Military Training Procedure Template - L3Harris...00110310 DOUBLE LOCKSTITCH ACROSS DOUBLE LOCKSTITCH ON EACH BRANCH CONNECTED THROUGH THE CROSS 00110311 DOUBLE LOCKSTITCH …

MILITARY TRAINING PROCEDURE

LMS 11-6 Cable and Harness Making

Effective Date: 12/1/2020 Version: 2

Owner: Paul Mueller, Director of Engineering //Signature on File//

Function: Hardware Engineering

Page 1 of 20

L3Harris Instruction Printed or electronic copies are uncontrolled, validate prior to use Printed on: December 17, 2020

PURPOSE Establishes requirements for the fabrication and inspection of cables and harnesses.

Requirements of this instruction shall be met by all Link Training & Simulation

(hereafter referred to as Link) personnel involved in the manufacture of cables and

harnesses.

AFFECTED Hardware Engineering

FUNCTIONS Manufacturing

REFERENCES ASTM-D-4388, “Standard Specification for Nonmetallic Semi-conducting

and Electrically Insulating Rubber Tapes”

MIL-R-6855, “Rubber, Synthetic, Sheets, Strips, Molded or Extruded

Shapes, General Specification for”

DEFINITIONS Cable assembly. A cable assembly is an assembly of more than one wire, branched if

necessary, and terminated with connectors or lugs. A cable assembly normally serves as

an electrical interconnection between units (cabinets, cockpit, console, etc.).

Cold flow. Distortion of the jacket or insulation on wires caused by sustained pressure.

Wiring harness assembly. A wiring harness is a bundle of wires bound as a group by

lacing, ties, or similar means. The wiring harness serves as an electrical interconnection

between the components, assemblies, drawers, etc., within a unit (cabinet, rack, cockpit,

console, panel, etc.). A wiring harness may be:

a. Prefabricated and installed as an assembly and identified by a part number.

b. Fabricated in place per a wiring list or diagram. This option is at the

discretion of Industrial Engineering.

Main trunk. The main trunk is that portion of the assembly which has the largest number

of wires.

Front face of a connector. The front face of a connector or terminal lug is the mating face

of the connector or terminal lug. Examples are as follows:

INSTRUCTION

1. Requirements. The requirements of this instruction are divided into three parts.

Cable and harness assemblies. (See paragraph 1.1.)

Fabrication of cable assemblies. (See paragraph 1.2.)

Harness instructions. (See paragraph 1.3.)

00110301

FRONT FACE OFTERMINAL

FRONT FACEOF CONNECTOR

Procedure Number: LMS 11-6 Version: 2

Procedure Name: Cable and Harness Making Page 2 of 20


1.1 Cable and harness assemblies.

a. Splices and ferrules. Except when specified on the engineering drawing, the splicing of

wires is only permitted for commercial products. When splices, ferrules, etc., are

specified on the drawing, they shall be staggered in the cable or harness in order to

prevent buