTI71211 5 CTI84811 CTI74811

1.30 0.38 #2 - #4/0 2 CTI80813 2 CTI81213 5 CTI84813

1.50 0.50 #2/0 - 500 2 CTI80815 2 CTI81215 2 CTI84815

1.70 0.50 #2/0 - 500 2 CTI80817 2 CTI81217 2 CTI84817

2.00 0.75 #350 - 1000 2 CTI80820 2 CTI81220 2 CTI84820

3.00 1.25 #900 - 1500 2 CTI80830 2 CTI81320 2 CTI84830

4.00 1.75 #1500 - 2500 2 CTI80840 2 CTI81240 2 CTI84840

*Important: Diam. 0.40 is available in lengths of 6”, 10” or 30” (i.e. not 8”, 12” or 4’)

Diameter (in) Length (in) # of Pcs Colour Part #

0.75 48 10 Black CTI84807NA

1.1 48 5 Black CTI84811NA

1.5 48 2 Black CTI84815NA

Diameter (in) Length (in) # of Pcs Colour Part #

1.10 1.5 6 Black CTI15005

1.10 1.5 6 Red CTI15025

1.10 1.5 6 3 Black & 3 Red CTI15085

1.10 6.0 2 Black CTI15605

1.10 6.0 2 Red CTI15625

0.75 6.0 4 Black CTI80607

0.75 6.0 4 Red CTI70607



Braided PET Sleeving• Bundling • Organization • Colour Coding• Chafe Proofing • Wire Harnessing

Electrical TapeHigh quality 7 mil thick PVC electrical tape is 18 mm

(3/4”) wide x 20 m (66’) long and is CSA approved.

Sold in sleeves of 6 in several colours.

Standard Colours0-Black

1-Clear

2-Red

3-Orange

4-Yellow

Custom ColoursB-Beige

P-Pink

2N-Neon Red

5-Green

6-Blue

7-Purple

8-Grey

9-white

4N-Neon Yellow

5N-Neon Green

6N-Neon Blue

Size Nominal Length Part Numbers

Diameter

Inches Inches Feet Black Clear Red Orange Yellow Green Blue Purple Grey White

Standard Colours

3/8 3/16 to 5/8 500 CTI50038-0 CTI50038-1 CTI50038-2 CTI50038-3 CTI50038-4 CTI50038-5 CTI50038-6 CTI50038-7 CTI50038-8 CTI50038-9

3/8 3/16 to 5/8 50 CTI55038-0 - - - - - - - CTI55038-8 -

1/2 1/4 to 3/4 500 CTI50012-0 CTI50012-1 CTI50012-2 CTI50012-3 CTI50012-4 CTI50012-5 CTI50012-6 CTI50012-7 CTI50012-8 CTI50012-9

1/2 1/4 to 3/4 50 CTI55012-0 - - - - - - - CTI55012-8 -

3/4 1/2 to 1-1/4 250 CTI50034-0 CTI50034-1 CTI50034-2 CTI50034-3 CTI50034-4 CTI50034-5 CTI50034-6 CTI50034-7 CTI50034-8 CTI50034-9

3/4 1/2 to 1-1/4 25 CTI52034-0 - - - - - - - CTI52034-8 -

1-1/4 3/4 to 1-3/4 250 CTI50125-0 CTI50125-1 CTI50125-2 CTI50125-3 CTI50125-4 CTI50125-5 CTI50125-6 CTI50125-7 CTI50125-8 CTI50125-9

1-1/4 3/4 to 1-3/4 25 CTI52125-0 - - - - - - - CTI52125-8 -

*Note: Some colours are not kept in stock and are available by special order and are subject to minimum order quantity.

PET is braided from a 10 mil

monofilament yarn of polyethyl-

ene terephthalate. It is especially

useful in passive applications

where flexibility, durability and

economy are important con-

siderations.

Part #

CTI33001 PVC Elect tape black 20 m 6pk

CTI33002 PVC Elect tape 3 black & 3 red 20 m 6pk

CTI33003 PVC Elect tape 3 black & 3 orange 20 m 6pk

CTI33004 PVC Elect tape 3 black & 3 yellow 20 m 6pk

CTI33005 PVC Elect tape 3 black & 3 green 20 m 6pk

CTI33006 PVC Elect tape 3 black & 3 blue 20 m 6pk

CTI33007 PVC Elect tape 3 black & 3 purple 20 m 6pk

CTI33008 PVC Elect tape 3 black & 3 white 20 m 6pk

CTI33009 PVC Elect tape 3 black & 3 grey 20 m 6pk

Tape AssortmentAn assortment of PVC tape in 5 different colours.

Each roll is 3.7 m (12’).

Part #

CTI73250 Elect Tape 5 x 3.7 m Colour Assortment

Self-Bonding Tape

Self-Bonding Tape bonds to itself to form a rubber

covering. By stretching the tape, its adhesive like

properties are activated. Has many uses around the

home and shop.

Weather Resistant TapeCold and weather resistant. This 8 mil thick tape is

18 mm (3/4”) wide x 20 m (66’) long and is CSA

approved. Sold in sleeves of 6.

Part #

CTI38901 Weather Resistant Tale 20 m

Part #

CTI69972 Self Bonding Tape

S e c t i o n 5


Elastomeric Sleeving for Wire & CableNeoprene Rubber ‘Hellermann’ Sleeves

Hellermann brand neoprene rubber sleeves are ideally suited for identification and protection of wire terminations. Available in a wide

variety of colours, they can be installed quickly by stretching (up to 5x) using the 3-pronged applicator tools shown below. Known as

‘H-Series’ sleeves, these are very popular in the telecommunications and broadcasting industries where quick removal can be important.

• Temp. range of -65°C to 95°C

• Sizes (Diam) from 1.2 mm to 20 mm

• Available in all international resistor colour codes, as well as pink

Please contact customer service for other formulations available:

TH Series Neoprene for applications where thinner wall thickness is required

HT Series (Nitrile Rubber) for higher temperature environments (up to 120°C)

SLP Series (Silicone Rubber) for even higher temperatures (up to 180°C)

P Series (PVC) thin wall and colour-coded, wire identification markers.

‘H’ Series Standard Pack SizesPart # Nominal ID Nominal Wall Standard Pack Standard Lengths Available

(mm) (mm) Size 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”

CTIH12 1.20 0.75 1000 • • • • •

CTIH15 1.50 0.75 1000 • • • • •

CTIH20 2.00 0.75 1000 • • • • •

CTIH25 2.50 0.75 1000 • • • • •

CTIH30 3.00 0.75 1000 • • • • •

CTIH40 4.00 1.00 1000 • • • • •

CTIH50 5.00 1.00 1000 • • • • •

CTIH75 7.50 1.25 100 • • • • •

CTIH100 10.0 1.50 100 • • • • •

CTIH150 15.0 1.70 100 • • • • •

CTIH200 20.0 2.00 100 • • • • •

AccessoriesPart #

CTID-Kit Tool body, 3 prongs, lubricant & sizer

CTISFT-3033 Replacement ‘SS’ prongs for above

CTISFT-3034 Replacement ‘S’ prongs for above

CTISFT-3035 Replacement ‘K’ prongs for above

CTISS Tool Tool for H12 to H20 x 3/4” long

CTIS Tool Tool for H25 to H40 x 3/4” long

CTIK Tool Tool for H50 to H100 x 1-1/4” long

CTIG Tool Tool for H150 to H200 x 2” long

CTIHD-SS Heavy duty ‘SS’ tool

CTIHD-S Heavy duty ‘S’ tool

Part #

CTIHD-K Heavy duty ‘K’ tool

CTIHD-G Heavy duty ‘G’ tool

CTILube-M Type ‘M’ lubricant 284 ml

To order please specify: Part # - Length - Colour Code eg. H20-3/4-2 (2.0 mm ID, 3/4” long, Red)

K-Tool Heavy Duty

S-Tool

D-Kit Complete with:

• Tool body

• 3 prongs

• Lubricant

• Sizer

Color Code0-Black1-Brown

2-Red3-Orange4-Yellow

5-Green6-Blue7-Violet

8-Grey9-WhiteP-Pink



Looms and TubingPolyethylene Slit LoomSlit seam construction allows for easy wire insertion and repair, yet

retains wire even when bent or twisted. Maximum temperature

93˚C (200˚F). Ideal for protecting wire from heat, sunlight, water,

snow, ice, salt, friction and vibration wear, fraying and puncture.

UV stabilized black.

Diam. Length Colours and Part #’s(in) (ft) Black White Red Yellow Blue Teal Purple

Convenience Packs

1/4 12 CTI47114


3/8 10 CTI47138


1/2 8 CTI47112


5/8 50 CTI47058


1 50 CTI47010

1-1/4 50 CTI47125

Bulk Packs




5/8 800 CTI47958


1 300 CTI47910

1-1/4 250 CTI47925

1-1/2 150 CTI47915

2 100 CTI47920

Note: Some sizes and colours are avail-

able by special order only. Contact cus-

tomer service to determine availability.

Slit Loom Installation Tool

Diameter Length Part #

(in) (ft) Black

Convenience Packs

1/4 50 CTI48014

3/8 50 CTI48038

1/2 50 CTI48012

5/8 50 CTI48058

3/4 50 CTI48034

1 50 CTI48010

Diameter Length Part #

(in) (ft) Black

Bulk Packs

1/4 3200 CTI48914

3/8 1900 CTI48938

1/2 1100 CTI48912

5/8 800 CTI48958

3/4 550 CTI48934

1 300 CTI48910

1-1/4 250 CTI48925

1-1/2 150 CTI48915

Part #

CTI50241 For smaller diameters (1/4”, 3/8” & 1/2”)

CTI50242 For larger diameters (1/2”, 5/8” & 1”)

High TemperatureNylon Slit LoomSuitable for engine compartments this nylon slit loom,

identified by a grey stripe, has a temp-

erature rating of 149˚C (300˚F)

S e c t i o n 5


Plastic LoomProvides a neat, professional appearance.

Flexible plastic facilitates easy wire feeding.

Maximum temperature rating 90˚C (194˚F).

Fiber LoomDurable non-metallic loom withstands abrasion,

provides excellent protection against electrical

interference and short circuits. Saturated with an

asphalt compound to provide moisture protec-

tion. Maximum temperature rating 135˚C (275˚F).

Braided Nylon SleevingA protective wire covering, designed to be used where a combi-

nation of abrasion resistance and high flexibility must be obtained

at a moderately high temperature. Ideal for automotive wire

harnesses and in commercial applications such as robotics and

assembly equipment where continuous flexing is required.

Operating Temp. Range: 55°C (-67°F) to +170°C (338°F)

Shrinkage: 7% max @ 100°C

Abrasion resistance: 1,300,000 cycles

Note: where chemical, electrical and temperature resistance are

not required, see our general purpose PET monofilament braided

sleeving on next page.

Spiral WrapFor protection of wire bundles from 0.063” to 7”.

Polyethylene (UL flammability-not rated).

Vinyl Coated Braided Fiberglass SleevingA new alternative to the traditional, asphalt-saturated Fiber Loom.

This vinyl-coated, heavy duty insulating sleeving is especially suit-

ed where a combination of electrical characteristics, chemical

resistance, thermal properties and cut-through resistance is

required. Ideal as a protective covering on leadwires, connectors

in motors, transformers and similar apparatus.

Operating Temperature Range:-20°C (-4°F) to +130°C (266°F)

Dielectric Strength: 4000 volt min. avg. (MIL-I-21557)

Other Ratings: VW-1 flame retardant, UL #E80713

Bench Mount Hot Knife110 volt ACThis tool enables the operator to draw the sleeving down across the knife blade - under tension. Both hands are thenfree to manipulate the sleeving and to seal and flare the ends.

• Tool should be used in well

ventilated areas.

• Warms up in less than 30 seconds.

• Cuts through a 1” nylon

line in ten seconds.

Part # ID Size Length

CTI69841 1/4” (6.40 mm) 100’ coil (30.5 m)

CTI69843 3/8” (9.50 mm) 100’ coil (30.5 m)

CTI69845 1/2” (12.70 mm) 100’ coil (30.5 m)

CTI69847 5/8” (15.90 mm) 100’ coil (30.5 m)

Part # ID Size Length

CTI69801 1/4” (6.4 mm) 100’ coil (30.5 m)

CTI69803 3/8” (9.5 mm) 100’ coil (30.5 m)

CTI69805 1/2” (12.7 mm) 100’ coil (30.5 m)

CTI69807 5/8” (15.9 mm) 100’ coil (30.5 m)

CTI69833 3/4” (19.1 mm) 25’ coil (7.6 m)

CTI69859 1” (25.4 mm) 25’ coil (7.6 m)

Part # - Spool Size (ft)

Diameter 50 100 250 500

3/8 CTI69200 CTI69400

1/2 CTI69201 CTI69401

3/4 CTI69202 CTI69402

1 CTI69203 CTI69403

Part # - Spool Size (ft)

Diameter 50 100 250

1/3 CTI69000 CTI69100

1/2 CTI69001 CTI69101

3/4 CTI69002 CTI69102

1 CTI69003 CTI69103

Diameter Bundle Range (in) Part #(in) min max Natural Black

1/8 0.063 0.50 CTI49018 CTI59018

1/4 0.188 2.00 CTI49014 CTI59014

3/8 0.313 3.00 CTI49038 CTI59038

1/2 0.375 4.00 CTI49012 CTI59012

3/4 0.750 5.00 CTI49034 CTI59034

1 1.000 7.00 CTI49010 CTI59010

Part #

CTIHKBM Bench Mount Hot Knife



Thermafix DCTM Flexible, Flame-Retardant, Dual Colour Polyolefin TubingUsed to identify ‘ground’ on wires and in cables, and to jacket and insulate light duty harnesses.

• CSA/UL rated for 600V, 125ºC

• Shrink ratio of 2:1

• Dual colours (yellow/green) for instant identification

• Flame retardant

• Flexible to conform to irregular shapes

• Excellent physical, chemical and electrical properties that meet

industry standards for highly reliable, general purpose tubing

Thermafix AdhesiveTM Hot Melt Glue in Film FormNot heat shrink tubing, but ideal for use with non-adhesive lined heat shrink

tubings in low temperature applications. Simply place underneath tubing,

prior to heating, and material will melt and flow similar to pre-installed

adhesive linings. Use with single wall tubing to get dual wall results.

Thermafix Kynar® High TemperatureHeat Shrinkable Tubing• Semi-rigid, high performance, flame resistant,

polyvinylidene fluoride

• Ideal for high temperature applications to 175°C (347°F)

• Superior chemical and solvent properties


• Meets CSA Std 198 OFT 600V, 125°C ; UL224 VW-1; and,

MIL-I-23053/8

• Standard colour is clear

Other Specialty Heat Shrink Products and Tubing:Thermafix 3XTM Low Shrink Temperature/High Shrink Ratio Heat Shrinkable Tubing• Very flexible, highly flame retardant,

low-shrink temperature polyolefin


• UL VW-1and CSA OFT

• Standard colours are black and white

(for custom colours please contact us)

Original Medium Spools Bulk Spools

Diameter Part # Part #

(in) (ft) Black White (ft) Black White

1/4 75 CTI23002 CTI23092 250 CTI23902 CTI23992

3/8 50 CTI23003 CTI23093 200 CTI23903 CTI23993

1/2 40 CTI23004 CTI23094 150 CTI23904 CTI23994

3/4 20 CTI23005 CTI23095 250 CTI23905 CTI23995

1 10 CTI23006 CTI23096 250 CTI23906 CTI23996

1-1/2* 8 CTI23007 CTI23097 98 CTI23907 CTI23997

*1-1/2” x 8’ is poly bagged

Original Diameter Medium Spools Bulk Spools

(in) (ft) Yellow Green (ft) Yellow Green

1/8 100 CTI13451 450 CTI19451

1/4 75 CTI13452 225 CTI19452

3/8 50 CTI13453 150 CTI19453

1/2 40 CTI13454 150 CTI19454

3/4 20 CTI13455 150 CTI19455

1 10 CTI13456 75 CTI19456

Original Diameter Standard 4 ft Lengths

(in) Pcs Part # Pcs Part #

1/16 50 CTI29009 10 CTI29019

3/32 50 CTI29200 10 CTI29210

1/8 50 CTI29000 10 CTI29010

3/16 50 CTI29001 10 CTI29011

1/4 25 CTI29002 5 CTI29012

3/8 25 CTI29003 5 CTI29013

1/2 25 CTI29004 5 CTI29014

3/4 25 CTI29005 5 CTI29015

Part # Width Length

CTI10175 1” 5’ strip

CTI10170 1” 50’ roll

S e c t i o n 5


Custom Cut & Printed Thermafix® Whether for identification or function, custom cut and printed Thermafix® is an effective and economical solution.

Flat

Height

is 1.25”

Side view

-------------------- Cross-sectional view --------------------

Example for 3/4” tubing:A B C D

(Original diameter) (Full recovery 2:1) (Full recovery 3:1)

3/4” 3/8”

Design

Determine elements required such as:

• Text/description

• Logos (e-mail or supply disk with graphics file in .jpeg or .tiff format)

• Any sequential numbering required (e.g. serial numbers)

• Submit a sample drawing using ‘flat height’ sizing

• Please allow an adequate margin on all sides of image

Other Considerations

• Available cut, or not cut (i.e. rolled)

• Available in single or dual wall (black only)

• Heat Shrinkable adhesive tape available for extra durability and grip

Colours Available

Colours of tubing available:

2:1 Shrink Ratio

3:1 Shrink Ratio

Colours of print available:

Sizing

• Tubing is available in 2:1 or 3:1 shrink ratios.

• Pieces are available in any length (priced perinch). Most common lengths are 1 to 2” ( 25 to50 mm).

• Printing can be on one or both sides of the flat-tened tube. Flat tube ‘height’ in relation toround diameter is shown as per the followingexample and in the table below:

1/4”

A B C D

(Flat height) (Original diameter) (Full recovery 2:1) (Full recovery 3:1)9/32 1/8 1/16 N/A

12/32 3/16 3/32 N/A

7/16 1/4 1/8 1/12

9/16 3/8 3/16 1/8

7/8 1/2 1/4 1/6

1-1/4 3/4 3/8 1/4

1-11/16 1 1/2 1/3

2-3/8 1-1/2 3/4 1/2

Grey Violet Orange

White Black Red Yellow Blue Green

White Black Red

Black Silver White Blue Red Green Gold

ID MARKER

ID MARKERCLEEVE CABLE

1

4

6 7

5

3

2

8

HARNESS NUMBER

LENGTH A

1.0 TYP.3

NOTES, UNLESS OTHERWISE SPECIFIEDIDENTIFICATION MARKER TO BE USED AT EACH CONNECTOR END1.

SHIELDS CONNECTED TO PIN "E" ON BOTH CONNECTORS2.


ITEM 7 TO BE APPLIED OVER MARKERS

3

-1

REVISIONS


- PRELIMINARY RELEASE AUG 24 2006 PC

1 ADD BAND MARKERS, TITLE CHANGE, BOM MOD OCT 4 06 PC

2 ADD PART MARKER, EDIT BOM OCT 17 06 CS

ITEM NO. PART NUMBER DESCRIPTION QTY.1 FAE-3475-14-5SN CONNECTOR, PLUG 12 SB-CABO-1406-UN40 BACKSHELL 23 FMP-K121-25WA MOULDED PART 24 FAE-3474-14-5PN CONNECTOR, RECEPTICLE 1

5 FRCL-AA001BA CABLEA/R

SEE LENGTH "A"ADD10%

6 M053-5-3/4-9 (WHITE) HEAT SHRINK TUBING (50mm) 3

7 M053-5-3/4-C (CLEAR) HEAT SHRINK TUBING (60mm) 3

8 M053-5-1-4 (YELLOW) HEAT SHRINK TUBING (30mm) 3

CONFIG LENGTH A-1 9FT



NEXT ASSY USED ON

APPLICATION



FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


TITLE:

SIZE

BDWG. NO. REV

SCALE : NA


2

CS AUG 24 06

CLEEVE HARNESSEXAMPLE 3

SHEET 1 OF 2

EXAMPLE 2DO NOT SCALE DRAWING CAGE: 3AN64

MATERIAL

kits, assemblies and feedthroughskits, assemblies and feedthroughsS e c t i o n 6


CTI Value Added Solutions and CapabilitiesCTI can provide products in component form such as kits, sub assemblies or as finished and tested

assemblies. CTI can support existing designs, from ‘build to print’ to suggestions of product improvements

and cost saving opportunities through to new designs supported with samples, drawings and test data.

Mechanical Engineering, Design and Manufacturing Capabilities:

• Conceptual design providing 3D models and 2D drawings to current industrial/aerospace standards

• Fabrication services for machined and sheet metal components and assemblies, complex and standard

- Mechanical piece parts/assemblies, enclosures, chassis and test boxes

- Production/manufacturing assembly tooling

- Tooling/jigs/fixtures and mechanical test equipment

• Prototype and production manufacturing

• Mechanical packaging

• Mature product design improvement and feasibility studies

- Cost effective design analysis incorporating design modifications to avail more economic

manufacturing utilizing current processes and procedures to reduce cost and lead times

• Build to print prototype, pre and full production manufacturing/assembly

• Concurrent engineering and advanced manufacturing

Complementing these capabilities, CTI can provide turn key support to the design, manufacture, finishing,

assembly and delivery of our products.

14' - .0+3.0 INCHES INCHES1.0+

.0-2'

6' - .0+2.0 INCHES



NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL .005THREE PLACE DECIMAL


MATERIAL

FINISH

SEE DETAIL

NA

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAMECLEEVE TECHNOLOGY INCORPORATED

TITLE:

SIZE

BDWG. NO. REV

SCALE: NA


2

CS SEP 18 06

EXAMPLE 1 CLEEVEHARNESS

SHEET 1 OF 2

EXAMPLE 1DO NOT SCALE DRAWING CAGE: 3AN64


3 ITEM 9 TO BE APPLIED OVER MARKERS

IDENTIFICATION MARKER TO BE USED AT EACH CONNECTOR END1.

SHIELDS CONNECTED TO PIN "E" ON ALL CONNECTORS2.


3

REVISIONS


- PRELIMINARY RELEASE OCT 2 06 PC

1 ADD BANDMARKER, TITLE CHANGE, BOM MODADD SCHEMATIC OCT 5 06 PC

2 MODIFY LENGTHS, PART NUMBERS, CABLE ROUTING OCT 17 06 CS

ITEMNO. PART NUMBER DESCRIPTION QTY.

1 FAE-24-WC35PN CONNECTOR, RECEPTICLE 12 SB-BABO-1308-UN40 BACKSHELL 13 FMP-K132-25WA MOULDED PART 14 FRCL-AA004AA CABLE 33 FT5 FAE-3475-10-7SF CONNECTOR, PLUG 46 SB-CABO-1006-UN40 BACKSHELL 47 FMP-K121-25WA MOULDED PART 48 M053-5-3/4-9 (WHITE) HEAT SHRINK TUBING (50mm) 5

9 M053-5-3/4-C (CLEAR) HEAT SHRINK TUBING (60MM) 5

10 M053-5-1-2 (RED) HEAT SHRINK TUBING (30mm) 5

1

2

3

7

6

5

10

8

4

ID MARKER

ID MARKERID MARKER

ID MARKER

9

ID MARKER

2.0 INCHES

INCHES2.0+.0-4'

5' 6" - .0+

1.0 TYP

2 (RED)

S e c t i o n 6

kits, assemblies and feedthroughs | CTI | 6-85

FMP207W213 to 264 2 Part Feedthrough

Materials available:




FMP207W213 10

FMP207W223 18

FMP207W234 28

FMP207W245 42

FMP207W256 64

FMP207W264 38

Coatings Material

EL

ZH

PL

Modifications Code

Two sided nut -01

Dimensions apply to all materials unless otherwise indicated.

Expanded as supplied (min) Recovered after heating (max)

J H J K M P R S T U

12 4 23 20 62 49 13 32 10

20 7 33 30 72 59 16 42 10

31 12 46 42 87 74 18 58 10

45 18 59 56 102 89 18 71 10

68 30 84 80 122 109 18 97 10

40 15 54 50 95 82 18 67 10

Available Coatings

WA High performance hot melt adhesive



Table of dimensions (mm)



Adaptor Boot AssembliesCTI’s FRKA are one part or many part assemblies for screened and unscreened cables. Constructed from CTI heat shrinkable Molded

parts and connector adaptors, the assembly consists of parts already well proven in harsh military environments. Installation is simply

achieved by coupling the adaptor to the connector and shrinking the rear of the Molded part onto the cable with a hot air gun. The

Molded part has a hot melt adhesive pre-installed to provide a bond between the cable jacket and the Molded part. When used in con-

junction with screened cables, the assembly provides electrical continuity between the cable screen and the connector.

Assemblies for most

connector interfaces

Straight assemblies 45° assemblies 90° assemblies

FAE 347 connectors or connector Code CConnector CTI Cable OD CTI Cable OD CTI Cable ODShell Size Part # Range (mm) Part # Range (mm) Part # Range (mm)

EL fluid resistant elastomer 08 FRKA0520 5.0-9.0 FRKA0560 5.0-8.0 N/A N/A10 FRKA0521 6.0-12.0 FRKA0561 6.0-10.0 FRKA1051 6.0-13.012 FRKA0522 7.2-16.0 FRKA0562 7.2-12.0 FRKA1052 7.2-16.014 FRKA0523 7.2-16.0 FRKA0563 7.2-12.0 FRKA1053 7.2-16.016 FRKA0524 8.5-20.0 FRKA0564 8.5-18.0 FRKA1054 8.5-20.018 FRKA0525 8.5-20.0 FRKA0565 8.5-18.0 FRKA1055 8.5-20.020 FRKA0526 10.0-24.0 FRKA0566 10.0-22.0 FRKA1056 10.0-24.022 FRKA0527 10.0-24.0 FRKA0567 10.0-22.0 FRKA1057 10.0-24.024 FRKA0528 15.8-34.0 FRKA0568 15.8-30.0 FRKA1058 15.8-34.0

ZH Low fire hazard material 08 FRKA0465 5.0-8.0 FRKA0603 5.0-8.0 N/A N/A10 FRKA0466 6.0-10.0 FRKA0604 6.0-10.0 FRKA1251 6.0-10.012 FRKA0467 7.2-12.0 FRKA0605 7.2-12.0 FRKA1252 7.2-12.014 FRKA0468 7.2-12.0 FRKA0606 7.2-12.0 FRKA1253 7.2-12.016 FRKA0469 8.5-18.0 FRKA0607 8.5-18.0 FRKA1254 8.5-18.018 FRKA0470 8.5-18.0 FRKA0608 8.5-18.0 FRKA1255 8.5-18.020 FRKA0471 10.0-22.0 FRKA0609 10.0-22.0 FRKA1256 10.0-22.022 FRKA0472 10.0-22.0 FRKA0610 10.0-22.0 FRKA1257 10.0-22.024 FRKA0473 15.8-30.0 FRKA0611 15.8-30.0 FRKA1258 15.8-30.0

FRKA ExampleAssemblies

S e c t i o n 6


Straight assemblies 45° assemblies 90° assemblies

FAE 26 connectors or connector code BConnector CTI Cable OD CTI Cable OD CTI Cable ODShell Size Part # Range (mm) Part # Range (mm) Part # Range (mm)

EL fluid resistant elastomer 08 FRKA0840 5.0-9.0 FRKA0970 5.0-8.0 N/A N/A10 FRKA0841 6.0-12.0 FRKA0971 6.0-10.0 FRKA0851 6.0-13.012 FRKA0842 7.2-16.0 FRKA0972 7.2-12.0 FRKA0852 7.2-16.014 FRKA0843 7.2-16.0 FRKA0973 7.2-12.0 FRKA0853 7.2-16.0

ZH low fire hazard material 08 FRKA0612 5.0-8.0 FRKA0780 5.0-8.0 N/A N/A10 FRKA0613 6.0-10.0 FRKA0781 6.0-10.0 FRKA1241 6.0-10.012 FRKA0614 7.2-12.0 FRKA0782 7.2-12.0 FRKA1242 7.2-12.014 FRKA0615 7.2-12.0 FRKA0783 7.2-12.0 FRKA1243 7.2-12.016 FRKA0616 8.5-18.0 FRKA0784 8.5-18.0 FRKA1244 8.5-18.0

M5015 connectors or connector code MConnector CTI Cable OD CTI Cable OD CTI Cable ODShell Size Part # Range (mm) Part # Range (mm) Part # Range (mm)


ZH low fire hazard material 08 FRKA0444 5.0-8.0 FRKA0580 5.0-8.0 N/A N/A10 FRKA0445 6.0-10.0 FRKA0581 6.0-10.0 FRKA1021 6.0-10.012 FRKA0446 7.2-12.0 FRKA0582 7.2-12.0 FRKA1022 7.2-12.014 FRKA0447 7.2-12.0 FRKA0583 7.2-12.0 FRKA1023 7.2-12.016 FRKA0448 8.5-18.0 FRKA0584 8.5-18.0 FRKA1024 8.5-18.018 FRKA0449 10.0-22.0 FRKA0585 10.0-22.0 FRKA1025 10.0-22.020 FRKA0450 10.0-22.0 FRKA0586 10.0-22.0 FRKA1026 10.0-22.022 FRKA0451 10.0-22.0 FRKA0587 10.0-22.0 FRKA1027 10.0-22.024 FRKA0452 15.8-30.0 FRKA0588 15.8-30.0 FRKA1028 15.8-30.0

D38999 Series I and II connectors or connector code AConnector CTI Cable OD CTI Cable OD CTI Cable ODShell Size Part # Range (mm) Part # Range (mm) Part # Range (mm)


ZH low fire hazard material 08 FRKA0640 5.0-8.0 FRKA0630 5.0-8.0 N/A N/A10 FRKA0641 6.0-10.0 FRKA0631 6.0-10.0 FRKA0721 6.0-10.012 FRKA0642 7.2-12.0 FRKA0632 7.2-12.0 FRKA0722 7.2-12.014 FRKA0643 7.2-12.0 FRKA0633 7.2-12.0 FRKA0723 7.2-12.016 FRKA0644 8.5-18.0 FRKA0634 8.5-18.0 FRKA0724 8.5-18.0



Feedthrough Boot AssembliesCTI’s Cable Feedthrough System (FRFS) is available as a one-piece part or as a kit of parts providing environmental sealing and screen

continuity to a bulkhead as a cable passes through. The assembly consists of a specifically designed locknut and `O' ring seal, onto the

rear of which is pre-installed heat shrinkable Molded parts. Installation is achieved by tightening the locknut on the rear of the

bulkhead which compresses the 'O' ring and ensures a small knife edge provides electrical contact between the assembly and the

bulkhead. When heat is applied to the Molded part, in the form of hot air, a seal to the cable is formed with hot melt adhesive. When

used in conjunction with screened cables the assembly contains a conductive adhesive which provides electrical continuity between the

screen and the bulkhead via an integral shield inside the Molded parts.

- Screened or unscreened cables;

- One-piece part, or kit of parts;

- One part covers wide cable range;

- Lightweight;

- Single or double sided assembly.

FRFS - Feedthrough

Adhesive SystemWA = Pre-coated

Molded part typeA = Straight unscreened D = 45° screenedB = 90° unscreened E = 90° screenedC = Straight screened

Molded part material EL semi-rigid elastomerZH zero halogen PL Semi-rigid modified polyolefin

Thread length 20mm standard(±5mm increments - available on request)

Assembly modification code0 = Standard assembly1 = Double sided assembly (only straight unscreened

boot available on double nut)3 = LocknutFeedthrough material/finish19B Aluminum alloy plated cadmium olive drab over electroless nickel19C Aluminum alloy plated electroless nickel62C Stainless steel plated electroless nickel

Feedthrough size

PartNumberingSystem

FRFS -12 - 62C - 0 - 20 - ZH - A - WA

S e c t i o n 6


Table of dimensions (mm)Feedthrough ‘J’ Diameter ‘M’ Thread ‘A’ Diameter A/F A/F P HoleSize Unscreened Screened Max Body Nut ±10% Size

Ja Jb Ja Jb Unscreened (H7)FRFS-12 11 5.6 7.5 5.0 M12 x 1.5 7.50 24 17 31 13.0FRFS-16 15 5.9 9.5 6.0 M16 x 1.5 10.20 29 22 48 17.0FRFS-20 19 7.1 11.5 7.2 M20 x 1.5 14.20 34 27 52 21.0FRFS-24 23 8.4 17.5 8.5 M24 x 1.5 19.20 38 30 65 25.0FRFS-30 29 9.9 21.5 10.0 M30 x 1.5 24.20 48 36 64 31.0FRFS-36 35 15.7 29.5 15.8 M36 x 1.5 30.20 52 41 95 37.0FRFS-48 45 16.8 N/A N/A M48 x 1.5 40.20 67 55 135 50.0

Ja = supplied dimension. Jb = dimension after free recovery

cable ties & cable management systemscable ties & cable management systemsS e c t i o n 7


Labour Saving Wire IdentificationCTI’s wire identification systems bring the timesaving advantages of the computer and the

ruggedness of CTI’s tubing to the labour intensive world of electrical harness building.

Lists of wire labels can be easily created and edited on a computer, then printed out using

standard printing equipment. The labels meet commercial aerospace standards for mark perma-

nence. Their ladder-style configuration allows the marker sleeves to be printed on both sides.

Products include heat shrinkable marker sleeves in thin-wall and high-temperature versions,

tie-on cable markers and adhesive-backed wraparound markers for large cables or open wire

bundles, and adhesive-backed panel markers.

Terminations that Install Easily and ReliablyCTI’s large family of wire and cable interconnection devices provides high-performance

terminations that can be installed easily and reliably. In addition to electrical connections, these

products offer protection against corrosion, mechanical abuse, and the effects of electromag-

netic interference in sensitive equipment and unpressurized exposed areas.

The smallest, lightest, sealed crimp splices available, MiniSeal crimp splices preserve the quali-

ty of electrical connections.

CTI’s high-temperature shielded cable splices provide tough, low profile, fully shielded termina-

tions that can withstand the very high operating temperatures normally found in engine and

engine strut areas. When used in place of connectors, the splices maintain shielding while

saving weight and space. The splices install quickly and efficiently, and can be inspected

immediately. Splice components are available in convenient kits.

SolderSplice shield terminators can be installed quickly, yet pass the most stringent quality

assurance tests. When a device’s thermal ring melts and disappears, it gives positive indication

of a completely soldered joint. And the heat shrinkable tubing and meltable inserts provide

one-step strain-relief and encapsulation.

When repairing or connecting shielded cable, SolderSplice splices provide shielding equal to or

better than the original cable. Repeatable terminations ensure reliability and high performance.

S e c t i o n 7

cable ties and cable management systems | CTI | 7-91

Nylon Cable Ties Material SpecificationsMaterial Standard Colours Continuous Operating Temp. UL Flame Rating UV Resistance Agency Approvals

Max MinNylon 6/6 - Natural 185˚F -40˚F 94V-2 Poor MIL-M-20693A

General Purpose White 85˚C -40˚C ASTM-D 4066PA111Nylon 6/6 - Black 185˚F -40˚F 94V-2 Very good UL E64139(N)

UV Stabilized 85˚C -40˚C

Terminations Individual screens of primary wires that are to be terminated to a connector pin can be terminated with a SolderSplice termination

device. The most commonly used SolderSplice devices are detailed both with and without a primary wire lead.

The overall cable screen can be terminated by one of three termination methods: braided backshells, Tinel-lock or EMI bands.

CTI SolderSplice devices are used to terminate screened wires within FRCL or hand built cable. The device consists of a heat shrinkable

thermoplastic sleeve containing a precisely engineered preform of fluxed solder and thermoplastic inserts in each end. When placed over

a cable shield and heated, the solder melts and flows, connecting the ground lead to the cable shield. As the outer sleeve shrinks the

thermoplastic inserts melt and provide an environmentally sealed termination. SolderSplice devices are available with ground leads pre-

installed to make installation even easier.

Listed below are the most commonly used SolderSplice devices for use with wire rated up to 150°C.

For other applications consult CTI at [email protected]

SolderSplice devices

SolderSplice devices with ground lead

Cable Dimensions:

D max d min Part #

1.9 1.1 FRSS144-25

2.7 1.6 FRSS100-00

4.5 2.4 FRSS101-00

6.0 3.0 FRSS107-00

6.8 3.7 FRSS103-00

11.0 6.0 FRSS104-00

13.3 8.9 FRSS105-00

Cable Dimensions: Ground Lead Gauge (AWG)

D max d min Part #

2.7 1.6 FRSS100-34 FRSS900-01

4.3 2.4 FRSS101-34 FRSS900-02

6.8 3.7 FRSS103-34 FRSS900-03

Can be supplied with 6 inch length of M044 wire

with addition of suffix.

Example: FRSS-100-20-5

Colour

Wire AWG



StandardApproximate Approximate Max Bundle Tensile Colour Pcs/pack - Part # Length (in) Width (in) Diameter (in) Strength (lbs) 25 100 500 1000

4.00 0.10 5/8 18 Natural CTI17501 CTI17001 CTI179014.00 0.10 5/8 18 Black CTI17502 CTI17002 CTI179028.00 0.10 2.00 18 Natural CTI17015 CTI179158.00 0.10 2.00 18 Black CTI17016 CTI179166.00 0.13 1.25 30 Natural CTI17503 CTI17003 CTI179036.00 0.13 1.25 30 Black CTI17504 CTI17004 CTI179047.50 0.18 1.75 50 Natural CTI17505 CTI17005 CTI179057.50 0.18 1.75 50 Black CTI17506 CTI17006 CTI179067.50 0.18 1.75 50 Red CTI17025 CTI179257.50 0.18 1.75 50 Orange CTI17085 CTI179857.50 0.18 1.75 50 Yellow CTI17045 CTI179457.50 0.18 1.75 50 Green CTI17055 CTI179557.50 0.18 1.75 50 Blue CTI17065 CTI17965 7.50 0.18 1.75 50 Purple CTI17075 CTI17975

11.00 0.18 3.00 50 Natural CTI17507 CTI17007 CTI1780711.00 0.18 3.00 50 Black CTI17508 CTI17008 CTI1780811.00 0.18 3.00 50 Red CTI17027 CTI1782711.00 0.18 3.00 50 Orange CTI17087 CTI1788711.00 0.18 3.00 50 Yellow CTI17147 CTI1744711.00 0.18 3.00 50 Green CTI17057 CTI1785711.00 0.18 3.00 50 Blue CTI17067 CTI1786711.00 0.18 4.00 50 Purple CTI17077 CTI1787714.00 0.18 4.00 50 Natural CTI17509 CTI17009 CTI1780914.00 0.18 4.00 50 Black CTI17514 CTI17014 CTI1781417.00 0.18 4.50 50 Natural CTI17550 CTI17050 CTI1785017.00 0.18 4.50 50 Black CTI17560 CTI17060 CTI17860

MountingApproximate Approximate Max Bundle Tensile Colour Pcs/pack - Part #Length (in) Width (in) Diameter (in) Strength (lbs) 25 100 500 1000

6.0 0.140 1.25 30 Natural CTI17543 CTI17043 CTI179436.0 0.140 1.25 30 Black CTI17544 CTI17044 CTI179447.5 0.185 1.75 50 Natural CTI17510 CTI17010 CTI179107.5 0.185 1.75 50 Black CTI17513 CTI17013 CTI17913

14.0 0.187 4.0 50 Natural CTI17547 CTI17047 CTI1784714.0 0.187 4.0 50 Black CTI17548 CTI17048 CTI17848

Heavy Duty Mounting15.0 0.30 4.0 120 Natural CTI17231 CTI1703115.0 0.30 4.0 120 Black CTI17232 CTI17032

S e c t i o n 7


FluorescentApproximate Approximate Max Bundle Tensile Colour Pcs/pack - Part #Length (in) Width (in) Diameter (in) Strength (lbs) 100 1000

7.5 0.185 1.75 50 Pink CTI27025 CTI279257.5 0.185 1.75 50 Orange CTI27085 CTI279857.5 0.185 1.75 50 Blue CTI27065 CTI279657.5 0.185 1.75 50 Green CTI27055 CTI279557.5 0.185 1.75 50 Yellow CTI27045 CTI27945

Metal ToothCable Ties

Approximate Tensile Colour Pcs/pack - Part # Length (in) Strength (lbs) 50 100 500 1000

4.0 18 Natural CTI97001 CTI979014.0 18 Black CTI97002 CTI979025.5 30 Natural CTI97003 CTI979035.5 30 Black CTI97004 CTI979047.5 50 Natural CTI97005 CTI979057.5 50 Black CTI97006 CTI979068.0 120 Natural CTI97619 CTI978198.0 120 Black CTI97620 CTI97820

11.0 50 Natural CTI97007 CTI9790711.0 50 Black CTI97008 CTI9790814.0 50 Natural CTI97009 CTI9790914.0 50 Black CTI97014 CTI9791414.0 120 Natural CTI97611 CTI9781114.0 120 Black CTI97612 CTI97812

HeavyDuty Ties

Approximate Approximate Max Bundle Tensile Colour Pcs/pack - Part # Length (in) Width (in) Diameter (in) Strength (lbs) 25 50 100 500

8 0.30 2 120 Natural CTI17219 CTI17019 CTI178198 0.30 2 120 Black CTI17220 CTI17020 CTI1782014 0.30 4 120 Natural CTI17221 CTI17011 CTI1781114 0.30 4 120 Black CTI17212 CTI17012 CTI1781218 0.30 5 120 Natural CTI17131 CTI1763118 0.30 5 120 Black CTI17132 CTI1763224 0.30 7 120 Natural CTI17115 CTI1761524 0.30 7 120 Black CTI17116 CTI1761628 0.30 8 120 Natural CTI17113 CTI1761328 0.30 8 120 Black CTI17114 CTI17614

Extra HeavyDuty Ties

Approximate Approximate Max Bundle Tensile Colour Pcs/pack - Part # Length (in) Width (in) Diameter (in) Strength (lbs) 25 50

24 0.35 7 175 Natural CTI1761724 0.35 7 175 Black CTI1761836 0.35 11 175 Natural CTI1762136 0.35 11 175 Black CTI1762241 0.35 12 175 Grey CTI1762341 0.35 12 175 Black CTI1762448 0.35 15 175 Grey CTI1764948 0.35 15 175 Black CTI1765020 0.50 5 250 Black CTI1752632 0.50 10 250 Black CTI1752840 0.50 12 250 Black CTI17530



Approx. Approx. Max bundle Tensile Colour Pcs/pack - Part #Length (in) Width (in) Diam. (in) Strength (lbs) 100 1000

Releasable6.0 0.30 1.25 50 Black CTI17034 CTI179346.0 0.30 1.25 50 Natural CTI17033 CTI17933

11.75 0.30 3.0 50 Black CTI17036 CTI1793611.75 0.30 3.0 50 Natural CTI17035 CTI17935Identification8.0 0.18 1.75 50 Black CTI17040 CTI179408.0 0.18 1.75 50 Natural CTI17039 CTI17939

Button Head9.625 0.22 2.625 100 Black CTI17042 CTI17942Beaded4.20 1.14 8 Natural CTI17080 CTI17980Cord Band, Ladder Type7.10 1.85 Natural CTI17070 CTI17870

Releasable and Other Special Use Cable Ties1

2

3

4

5

ChromePlatedCable TiesModern style of cable ties

are perfect for custom

shops, bikes and other

customized vehicles.

Pcs/pack - Part # Length (in) Bundle Diameter (in) Strength (lbs) Colour 10 1008 (200 mm) 2 (50 mm) 18 Blue CTI57165 CTI570658 (200 mm) 2 (50 mm) 18 Gold CTI57185 CTI570858 (200 mm) 2 (50 mm) 18 Green CTI57155 CTI570558 (200 mm) 2 (50 mm) 18 Purple CTI57175 CTI570758 (200 mm) 2 (50 mm) 18 Red CTI57125 CTI570258 (200 mm) 2 (50 mm) 18 Silver CTI57105 CTI57005

Max. Bundle Pcs/pack - Part # Length (in) Width (in) Strength (lbs) Diameter 10 1008 (200 mm) 0.187 (4.74 mm) 150 2 (51 mm) CTI67105 CTI6700514 (360 mm) 0.187 (4.74 mm) 150 4 (102 mm) CTI67109 CTI6700920 (510 mm) 0.187 (4.74 mm) 150 6 (152 mm) CTI67111 CTI6701127 (690 mm) 0.187 (4.74 mm) 150 8 (200 mm) CTI67115 CTI6701514 (360 mm) 0.313 (7.94 mm) 250 4 (102 mm) CTI67119 CTI67019

Stainless Steel Cable TiesMade with 316 stainless steel. Resistant to temperature and moisture variations, ideal for high corrosion areas.

Cable Tie Mounting Part # Dimensions (in) Standard packSize (lbs) Screw White Black W L H quantity

4-way (adhesive-backed)18 to 30 #6 CTI27300 CT28300 0.75 0.75 0.21 10018 to 50 #6 CT27400 CT28400 1.00 1.00 0.22 100

2-way (adhesive backing)18 to 150 #6 CT27500 CT28500 1.25 1.25 0.25 100

2-way (no adhesive backing)18 to 50 #8 CT37100 CT38100 0.38 0.60 0.28 10018 to 120 #10 CT37300 CT38300 0.62 0.88 0.39 100

Cable Tie Mounting Bases

1

2

3

4

5

S e c t i o n 7


Part # Pcs/Pack

CTI66086 25

CTI66186 100

CTI66886 500

Push Mount Clips• Push mount clip (natural).

• Accepts all cable ties up to 50 lbs tensile strength. For use in 0.250”(6.4 mm) hole. 25 pack.

Cable Tie Application ToolsLT-400

• Heavy duty tool for use with 18-50 lbs ties

• Automatic cut-off and adjustable tensioning

LT-100

• Lightweight tool for use with 18-50 lbs ties

• Cinch tie to desired bundle and twist tool to removeexcess strap

Stainless Steel Tool 62866

• Steel tie gun for tensioning and cut off. Tool is a ball lockand ladder type. For use with our stainless steel ties.

ERG-299 Professional

• Ideal for assembly line use with 18-50 lb. ties

• 360˚ rotatable nose allows use in any position

• Quick tension-adjustment wheel is located towards the frontfor easy access and fast changes

• Adjustable handle

• Light weight with a well balanced centre of gravity andsmooth grip surface

Nylon Cable ClampsNylon cable clamps resist corrosion road salt, gas, oil

and solvents. Available in white or black.

Temperature rating is 85ºC (185ºF).

Part # Mounting Hole ID Size Width Pack

Diameter (in) (in) (in) Qty

White Black ‘H’ ‘D’ ‘W’

CTI22002 CT124002 0.2 (5mm) 1/8 3/8 100

CTI22004 CT124004 0.2 (5mm) 1/4 3/8 100

CTI22005 CT124005 0.2 (5mm) 5/16 3/8 100

CTI22006 CT124006 0.2 (5mm) 3/8 3/8 100

CTI22008 CT124008 0.2 (5mm) 1/2 3/8 100

CTI22010 CT124010 0.2 (5mm) 5/8 3/8 100

CTI22515 CT124515 0.2 (5mm) 1 1/2 50

CTI22518 CT124518 0.2 (5mm) 1-1/4 1/2 50

CTI22520 CT124520 0.2 (5mm) 1-1/2 1/2 50

Steel-Plated NeopreneCable ClampsNeoprene cushion for electrical insulation and vibration

absorption. Neoprene meets specifications MIL R-3065

and AMS-3209. Steel clamps are zinc

electroplated for corrosion

resistance. 10 per pack.

Add ‘-C’ to part number

for 100 piece pack.

Part # Mounting Hole ID Size Width Pack

Diameter (in) (in) (in) Qty

‘H’ ‘D’ ‘W’

CTI66321 0.27 (6.7 mm) 1/4 (6.4 mm) 9/16 (14.3 mm) 10

CTI66322 0.27 (6.7 mm) 3/8 (9.5 mm) 9/16 (14.3 mm) 10

CTI66332 0.41 (10.4 mm) 1/2 (12.7 mm) 3/4 (19.1 mm) 10

CTI66333 0.41 (10.4 mm) 5/8 (15.9 mm) 3/4 (19.1 mm) 10

CTI66334 0.41 (10.4 mm) 3/4 (19.1 mm) 3/4 (19.1 mm) 10

CTI66335 0.41 (10.4 mm) 7/8 (22.2 mm) 3/4 (19.1 mm) 10

CTI66336 0.41 (10.4 mm) 1 (25.4 mm) 3/4 (19.1 mm) 10



Loom-Type Steel Clampswith Vinyl CushionThese clamps are ideal for loom,

tubing, and wire and contain

an oval opening for

easy alignment.

Add ‘-C’ to part number

for 100 piece pack.

Part # Mounting Hole ID Width Pack

Diameter (in) Size (in) (in) Qty

CTI66087 9/32 (7.1 mm) 1/2 (12.7 mm) 1/4 (6.4 mm) 10

CTI66088 9/32 (7.1 mm) 1/2 (12.7 mm) 3/8 (9.5 mm) 10

CTI66089 9/32 (7.1 mm) 1/2 (12.7 mm) 1/2 (12.7 mm) 10

CTI66090 9/32 (7.1 mm) 1/2 (12.7 mm) 5/8 (15.9 mm) 10

CTI66091 9/32 (7.1 mm) 1/2 (12.7 mm) 3/4 (19.1 mm) 10

CTI66092 9/32 (7.1 mm) 1/2 (12.7 mm) 1 (25.4 mm) 10

CTI66093 9/32 (7.1 mm) 1/2 (12.7 mm) 1-1/2 (38.1 mm) 10

GrommetsGrommets protect wires and

cables passing through panels

while resisting oils and grease.

They can also withstand

temperatures from -40ºC to

135ºC. Also available

#CTI18500 25 pc assortment.

Part Hole Size Inside Panel Outside Grommet Pack

# ‘H’ Diameter ‘ID’ Thickness ‘P’ Diameter ‘OD’ Thickness ‘T’ Qty

CTI18301 6.4 4.0 1.6 9.5 6.4 25

CTI18302 6.4 4.8 3.2 9.5 8.7 25

CTI18303 7.5 4.0 2.4 10.3 38.9 25

CTI18304 7.9 4.8 4.8 14.7 28.6 25

CTI18305 9.5 7.9 1.6 14.3 7.9 25

CTI18306 12.7 7.9 3.2 19.1 9.5 25

CTI18307 12.7 7.9 1.6 19.0 7.9 25

CTI18308 15.9 11.1 0.8 19.1 9.5 25

CTI18309 15.9 12.7 1.2 20.6 5.1 25

CTI18310 19.1 11.9 1.6 25.4 7.9 25

CTI18311 19.1 14.3 3.0 25.4 9.5 25

CTI18312 20.0 16.0 1.6 31.8 7.9 25

CTI18313 25.4 19.1 1.6 31.8 7.9 25

CTI18314 25.4 22.2 1.6 31.8 7.9 25

CTI18315 28.6 22.2 3.2 34.9 9.5 25

Thermafix SolderSplice™ wire-to-wire splices feature a fluxed solder preform

within a heat shrinkable thermoplastic sleeve. This provides a completely

soldered, strain-relieved, encapsulated connection. The one-piece, one-step

design simplifies installation.

• Controlled soldering combined with shrink tubing in one-step

• Strain relief

• Max operating temperatures to 125°C (257°F)

• Colour-coded sealing rings

• Transparent sleeves easy to inspect

Triple action:

• Sleeve shrinks

• Center ring of solder melts to connect

• Outer rings of colour-coded plastic seal

Thermafix SolderSpliceTM Wire-to-Wire Splices

S e c t i o n 7


Thermafix CrimpTM

Heat Shrinkable and adhesive-lined, Thermafix Crimp™

products insulate and protect electrical connections from

mechanical abuse, wire pull-out, and abrasion while resisting

water, salt, and other contaminants.

• Rugged, heat shrinkable nylon

• Hot melt adhesive lining

• Transparent for easy installation

• Extended temp. range of -55˚C to 125˚C

• Colour-coded for AWG 22 to 10

• High strength crimp barrels

C

Butt Splices

Convenience PacksPcs/pack Part #

18 CTI26004

100 CTI26104Bulk PackPcs/pack Part #

1000 CTI26904


18 CTI26005

100 CTI26105Bulk PackPcs/pack Part Number

1000 CTI26905


12 CTI26006

50 CTI26106Bulk PackPcs/pack Part Number

500 CTI26806

Wire Gauge 22-18 Wire Gauge 12-10 Wire Gauge 16-14


18 CTI16004

100 CTI16104Bulk PackPcs/pack Part #1000 CTI16904


18 CTI16005

100 CTI16105Bulk PackPcs/ pack Part #

1000 CTI16905

Convenience PacksPcs/pack Part #12 CTI16006

50 CTI16106Bulk PackPcs/ pack Part #

500 CTI16806

Wire Gauge 22-18 Wire Gauge 12-10


18 CTI16001

Butt Splice Assorted


18 CTI16002

Terminals Assorted

Wire Gauge 16-14



Thermafix CrimpTMPart Numbers and Pack Sizes for Standard Shapes

Convenience PacksPcs/pack Part #18 CTI16023100 CTI16123Bulk PackPcs/pack Part #1000 CTI16923

#8 Wire Gauge 22-18


#10 Wire Gauge 22-18


1/4 Wire Gauge 22-18




#8 Wire Gauge 22-18


#8 Wire Gauge 16-14


#8 Wire Gauge 16-14








#8 Wire Gauge 12-10


#8 Wire Gauge 12-10


#8 Wire Gauge 12-10


#8 Wire Gauge 12-10


#8 Wire Gauge 12-10


#8 Wire Gauge 22-18


#8 Wire Gauge 16-14


#8 Wire Gauge 12-10

Ring Terminal

Spade Terminal

S e c t i o n 7



Male Wire Gauge 16-14


Female Wire Gauge 16-14











Bullet Terminal

Quick Disconnect

Installation Tip

Use of reflector tip attach-

ment will improve the

installation of heat shrink

terminals.

Heat Shrink Assortments

Assortment Part # CTI10002

ThermafixTM Single Wall 167 pcs (1/8-3/4 black & red)

Dual Wall ThermafixTM Plus 10 pcs (all sizes)

Heavy Wall ThermafixTM ST 4 pcs (1.1” diameter)

Thermafix CrimpTM Terminals 18 pcs (assorted)

Thermafix CrimpTM Splices 18 pcs (assorted)

Cable Ties 40 pcs (black & white)

*Starter refill for CTI10002 is available as number CTI10012(single wall only).


Thermafix CrimpTM Terminals 252 pcs (blue,yellow & red-21 types)

Thermafix CrimpTM Splices 36 pcs (blue, yellow & red)



Heat Shrink Assortments Continued


ThermafixTM Single Wall 166 pcs (1/8-3/8 black & red)

Dual Wall ThermafixTM Plus 26 pcs (sizes 1 & 2)

Thermafix CrimpTM Terminals 66 pcs (blue & yellow - 4 types)

Thermafix CrimpTM Splices 30 pcs (blue & yellow)


Dual Wall ThermafixTM Plus 27 pcs (sizes 1, 2, 3 & 4)

Thermafix CrimpTM Terminals 40 pcs (blue, yellow & red)



ThermafixTM Single Wall 36 pcs (1/8”-3/16” & 1/4 red, yellow, blue,green, black, white)

Dual Wall ThermafixTM Plus 25 pcs (sizes 1, 2 & 3)


Dual Wall ThermafixTM Plus 62 pcs (sizes 1, 2 & 3)


Thermafix CrimpTM Terminals 325 pcs (blue & yellow, 13 types)



Dual Wall ThermafixTM Plus 63 pcs (all sizes)

S e c t i o n 7


Primary Terminals & Connectors• Pure electrolytic copper with electro-tin plating for corrosion resistance

• Deep internal serrations promote firm wire grip for maximum strength

• Insulation (where applicable) is colour coded to NEMA standards and flared for easy insertion of stranded and solid wire

Which Terminal / Connector to Choose?Non-Insulated, PVC Insulated, Nylon Insulated or High Temperature

N O N - I N S U L A T E Dterminals are used wherethere is no worry about‘grounding’ or ‘shortingout’ against other wiresor metal frames, or withheat shrink tubing tocover the connectionafter seeing that it hasbeen made properly.

PVC insulated terminals aremanufactured using a two-partconstruction; an inner lug covered with a friction fit PVC sleeve. Generally speakinga single crimp is sufficient tomake a proper connection.

NYLON insulated terminals are manufactured using a three-part construction: an inner lug, a copper sleeve, and an outer Nylon coating. The copper sleeve acts as a ‘funnel’ to direct the wire properly into the lug. Generally a dual crimp is utilized—one whichcrimps the inner lug, one which crimps the sleeve.

This connection is regarded as a better design as it gives strain reliefat the connection and subsequently less fatigue

Both NYLON and PVC connections are rated at 90˚C to 105˚C and canbe used in auto applications (12V) or AC (110V). The actual rating of each is up to 600V. Both NYLON and PVC offer excellent protection from surrounding metal or wire contact to prevent “shorting out” situations.

High Temperature terminals arenickel plated and excellent forhigh-heat applications, able towithstand temperatures of up to 900ºF (482ºC).

Pcs/pack Part #15 CTI7521170 CTI772111000 CTI87211

1/4” Wire Gauge 22-18








#8 Wire Gauge 22-18


#6 Wire Gauge 22-18

Non-InsulatedRingTerminals


#6 Wire Gauge 12-10


#8 Wire Gauge 12-10




#8 Wire Gauge 16-14


#6 S Wire Gauge 22-18


#6 Wire Gauge 22-18


#10 Wire Gauge 22-18 Non-InsulatedSpadeTerminals






#8 Wire Gauge 22-18




#6 Wire Gauge 16-14


#8 Wire Gauge 16-14



Non-InsulatedSpade

TerminalsContinued




















Wire Gauge 12-10


Wire Gauge 16-14


Wire Gauge 22-18


Wire Gauge 12-10


Wire Gauge 16-14


Wire Gauge 22-18

Non-Insulated

MaleDisconnects

Non-Insulated

FemaleDisconnects

Non-Insulated

FlagTerminals

Non-Insulated

Butt SpliceConnectors

Non-InsulatedSeamless

Butt SpliceConnectors

S e c t i o n 7







#6 Wire Gauge 22-18














#8 Wire Gauge 16-14


#6 Wire Gauge 16-14


#6 Wire Gauge 12-10


15/16” Wire Gauge 12-10






#6 Wire Gauge 22-18




#6 Wire Gauge 16-14


#8 Wire Gauge 22-18


15/16” Wire Gauge 16-14




#8 Wire Gauge 12-10






#8 Wire Gauge 22-18

PVC RingTerminals

PVC SpadeTerminals

S e c t i o n 7






#8 Wire Gauge 16-14


#6 Wire Gauge 12-10


#8 Wire Gauge 12-10


#6 Wire Gauge 12-10

PVC SpadeTerminals

Continued












.156 Wire Gauge 16-14

















PVC Piggy BackConnectors

PVC Tap Splice

Connectors

PVC Snap Plugs

PVC

MaleDisconnects

PVC Female

Disconnects

S e c t i o n 7











Wire Gauge 12-10


Wire Gauge 16-14


Wire Gauge 16-14


Wire Gauge 16-10


Wire Gauge 22-14




#6 Wire Gauge 16-14




#6 Wire Gauge 22-18









PVC RingTerminals

PVC ButtSpliceConnectors

PVC Closed EndConnectors

Nylon RingTerminals











Nylon Heavy Duty

Terminal

Nylon Spade

Terminal

























Nylon FullyInsulated

MaleDisconnects

Nylon FullyInsulated

FemaleDisconnects

Nylon Male

Disconnects

Nylon Flag

Terminals

S e c t i o n 7



Wire Gauge 12-10


Wire Gauge 16-14


Wire Gauge 22-18



Pcs/pack Part #100 CTI773051000 CTI87305

Wire Gauge 12-10


Wire Gauge 16-14












Wire Gauge 22-18

#10 Wire Gauge 16-14 #10 Wire Gauge 22-18



#6 Wire Gauge 22-18 #10 Wire Gauge 22-18

#10 Wire Gauge 12-10 3/8” Wire Gauge 12-10 1/4” Wire Gauge 12-10 #8 Wire Gauge 16-14





1/4” Wire Gauge 16-14 #6 Wire Gauge 16-14 #10 Wire Gauge 16-14 #8 Wire Gauge 22-18

Nylon Butt SpliceConnectors

Non-InsulatedHigh TempButt SpliceConnectors

Non-Insulated HighTemp SpadeRing Connectors

Non-InsulatedHigh Temp Ring Connectors

Nylon 3-WaySplice




#8 Wire Gauge 12-10


#6 Wire Gauge 12-10










Part # Qty Part # Qty Part # QtyCTI75101 25 CTI75491 10 CTI75245 15CTI75103 25 CTI75193 25 CTI75253 20CTI75105 15 CTI75205 25 CTI75255 15CTI75139 25 CTI75229 25 CTI75257 15CTI75147 15 CTI75241 25 CTI75271 12CTI75489 10 CTI75243 15 CTI75277 15


1/4” Wire Gauge 16-14 1/4” Wire Gauge 22-18




Min: 2 #14 Ga. Max: 3 #10 & 1 #12 Ga.Min: 2 #14 Ga. Max: 3 #12 Ga.Min: 2 #18 Ga. Max: 2 #14 Ga.




1/4” Wire Gauge 12-101/4” Wire Gauge 16-14 1/4” Wire Gauge 22-18

Non-InsulatedHigh Temp Ring

Connectors(continued)

Non-InsulatedHigh Temp

FemaleDisconnects

Non-Insulated High

Temp MaleDisconnects

Non-Insulated

High TempFlag Terminals

Colour Coded Wire

Nuts

Terminal AssortmentTerminal Assortment in Plastic Storage Box

Comes complete with 332 terminals in 18 of the most popular styles. Each part

number is indexed on the reference chart for ease of identification and quick

reorder. Part #CTI10077

S e c t i o n 7


Toggle Switches: Light, Medium, Heavy-Duty

Terminal HandlePart # Duty Position Type Type # Rating Type Colour Pole Throw

CTI65075 Light ON-OFF Screw 2 35 a @ 6V; 20 a @ 12V Bat Chrome Single Single

CTI65072 Light OFF-ON Screw 2 6 a @ 125 volts; 3 a @ 250 volts Bat Nickel Single Single

CTI65073 Light OFF-ON Leads* 2 6 a @ 125 volts; 3 a @ 250 volts Bat Nickel Single Single

CTI65046 Medium ON-OFF Screw 2 20 a @ 12VDC Standard Chrome Single Single

CTI65047 Medium ON-OFF Blade 2 20 a @ 12VDC Standard Chrome Single Single

CTI65048 Medium ON-MOM. OFF Screw 2 20 a @ 12VDC Long Chrome Single Single

CTI65049 Medium MOM. ON -OFF Screw 2 20 a @ 12VDC Standard Chrome Single Single

CTI65054 Medium ON-ON Screw 3 20 a @ 12VDC Standard Chrome Single Double

CTI65055 Medium ON-OFF-ON Screw 3 20 a @ 12VDC Standard Chrome Single Double

CTI65056 Medium ON-OFF-ON Blade 3 20 a @ 12VDC Standard Chrome Single Double

CTI65057 Medium MOM. ON-OFF-MOM. ON Screw 3 20 a @ 12VDC Standard Chrome Single Double

CTI65058 Medium ON-OFF Screw 4 20 a @ 12VDC Standard Chrome Double Single

CTI65059 Medium ON-OFF Blade 4 20 a @ 12VDC Standard Chrome Double Single

CTI65064 Medium ON-ON Screw 6 20 a @ 12VDC Standard Chrome Double Double

CTI65065 Medium ON-OFF-ON Screw 6 20 a @ 12VDC Standard Chrome Double Double

CTI65066 Medium ON-OFF-ON Blade 6 20 a @ 12VDC Standard Chrome Double Double

CTI65067 Medium MOM. ON-OFF-MOM. ON Screw 6 20 a @ 12VDC Standard Chrome Double Double

CTI65012 Heavy ON-OFF Screw 2 50 a @ 6-24volts Standard Black Single Single

CTI65030 Heavy ON-OFF Screw 2 50 a @ 6-24volts Standard Chrome Single Single

CTI65031 Heavy ON-OFF Screw 2 50 a @ 6-24volts Long Chrome Single Single

CTI65033 Heavy ON-OFF Blade 2 30 a @ 6-24volts Standard Chrome Single Single

CTI65020 Heavy MOM. ON-OFF-MOM. ON Screw 3 50 a @ 6-24volts Long Chrome Single Double

CTI65032 Heavy MOM. ON-OFF-MOM. ON Screw 3 50 a @ 6-24volts Standard Chrome Single Double

CTI65034 Heavy ON-OFF-ON Screw 3 50 a @ 6-24volts Standard Chrome Single Double

CTI65210 X-Heavy ON-ON Blade 6 10 a @ 277V; 20 a @ 125V Bat Nickel Single Single

# 65058 # 65072 # 65012 # 65020

# 65100 # 65120 # 65103 # 65114

# 65210

Nylon Handle (with & without light)

Terminal Handle

Part # Position Type # Type Rating Style Colour Pole Throw

CTI65100 ON-OFF 2 Screw 35 a @ 12VDC Decorator Black Single Single

CTI65101 ON-OFF 2 Blade 35 a @ 12VDC Bat Black Single Single

CTI65102 ON-OFF 2 Screw 20 a @ 12VDC Decorator w/Light Single Single

CTI65103 ON-OFF 4 Screw 20 a @ 12VDC Decorator w/Light Single Single

CTI65104 MOM. ON-OFF-MOM. ON 3 Screw 35 a @ 12VDC Decorator Black Single Double

CTI65105 MOM. ON-OFF-MOM. ON 3 Blade 35 a @ 12VDC Decorator Black Single Double

CTI65106 ON-OFF-ON 5 Blade 20 a @ 12VDC Decorator w/Light Single Double

CTI65107 ON-OFF-ON 5 Blade 20 a @ 12VDC Decorator w/Light Single Double

CTI65114 ON-OFF-ON 6 Screw 35 a @ 12VDC Bat Black Double Double

CTI65115 ON-OFF-ON 6 Blade 35 a @ 12VDC Decorator Black Double Double

CTI65116 MOM. ON-OFF-MOM. ON 6 Screw 35 a @ 12VDC Decorator Black Double Double

CTI65117 MOM. ON-OFF-MOM. ON 6 Blade 35 a @ 12VDC Bat Black Double Double

CTI65120 ON-OFF 2 Blade 20 a @ 12VDC Duckbill Black Single Single

CTI65121 ON-OFF 3 Blade 20 a @ 12VDC Duckbill Black Single Single

CTI Protection and Safety Products:Safeguarding Systems Worldwide, for the Present and the Future

CTI has teamed with E-T-A for the distribution and support of its circuit protection products. Like CTI,

E-T-A's global strategy for customer support and product excellence has succeeded in gaining E-T-A an

international reputation for quality, on time delivery and on going support in circuit breakers for

equipment. Through CTI and E-T-A subsidiary companies, strategically situated around the world,

technical support and advice is provided to help customers make the right choice from the wide range

of intelligent solutions offered. In a world market which demands superior levels of reliability and

safety, E-T-A has set high standards with full approvals from leading international authorities and agen-

cies including UL, CSA and VIDE. Quality design, supply and support are assured with CTI’s ISO

accreditation. With its leadership position based on extensive expertise, close customer collaboration

and a thriving capacity for innovation, CTI provides a comprehensive range of circuit breakers for the

aerospace, defense and industrial industries with many applications.

In every type of aircraft, from the largest long-range commercial jets to the most agile powered gliders,

civil and military aircraft, fixed-wing and helicopter, E-T-A circuit breakers provide the electrical safety

that helps to keep the aircraft flying. E-T-A's comprehensive product range is specifically designed to

meet the needs of this demanding market and covers almost every aerospace application.

The unparalleled price/performance advantage of E-T-A circuit breakers makes them the preferred

choice of aircraft manufacturers around the world who know that, in an area where compromise can-

not be risked, E-T-A circuit breakers can be trusted. All models combine high interrupting capacity and

a strong tolerance of adverse conditions with the small physical size and low weight demanded by the

confined spaces within any aircraft

E-T-A aircraft circuit breakers reflect the company's long experience and acknowledged technical

expertise, and are proven through exhaustive testing to meet all relevant standards requirements.

Exceeding Standards and Reducing Cost

Modern aircraft are filled with electrical equipment, and any current overload or short-circuit could

cause overheating, a break down in circuit integrity and constituting a major fire risk.

The latest generation of E-T-A aircraft circuit breakers, available from CTI, provide the most efficient and

comprehensive protection available, with low cost of ownership both for manufacturers and operators.

The high fault current interrupting capacities are vital, but their small dimensions and low weight are

also significant—even a few extra grams of weight make a difference to the overall cost per flying mile,

when multiplied by the several hundred devices installed within the typical aircraft.

E-T-A circuit breakers are also favored for their ruggedness, essential for conditions where ambient

temperatures may vary between -55°C and 125°C within the duration of a single flight. The built-in

shock (to 75 g) and vibration resistance enables them to withstand the turbulence of bad weather and

the impact of heavy landings while their high degree of corrosion resistance and random vibration

performance are specially suited to the most advanced military aircraft and helicopters. When combined

with explosion-proofing, dual-control, trip-free mechanisms and signal contacts, the result is a circuit

breaker which exceeds all existing international standards.

Modern aircraft design also benefits from the sophistication of E-T-A circuit breakers. The latest gener-

ation of civil aircraft tend to have circuit breakers concentrated in the nose-space rather than, more

circuit protection and controlcircuit protection and controlS e c t i o n 8


traditionally, on the flight deck. Although this approach releases cockpit space, it does require the need for circuit breaker status

information. E-T-A circuit breakers with auxiliary contacts featuring series-connected diodes are ideal for such applications, as the

polarized auxiliary contacts may be included in a diode matrix to provide a coded signal, thereby reducing the need for traditional

signal cables.

Electronic Remote Connection and Disconnection from the Flight Deck: Innovating for Increased Safety and EconomyRemote control circuit breakers (RCCB’s)

The use of E-T-A electronically controlled aircraft circuit breakers, available from CTI, results in significant reductions in the amount of

heavy cabling installed through the aircraft, as the devices are designed to be sited in close proximity to the load-generators for example.

The circuit breaker is switched on by applying system ground potential to the control input (and, conversely, switched off by removing

it). Remote control is enabled via a conventional single-pole thermal circuit breaker with a low current rating; this low current control

circuit is connected both to system ground and to the control input of the RCCB. The major weight reductions are an obvious benefit,

but a further advantage is the bi-stable switching system which requires little energy for operation and only for a short duration.

E-T-A RCCB’s available for current ratings between 5 A and 100 A are designed and tested to the MIL-C-83383 standard for world-

wide commercial and military applications.

Comprehensive aerospace-specific approvals to international standards

Safety is paramount in aviation and CTI products ensure a leading edge position by working closely with the world's leading aerospace

agencies. E-T-A circuit breakers have been designed to comply with, and are certified to the most demanding standards of the industry

including those established by defense agencies around the world, and the latest EN standards. They are OPL listed in many NATO coun-

tries, and meet VG, LTF and LN requirements. In addition E-T-A holds A1 Primary Company Approval from the UK Civil Aviation Authority.

Many internationally known aircraft manufacturers also award their own vendor approvals. CTI is among the companies awarded these

approvals.

S e c t i o n 8

circuit protection and control | CTI | 8-111



Blade FusesATO Autofuses

ATO Autofuses are used on most late model cars. Its

small size makes it more compact and easy to install

and remove. Meet or exceed OEM and SAE standards,

and rated at 32 volts. Colour coded to indicate amps.

Offers protection against shock and sparks as well as

corrosion resistance for a longer service life.

ATO Mini-Fuse Assortment Kit Part # CTI66000 (95 pcs) This kit contains popular varieties of

our ATO Autofuses (60 pcs) and ATO Mini-Fuses (35 pcs).

ATO Autofuse Assortment Kit Part # CTI66001 (100 pcs) This kit contains the entire

range of ATO Autofuses.

ATO Mini-Fuses (35pcs)

ATO Auto Fuses (60pcs)

Fuse Assortments

Amp. Colour Pcs/Pack Part # Rating 5 15 100

1 Black CTI66208 CTI663082 Grey CTI66209 CTI663093 Violet CTI66210 CTI663104 Pink CTI66211 CTI663115 Tan CTI66212 CTI66312

7.5 Brown CTI66213 CTI6631310 Red CTI66214 CTI6631415 Blue CTI66215 CTI6631520 Yellow CTI66216 CTI6631625 Clear CTI66217 CTI6631730 Green CTI66218 CTI6631840 Orange CTI66219 CTI66319

ATO Mini-Fuses

ATO Mini-Fuses are becoming more popular for late model

applications. Meet or exceed OEM and SAE standards, and

rated at 32 volts. Colour coded to indicate amps. Offers pro-

tections against shock and sparks as well as corrosion resist-

ance for a longer service life.

Amp. Colour Pcs/Pack Part # Rating 5 10 50

2 Grey CTI66240 CTI663403 Violet CTI66241 CTI663414 Pink CTI66242 CTI663425 Tan CTI66243 CTI66343

7.5 Brown CTI66244 CTI6634410 Red CTI66245 CTI6634515 Blue CTI66246 CTI6634620 Yellow CTI66247 CTI6634725 Clear CTI66248 CTI6634830 Green CTI66249 CTI66349

Amp ReplacementRating Colour Part # Quantity

1 Black CTI66208 5 pcs2 Grey CTI66209 5 pcs3 Violet CTI66210 5 pcs4 Pink CTI66211 5 pcs5 Tan CTI66212 15 pcs

7.5 Brown CTI66213 5 pcs10 Red CTI66214 15 pcs15 Blue CTI66215 5 pcs20 Yellow CTI66216 15 pcs25 Clear CTI66217 5 pcs30 Green CTI66218 15 pcs40 Orange CTI66219 5 pcs


5 Tan CTI66212 5 pcs10 Red CTI66214 15 pcs15 Blue CTI66215 5 pcs20 Yellow CTI66216 15 pcs25 Clear CTI66217 5 pcs30 Green CTI66218 15 pcs


5 Tan CTI66243 5 pcs10 Red CTI66245 5 pcs15 Blue CTI66246 5 pcs20 Yellow CTI66247 10 pcs25 Clear CTI66248 5 pcs30 Green CTI66249 5 pcs

S e c t i o n 8


Blade Fuses/Fuse HoldersMaxi-Fuses are used to protect circuits in the wiring harness, usually found under the hood, in a fuse panel or in the supplementary

panel near the battery and are rated at 32 volts.

Maxi-Fuses

Amp. ReplacementRating Colour Part # Quantity Part # Quantity

20 Yellow CTI66250 1 CTI66350 25030 Green CTI66251 1 CTI66351 25040 Orange CTI66252 1 CTI66352 25050 Red CTI66253 1 CTI66353 25060 Blue CTI66254 1 CTI66354 250

Fuse Holders for ‘ATO®/ATC’ Autofuses

Fuse Holders For Maxi/Mini Fuses

Fuse holders can be used with or without a cover. Maxi Fuse holder has 6 ga–6” lead wire and accommodates Maxi fuses from 20 to

60 amps. Mini-Fuse holder has 16 ga-6” lead wire and accommodates Mini-Fuses from 2-20 amps. 10/pack.

ATO Fuse HolderPart #CTI64103 Self-stripping, in-line fuse holder for ATO fuses.

10 pieces/pack (Part #CTI64103C for 100 pack).

Fuse Holders

Provides the most efficient method for full protection of

all electrical equipment. 16 ga. 2–4-1/4” (114 mm)

leads. Fuse holders accommodate all Autofuses from 3

through 20 amps. 25/pack.

Cover sold separately.

Amp Part #7.5 CTI6412710 CTI6412920 CTI6413130 CTI64126*

Cover CTI66259*12 ga. lead

Part # CTI67255

Maxi Fuse holder only.Supplied without fuse.

Part # CTI67256

Maxi Fuse holder only.

Part # CTI67257

Maxi Fuse holder only.Supplied without fuse.

Part # CTI67258

Maxi Fuse holder only.



Glass Fuses & Holders

Glass Fuse BlocksFor SFE-20 amp or 3AGC type fuses, 1/4”(6.4 mm) diameter. x 1-1/4” (31.8 mm)long. Screw terminals with phosphor bronzefuse clips and hard fiber insulator base.

Screw Type Terminal BlocksSelf-insulating molded housing.Tin-plate brass screws and binders.

Blade-Type Fuse BlocksCompact yet rugged, accepts ATO or ATCblade fuses or blade-type automatic ormanual reset circuits breakers.

Universal ‘Plug in’ Circuit Breakers Continuous self-resetting 6-12 volt circuitbreaker. Use with headlight switches, windowmotors, etc. and suitable for replacing fuses inmany other applications. Two #10-32 stud terminals hex nuts and washers.

Fuse Blocks & Terminal Blocks

Glass FusesReplacement glass tube-type fuses fordomestic vehicles. 5/box.

In-Line Fuse HolderSupplied with fuse. 25/box

Panel Fuse Holder

Part # CTI66042Maximum 20 amp rating. Mounts in 1/2” (12.7 mm) diameter hole.

Universal ‘Plug in’ Circuit Breakers Heavy-duty replacements for ATC and ATO blade typefuses. Saves time and money in replacing burned-outfuses. Simply snap off tabs with pliers at desired position for size adjustment.

Application: 12 volt DC electrical systemsDimensions: 0.840” (21.3 mm) x 400” (10.2 mm) x 1.5” (38.1 mm)

SFE Amp Part #9 CTI6618814 CTI6618920 CTI6619030 CTI66191

Colour SFE Amp Part #Red 14 CTI64082

Black 20 CTI64083Ivory 30 CTI64084Ivory 9 CTI64081

Positions Part #6 CTI660438 CTI6604410 CTI66045

Pairs Part #4 CTI621046 CTI6210510 CTI62106

Positions Part #3 CTI660204 CTI660216 CTI660236* CTI62132

*with solid brass bus barfor ‘hot feed’ connecting

Circuit Breakers

Amp Part #15 CTI6601320 CTI6601425 CTI6601530 CTI66016

Amp Part #10 CTI6607015 CTI6607120 CTI6607230 CTI66073

S e c t i o n 8


Fuse Block ConnectorsPart # CTICT6100

Fuse Block connectors allow:

• Tapping power for accessories;

• Checking voltage, shorts, opens and

current draw;

• 3 piece kit to fit maxi, ATO and mini size automotive blade fuse block connectors.

Circuit TesterPart # CTI64700

For 6/12/24 volt systems with an unbreakable handle and

a heavy-duty ground clip. Tester contains a 5 ft (1.5 m)

heavy-duty rubber coated lead wire.

tooling and equipmenttooling and equipmentS e c t i o n 9


Wire & Cable Tools

CR-CTI300: Ratchet tool crimps insulated terminals from #22-10 AWG.

CR-CTI100Crimps insulated & non insulated terminals from #22 to #10 AWG.Includes stripper and bolt cutter.

Cable Stripper

Ideal for stripping a full range of cable

from 8 ga to 4/0 ga

Compact Universal Crimping Tool

Ideal for crimping battery terminals from

8 ga (heavy duty only for 8 ga) to 1/0 ga.

Approximately 16” long.

Compact Cable Cutter

Easily cuts all cable sizes up to

2/0 ga. Approximately 8” long.

Part # CTI95728

Compact Universal Crimping Tool

Part # CTI95714

Cable Cutter

Part # CTI95731

Universal Crimping Tool 8 ga-4/0

Cable Cutter

The long handle provides excellent

leverage for cutting large cable

up to 350 MCM. Approximately

18” long.

Universal Crimping Tool 8GA-4/0

‘Mechanics choice’ for crimping battery terminals

from 8 ga to 4/0 ga. Approximately 25” long.

Part # CTI95721

Cable Striper

Part # CTI95712

Compact Cable Cutter

S e c t i o n 9

tooling and equipment | CTI | 9-117

Heating ToolsElectrical tooling may be available in various voltage ratings.120 volt AC is standard (for part numbers shown) and will be supplied unless specified otherwise.

TFX-3000 Two Stage General Purpose Hot Air Gun

• Rugged molded construction

• 400˚C/590˚C (750˚F/1100˚F), 1200 watts

• Shaped to free-stand on end

Includes Free Reflector Tip for TFX-3000

Part # CTIREF-35

TFX2050 Butane Micro Torch

• Electronic instant ignition system

• Adjustable flame

• Efficient, hand-held, free standing design

• Refillable butane fuel tank

• Optional flameless soldering head

• Optional hot blower and reflector

(ideal for use with Thermafix® products).

Specifications:

• Dimensions:155 mm x 90 mm x 35 mm

(Height x Width x Grip diam.)

• Max. temp.:1300˚C (2370˚F)

• Working time: approx. 90 minutes

TFX2050 ‘Special Edition’

Features the RK 2020 &

3 accessory tips in a handy

carrying case.

Butane sold separately.

SH-51Hot Blower Head

SH-41Flameless, HotBlower Head

SH-11Soldering Head

CT-1 Mini Torch

• Compact and economical

for small jobs

• Ships in a variety of colours

(not optional)

• Comes with refillable lighter

or compatible with most disposables

HL 1800 Electronically Monitored Heavy Duty Hot Air Gun

• Stepless settings

• 100˚C-600˚C, 2000 watts (max)


HG 3002 LCD Electronically MonitoredProfessional Hot Air Gun

• Digital display

• Air volume monitoring

• Cool air stage

• Stage 1 50˚C, Stage 2 50˚C-600˚C, 2000 watts


SA-51

Reflector

Butane Torch (optional)Accessory Tips

Available separately or in the 3-piece RK-SH3 Kit(SH-11, SA-51 and SH-51)

S e c t i o n 1 0technical data and specificationstechnical data and specifications


Manufacturing Support ServicesCTI can provide finished and tested products and assemblies to meet specific program orcustomer requirements, or can provide product to meet CTI specifications, such as the harness assembly specification that follows.

CTI can support existing designs, from build to print to suggestions of product improve-ments and cost saving opportunities through to new design supported with samples,drawings and test data.

CTI can offer and support:

• Mechanical engineering, design and manufacturing services;

• Prototype and production manufacturing;

• Mature product design improvement and feasibility studies;

• Cost effective design analysis incorporating design modifications utilizing currentprocesses and procedures to reduce cost and lead times;

• Build to print prototype, pre and full production manufacturing/assembly;

• Concurrent engineering and advanced manufacturing.

CAS–130159A Cable Assembly Specification

1. SCOPE

Cable assembly specification for a single or multi-branched electrical wiring harness for useon a military vehicle.

2. PURPOSE

This specification defines the requirements for the fabrication, inspection, and acceptanceof single or multi-branched electrical wiring harness assemblies for use on military vehicleprojects.

3. APPLICABLE DOCUMENTS

The following documents, of the issue in effect on the date of this specification, form a partof this specification to the extent specified herein.

4. REQUIREMENTS

4.1 General

The wiring harness assemblies shall be defined by the applicable wiring harness draw-

ings in the areas of dimensions, wiring schematics, wire gauge, connector and keyway

orientation, connector adaptor, molded parts, tubing, and other general assembly

requirements. The drawing takes precedence over any conflicts between this specifica-

tion and the respective drawing.

4.2 Materials

4.2.1 Connectors

Connectors shall be selected according to the specific customer requirements.

Attention should be made with respect to reliability, availability, and cost.

4.2.2 Ring and Lug Terminals

Terminals, such as ring or lug, shall be selected to fit the application. All terminals

shall be crimp-style, tin-plated copper unless otherwise specified. Insulated

barrels are preferred.

Product Support

Customer Support

Technical Information

S e c t i o n 1 0

technical data and specifications | CTI | 10-119

4.2.3 Primary wire

Unshielded individual wires shall be selected according to the specific customer requirements and using calculations derived

from MIL-W-5088.

4.2.4 Unshielded twisted pairs

Cables for unshielded twisted pairs or other multiple twisted conductors shall be selected according to the specific customer

requirements.

4.2.5 Shielded wire

Cables for shielded wire and shielded twisted pair wire shall be selected according to the specific project requirements.

4.2.6 Gross shield

Shield material over wire/cable bundle shall be tin-coated copper wire per ANSI C7.4 providing a minimum coverage of 90%

unless otherwise specified.

4.2.7 Outer jacket

Material shall be polychloroprene sleeving per M23053/16 or equivalent, sized as appropriate for the bundle diameter.

4.2.8 Molded parts

Molded parts shall be compatible with the outer jacket or insulation sleeving.

4.2.9 Dual wall sleeving

Insulation sleeving with pre-coated adhesive or dual wall sleeving shall be per MIL-I-23053/4 or equivalent.

4.2.10 Tape and adhesive

4.2.10.1 Heat curable

Heat sealable thermoplastic adhesive shall be used where required if the part to be bonded is not pre-coated. The

adhesive shall have a temperature rating of -55°C to 120°C.

4.2.10.2 Spot tape

Where necessary, spot taping shall be used to hold wire bundles together before application of heat-shrink tubing.

Tape shall be clear Mylar or equivalent. Kapton tape shall not be used. Spot taping shall also be used to protect wire

insulation from shield soldering. Tape shall be 200°C rated glass cloth per MIL-I-19166 or equivalent.

4.2.11 Connector adaptors

Connector adaptors shall be used to terminate overbraid and non-braided cable assemblies. The adaptor provides a mounting

surface for the molded boot and/or the overbraid. The adaptor is to stay locked into location on the connector after

vibration to M85049 and MIL-C-38999. The adaptors are to be of a material and finish that is compatible with the connectors

that they secure to. Cadmium finish is to be minimized with zinc-cobalt the preferred finish where available. Harnesses shall

use straight adaptors as much as possible. Use of 45° and 90° adaptors shall be avoided except where required by limited

space.

4.2.12 Markers

Individual wire markers and cable/harness identification markers shall be yellow polyolefin per MIL-I-23053/5, Class 1 or 3, or

equivalent material. Marking must meet the permanency requirements of MIL-M-81515.

4.2.13 Insulation sleeving

Insulation at connector pins and shield terminations shall be per MIL-1-23053/5, Class 1, 2,or 3 or equivalent.

4.2.14 Solder

Solder shall be Type SN60, SN62, or SN63 per QQ-S-571. Flux used with solid or cored solder shall be noncorrosive Type R or

RFnA per MIL-F-14256.

4.2.15 Splices

Junctions between two or more individual wires shall be joined by splices per MIL-S-83519/1 or equivalent as applicable.

Individual wire shields shall be terminated using splices per MIL-S-83519/2 or MIL-S-83519/1 or equivalent with a separate

wire.



4.3 Assembly Details

4.3.1 Workmanship

Assembly procedures shall be per MIL-STD-454, requirement 9.

4.3.2 Branches

All branches shall be shown on the drawing and dimensioned accordingly. Branch dimensions may be shown on each

individual leg as a tag. The dimension tag denotes the entire branch length including the connector. Straight connectors are

dimensioned to the end of the connector. Right angle connectors are dimensioned to the centre of the connector. Ring

terminals are dimensioned to the centre of the terminal.

4.3.3 Transitions and Breakouts

Harness branches shall be made using either a transition or breakout as specified on the drawing. A transition uses a

molded part to separate the branches. A breakout uses a piece of tubing (approximately 50 mm) to separate and seal the

branches. A longer piece of tubing (approximately 75 mm) may be used to cover splices where specified on the drawing. A sin-

gle cable tie per MS3367 shall be used as a strain relief at every breakout. Packing of joints is allowed where necessary to

increase the diameter of the branch.

4.3.4 Tolerances

Unless otherwise specified on the applicable harness drawing, tolerances on length dimensions shall be per the following table.

Tolerances on keyway clocking to connector backshells or boot angles shall be 15° unless otherwise stated on the applicable

drawing.

4.3.5 Soldering

Operations shall be per MIL-STD-454, requirement 5.

4.3.6 Crimping

Crimp type connector contacts and terminal lugs shall be crimped using crimping tools specified per the applicable

specification and procedures defined in MIL-C-22520, or by the connector manufacturer. Terminal lugs shall be end soldered

to seal the exposed end of the conductor. No wicking of solder into the conductor shall be allowed.

4.3.7 Splices

Splices shall only be used when specified on the harness drawing schematic to join two or more individual wires or to

terminate wire shields. Splices shall not be used as a repair method without customer approval. Individual wires shall be

stripped in accordance with MIL-W-5088, Section 3.17.2. Shielding shall be cut short of insulation 0.25 to 0.375 inches. Splices

shall be applied per MIL-S-83519.

4.3.8 Marking

The identification markings shall include conductor identification, termination identification and assembly identification.

4.3.8.1 Conductor marking

Each individual conductor in the assembly shall be identified at both ends except for cables containing a single conduc-

tor or if the conductors are colour coded. The conductor shall be marked with the connector reference designator and

pin number or letter. Example: Connector P1, wire in contact A is marked P1-A.

4.3.8.2 Termination marking

Each major connector termination shall be identified with the assembly part number, reference designation and harness

number unless otherwise specified on the assembly drawing. The marker shall be approximately 50 mm from, or as close

as practical, to the junction between the harness leg and the boot. Each minor connector termination (lug, ring termi-

nal, commercial connector, etc…) shall be identified with the reference designation only.

Length Tolerance

0 to 1000 mm -0, +25 mm

1000 to 3000 mm -0, +50 mm

Over 3000 mm -0, +75 mm

S e c t i o n 1 0


4.3.8.3 Assembly marking

The finished assembly shall be identified in accordance with MIL-STD-130. The marking shall include as a minimum, the

design activity CAGE, the part number, and the harness reference designation centrally located on the main branch of

the harness. For multi-branch harnesses, the marker shall be applied to the branch with the largest overall diameter, also

centrally located.

4.3.9 Insulation

Install heat shrinkable tubing over all contacts and exposed bare wire at all connectors. Tubing shall also cover unterminated

or exposed shielding. The sleeving when shrunk, must be snug fitting and provide a non-slip, permanently fixed assembly.

4.3.10 Circular metal connector torque

All threaded backshell parts and any special threaded adaptors at connectors or transitions shall be assembled, then tightened

to the torque specified per the table below unless otherwise specified by the adaptor manufacturer.

4.3.11 Gross shield installation

The shield shall maintain a minimal optical coverage of 90%. Where applicable, the gross shield shall be insulated from all

conductors and wire shielding to avoid damage to the bundle and to meet the requirements of the applicable specification.

Electrical continuity shall be maintained from connector to connector through the adaptors, gross shield, and transitions to

meet requirements of the specification. Attachment method shall be compatible with the adaptor and shall ensure 360°

contact between the gross shield and the adaptor.

4.3.12 Jacketing

The outer jacket shall be installed between all terminating points and transitions. Jacketing shall extend into the boot

or transition a minimum of 25 mm. The joint shall be sealed using adhesive to provide a visible, 360° watertight bond. The

adhesive shall be compatible with the material and have a temperature rating of -55°C to 105°C minimum unless

otherwise specified.

4.3.13 Terminations

4.3.13.1 Military specification terminations

Individual wires shall be stripped per MIL-W-5088, Section 3.17.2. Contacts and terminals shall be applied and installed

in accordance with the drawing schematic. Unused connector contacts shall be installed. Individual sealing plugs shall

not be used unless specified in the drawing. Exposed contacts shall be insulated. Terminal lugs shall be insulated using

dual wall sleeving such that the terminal barrel is completely covered. The sleeving shall also extend and overlap the

outer jacket. Boots shall be bonded to the outer jacket and the connector backshell with adhesive if the boot is not pre-

coated. The adhesive should provide a visible, 360° watertight seal.

4.3.13.2 Commercial/industriaI terminations

Individual wires shall be stripped per the connector manufacturer's specification. Contacts and terminals shall be applied

and installed in accordance with the drawing schematic. Unused connector contacts shall only be installed if required.

Individual sealing plugs shall be used where required. Where required, boots shall be bonded to the outer jacket and the

connector backshell with adhesive if the boot is not pre-coated. The adhesive should provide a visible, 36O° watertight

seal. Where no boots are used, individual wire slack shall be 10 to 20 mm for less than 10 circuits and 30 to 35 mm for

greater than 11 circuits.

4.4 Electrical Performance

The finished harness assembly shall be capable of meeting the following tests.

4.4.1 Insulation resistance

100 megaohms minimum measured between each conductor, the gross shield, and connectors per MIL-STD-202, Method 302,

Test condition B, with 1.0 second minimum electrification time, 500 ± 50 VDC test voltage.

4.4.2 Circuit resistance

500 milliohms maximum measured pin-to-pin through each conductor and 1.5 ohms maximum measured through the gross

shield between each connector shell per MIL-STD-202, Method 303.



4.5 Mechanical Performance

4.5.1 Appearance

The harness shall be free of mechanical imperfections such as nicks, cuts or abrasion marks along its entire length. Plating on

connectors and adaptors shall be free of scratches, pitting, or marring that would otherwise degrade the environmental per-

formance. Pins and terminal lugs shall not be bent.

4.6 Environmental

The finished harness assembly shall be capable of meeting the following conditions.

4.6.1 Temperature range

With connectors mated, shall be capable of operating over a temperature range of -40°C and 100% RH to 44°C and 14% to

44% RH. The storage temperature shall be -40°C to 63°C.

4.6.2 Fluid resistance

No degradation by exposure to diesel fuel per VV-F-800 and MIL-F-16884, brake fluid per MIL-B-48176, hydraulic fluid per

MIL-H-5606 and engine oil per MIL-L-2104 and MIL-L-46167.

4.6.3 Moisture resistance

With connectors mated or plugged, shall be subjected to the spraytight test per MIL-STD-108, paragraph 4.10.

5. QUALITY ASSURANCE PROVISIONS

5.1 Responsibility for inspection

CTI will be responsible for the performance of all inspection requirements. CTI may use our own or any other facilities

suitable for the performance of the inspection requirements. The customer or their agents reserves the right to perform any of the

inspections set forth in this specification.

5.1.1 Test equipment and inspection facilities

Test and measuring equipment and inspection facilities of sufficient accuracy, quality, and quantity to permit performance of

the required inspection shall be established and maintained by CTI. The establishment and maintenance of a calibration sys-

tem to control the accuracy of the measuring equipment shall be in accordance with recognized quality standards.

5.2 Classification of inspection

The inspection of harness and cable assemblies shall be classified as follows:

• First article inspection;

• Quality conformance inspection.

5.3 First article inspection

Unless otherwise specified, CTI shall perform first article inspection after award of contract and prior to serial production. First arti-

cle inspection shall be performed on wiring harness assemblies or cable assemblies that have been produced with production equip-

ment and procedures.

5.3.1 Sample size

First article inspection shall be performed on the first item of each new part number of each wiring harness or cable assembly

in the purchase order. Inspection by similarity is allowed with prior approval from the procuring activity.

5.3.2 First article failure

Failure of the first unit to pass any examination or test may cause refusal to grant first article approval. The customer may refuse

acceptance of production assemblies until corrective action is provided.

5.3.3 Sample disposition

First article samples are deliverable as the first unit of production provided they are not damaged by the first article inspection.

5.3.4 First article inspection tests

First article inspection tests shall be conducted as follows in the order listed.

5.3.4.1 Materials inspection

Material certifications shall be examined for conformance to the requirements of the customer cable specification.

S e c t i o n 1 0


5.3.4.2 Dimensional inspection

The sample shall be examined for compliance with dimensional requirements of the drawing.

5.3.4.3 Mechanical performance

There shall be no visible evidence of damage.

5.3.4.4 Environmental performance

The sample shall be exposed to the conditions described. There shall be no visible evidence of damage.

5.3.4.5 Electrical performance

Before and after the tests required, the sample shall be subjected to the tests described in this specification. The sample

shall meet the requirements of those tests.

5.4 Quality conformance inspection

5.4.1 Inspection of production deliverables

Inspection of product for production delivery shall be accomplished on 100% of the units produced.

5.4.2 Rejected units

If a unit is rejected, CTI may rework it to correct the defects within the confines of the drawing and this specification.

5.4.3 Inspection methods

Inspection of product for production delivery shall include the following examinations and tests.

5.4.3.1 Materials inspection

Material certifications shall be available for examination for conformance to the requirements the customer cable

specification.

5.4.3.2 Dimensional inspection

A sample shall be examined for compliance with dimensional requirements of the drawing.

5.4.3.3 Visual inspection

There shall be no visible evidence of damage in accordance with this specification.

5.4.3.4 Electrical inspection

Each assembly shall be inspected for proper circuit continuity per the drawing schematic and shall be tested for conformance

to the requirements of this specification.

6. PACKAGING

Packaging for the desired level of protection during shipping shall be in accordance with applicable packaging standard unless other-wise specified by the customer.



Multi-Conductor Cable Colour Chart ReferenceNo. Base 1st 2nd 3rd No. Base 1st 2nd 3rd

Colour Stripe Stripe Stripe Colour Stripe Stripe Stripe1 Black 51 White Blue Violet2 Red 52 White Brown Black3 White 53 White Brown Red4 Green 54 White Brown Green5 Orange 55 White Brown Blue6 Blue 56 White Brown Brown7 Brown 57 White Brown Violet8 Yellow 58 White Violet Red9 Violet 59 White Violet Green10 Gray 60 White Violet Blue11 Pink 61 White Black Red Green12 Tan 62 White Black Red Yellow13 Red Green 63 White Black Red Blue14 Red Yellow 64 White Black Red Brown15 Red Black 65 White Black Red Orange16 White Black 66 White Black Red Gray17 White Red 67 White Black Red Violet18 White Green 68 White Black Green Yellow19 White Yellow 69 White Black Green Blue20 White Blue 70 White Black Green Brown21 White Brown 71 White Black Green Orange22 White Orange 72 White Black Green Gray23 White Gray 73 White Black Green Violet24 White Violet 74 White Black Yellow Blue25 White Black Red 75 White Black Yellow Brown26 White Black Green 76 White Black Yellow Orange27 White Black Yellow 77 White Black Yellow Gray28 White Black Blue 78 White Black Yellow Violet29 White Black Brown 79 White Black Blue Brown30 White Black Orange 80 White Black Blue Orange31 White Black Gray 81 White Black Blue Gray32 White Black Violet 82 White Black Blue Violet33 White Black Black 83 White Black Brown Orange34 White Red Black 84 White Black Brown Gray 35 White Red Red 85 White Black Brown Violet36 White Red Green 86 White Black Orange Gray37 White Red Blue 87 White Black Orange Violet38 White Red Brown 88 White Black Gray Violet39 White Red Violet 89 White Red Black Green40 White Green Black 90 White Red Black Yellow41 White Green Red 91 White Red Black Blue42 White Green Green 92 White Red Black Brown43 White Green Blue 93 White Red Black Orange44 White Green Brown 94 White Red Black Gray45 White Green Violet 95 White Red Black Violet46 White Blue Black 96 White Red Green Yellow47 White Blue Red 97 White Red Green Blue48 White Blue Green 98 White Red Green Brown49 White Blue Blue 99 White Red Green Orange50 White Blue Brown 100 White Red Green Gray

Wire Specification Reference ChartCircular Coated Copper High Strength

Mil Ohms/1000 ft High StrengthAWG Strands OD Area Nickel Break Ohms/ Break

(CMA) Tinned Plated Strength (lbs) 1000 ft Strength (lbs)32 7/40 0.0093 67.3 157.0 165.0 1.8 176.0 3.430 7/38 0.012 112.0 95.4 97.4 3.0 107.0 5.628 7/36 0.015 175.0 60.9 61.9 4.7 68.5 8.426 7/34 0.019 278.0 38.2 38.7 7.0 43.2 14.026 19/38 0.020 304.0 35.3 36.1 8.2 39.6 15.224 7/32 0.024 441.0 23.7 23.9 11.9 25.8 21.724 19/36 0.025 475.0 22.5 22.9 12.7 25.4 22.822 19/34 0.032 754.0 14.2 14.3 19.0 16.0 38.020 19/32 0.040 1216.0 8.76 8.85 32.0 9.5 58.918 19/30 0.050 1900.0 5.60 5.64 51.0 - -16 19/29 0.057 2426.0 4.38 4.41 65.0 - -14 19/27 0.070 3830.0 2.77 2.79 103.0 - -12 19/25 0.090 5088.0 1.74 1.75 153.0 - -12 37/28 0.088 5874.0 1.81 1.83 155.0 - -10 37/26 0.111 9354.0 1.14 1.14 250.0 - -8 133/29 0.169 16983.0 0.634 0.663 450.0 - -6 133/27 0.213 26918.0 0.401 0.425 720.0 - -4 133/25 0.255 42615.0 0.252 0.263 1140.0 - -

S e c t i o n 1 0


Unit Conversion Chart ReferenceUnit X Constant =Unit Unit X Constant =Unit

Btu 778.0 Foot-pound (ft-lb) Horsepower (hp) 33000.0 Ft-lb/min

Btu 1054.8 Joules Horsepower (hp) 550.0 Ft-lb/sec

Btu 0.293 Watt-hours (w-hr) Horsepower (hp) 745.7 Watts (w)

Centimeters (cm) 0.032808 Feet (ft) Inch (in) 0.027178 Yards (yd)

Centimeters (cm) 0.3937 Inches (in) Inch (in) 0.083333 Feet (ft)

Centimeters (cm) 0.00001 Kilometers (km) Inch (in) 0.0000254 Kilometers (km)

Centimeters (cm) 0.010 Meters (m) Inch (in) 0.0254 Meters (m)

Centimeters (cm) 10.0 Millimeters (mm) Inch (in) 2.54000514 Centimeters (cm)

Circular mils 0.00064516 Circular millimeters Inch (in) 25.4000514 Millimeters (mm)

Circular mils 0.0000007854 Inches2 (in2) Inch (in) 1000.0 Mils

Circular mils 0.00050671 Square Millimeters (mm2) Joules 0.000948 Btu

Circular mils 0.7854 Mils2 Joules 107 Ergs

Circular mils 0.7854 Square mile Kilogram 2.205 Pound

Cubic Centimeter (cm3) 0.000035314 Cubic foot (ft3) Kilogram/km 0.6214 Pound/kft

Cubic Centimeter (cm3) 0.061023 Cubic inch (in3) Kilometers 0.6214 Miles

Cubic Centimeter (cm3) 0.000001 Cubic meter (m3) Liters (L) 61.025 Cubic inch (in3)

Cubic Centimeter (cm3) 0.00026417 Gallons Meters (m) 1.093611 Yards (yd)

Cubic Foot (ft3) 1728.0 Cubic inch (in3) Meters (m) 3.2808333 Feet (ft)

Cubic Foot (ft3) 28317.016 Cubic centimeter (cm3) Meters (m) 39.37 Inch (in)

Cubic Foot (ft3) 0.02832 Cubic meter Meters (m) 100.0 Centimeters (cm)

Cubic Inch (in3) 0.0005787 Cubic foot (ft3) Miles 1760.0 Yards (yd)

Cubic Inch (in3) 0.000016387 Cubic meter (m3) Miles 5280.0 Feet (ft)

Cubic Inch (in3) 16.387162 Cubic centimeter (cm3) Miles 1.6093 Kilometers (km)

Cubic Meter (m3) 1000000.0 Centimeter (cm) Millimeters (mm) 0.0032808 Feet (ft)

Cubic Meter (m3) 35.314456 Cubic foot (ft3) Millimeters (mm) 0.3937 Inch (in)

Cubic Meter (m3) 264.17 Gallons Millimeters (mm) 0.001 Meters (m)

Feet (ft) 0.00018939 Miles Millimeters (mm) 0.01 Centimeters (cm)

Feet (ft) 0.33333 Yards (yd) Millimeters (mm) 39.3701 Mils

Feet (ft) 12 Inches (in) Millimeters (mm) 1000 Microns

Feet (ft) 0.0003048 Kilometer (km) Ohms/kh 0.3048 Ohms/kft

Feet (ft) 0.3048 Meters (m) Ounce 28.35 Gram

Feet (ft) 30.48 Centimeter (cm) Pound 0.4536 Kilogram

Feet (ft) 304.8 Millimeters (mm) Pound/kft 1.4881 Kilogram/km

Feet/Pound (ft/lb) 0.00067197 Meters/grams (m/g) Square Inch 6.452 Square centimeter

Feet/Pound (ft/lb) 0.001285 Btu Square Centimeter 0.155 Square inch

Feet/Pound (ft/lb) 1.356 Joules Square Foot 0.0929 Square meter

Feet/Pound (ft/lb) 0.1383 Kilogram/meter (kg/m) Square Meter 10.76 Square foot

Gallons 3.785332 Liters (l) Square Miles 2.59 Square kilometer

Gallons 0.13368 Cubic foot (ft3) Square Kilometer 0.3861 Square mile

Gallons 231.0 Cubic inch (in3) Watts (w) 44.25 Ft-lb/minute

Gallons 3785.332 Cubic centimeter (cm3) Watts (w) 0.737562 Ft-lb/sec

Grams (g) 15.432 Grains Watts (w) 0.001341 Horsepower (hp)

Gram 0.03527 Ounce Watt-hour (w-hr) 3.41266 Btu

Gram/Centimeter3 0.0361275 Pounds/in3 (lb/in3)



S e c t i o n 1 0


Cross reference AWG to mm2

AWG mm2 AWG mm2 AWG mm2 AWG mm2

30 0.05 18 0.75 6 16 4/0 120

28 0.08 17 1.0 4 25 300MCM 150

26 0.14 16 1.5 2 35 350MCM 185

24 0.25 14 2.5 1 50 500MCM 240

22 0.34 12 4.0 1/0 55 600MCM 300

21 0.38 10 6.0 2/0 70 750MCM 400

20 0.50 8 10 3/0 95 1000MCM 500

Wire Bundle Chart: Multiplication factors for wire bundles with equal size wires. This table provides multiplica-tion factors for wire bundles of 1 to 61 wires. To determine the approximate diameter of a wire bundle when the wires are all the samesize, find the factor for the number of wires in the bundle and multiply the wire diameter by that factor.

Number of Wires Multiplication Factor Number of Wires Multiplication Factor

1 1.00 32 6.70

2 1.60 33 6.70

3 2.00 34 7.00

4 2.41 35 7.00

5 2.70 36 7.00

6 3.00 37 7.00

7 3.00 38 7.31

8 3.60 39 7.31

9 4.00 40 7.31

10 4.00 41 7.61

11 4.00 42 7.61

12 4.00 43 7.61

13 4.41 44 7.61

14 4.41 45 8.00

15 4.70 46 8.00

16 4.70 47 8.00

17 5.00 48 8.00

18 5.00 49 8.41

19 5.00 50 8.41

20 5.31 51 8.41

21 5.31 52 8.41

22 5.61 53 8.70

23 5.61 54 8.70

24 5.61 55 8.70

25 6.00 56 8.70

26 6.00 57 9.00

27 6.00 58 9.00

28 6.41 59 9.00

29 6.41 60 9.00

30 6.41 61 9.00

31 6.70



Take the universal time (GMT) from London, Englandand add the following to determine your time:

Time Zone Standard Time Daylight Saving Time

International Date Line East (IDLE) +12 hours

New Zealand Standard Time (NZST) +12 hours

New Zealand Time (NZT) +10 hours

Guam Standard Time (GST) +10 hours

Australian Eastern Standard Time (AEST) (AEDT) +10 hours +11 hours

Australian Central Standard Time (ACST) (ACDT) +9.5 hours +10.5 hours

Japan Standard Time (JST) +9 hours

China Coast Time (CCT) +8 hours

Australian Western Standard Time (AWST) +8 hours

India Standard Time (IST) +5.5 hours

Russian Zone 3 +4 hours

Baghdad Time (BT) +3 hours


Moscow Time(MSK) (MSD) +3 hours +4 hours

Eastern European Time (EET) (EEST) +2 hours +3 hours


Central Europe Summer Time (CEST) +2 hours

Central European Time (CET) +1 hour

Middle European Time (MET) +1 hour

Swedish Winter Time (SWT) 0 hours

Greenwich Mean Time (GMT) 0 hours

Universal Time (UT) 0 hours

Western European Time (WET) (WEST) 0 hours +1 hour

British Summer Time (BST) +1 hour

Irish Summer Time (IST) +1 hour

West African Time (WAT) -1 hour

Newfoundland Standard Time (NST) (NDT) -3.5 hours -2.5 hours

Atlantic Standard Time (AST) (ADT) -4 hours -3 hours

Eastern Standard Time (EST) (EDT) -5 hours -4 hours

Central Standard Time (CST) (CDT) -6 hours -5 hours

Mountain Standard Time (MST) (MDT) -7 hours -6 hours

Pacific Standard Time (PST) (PDT) -8 hours -7 hours

Alaskan Standard Time (AKST) (AKDT ) -9 hours -8 hours

Hawaiian Standard Time (HST) -10 hours

International Date Line West (IDLW) -12 hours

s o l u t i o n s @ c l e e v e t e c h . c o m

Although all information in this catalogue, including illustrations, is believed to be reliable, Cleeve Technology International, and all its subsidiary companies, makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding the use of the information contained herein.

Users are responsible to independently evaluate the suitability of the product for their application. Cleeve Technology International’s only obligations are those in the Standard Terms and Conditions of Sale forthese products and in no circumstances will the company, and all its subsidiary companies, be liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuse of the products.

Specifications are subject to change without notice. In addition, Cleeve Technology International reserves the right to make changes in materials or processing without notice to the purchaser which do not affectcompliance with any applicable specification.

The following are trademarks of E.I. du Pont de Nemours and Company: Mylar, Viton.

The following is a trademark of Elf Atochem North America Inc.: Kynar

Cleeve Technology Incorporated

716 Colonel Sam Drive

Oshawa, Ontario,

L1H 7Y2

Canada

Tel: 001-905-579-9502

Fax: 001-905-579-9991

Cleeve Technology GmbH

Masurenweg 11

65817 Eppstein,

Germany

Tel: +49 (0) 6198-587970

Fax: +49 (0) 6198-587971

Cleeve Technology Limited

Unit 2 Leopold Street

Lamberhead Industrial Estate

Pemberton, Wigan,

WN5 8EG,

England

Tel: +44 (0) 1942 217721

Fax: +44 (0) 1942 217717

Cleeve Technology Limited

Unit 12 Twigworth Court

Business Center

Twigworth, Gloucestershire,

GL2 9PG,

England

Tel: +44 (0) 1452-731118

Fax: +44 (0) 1452-731128

Cleeve Technology Pty Ltd.

Eastpint

23/42-46 Wattle Road

Brookvale NSW 2100

Austrailia

Tel: +61 (0)2 9939 6392

Fax: +61 (0)2 9939 6246

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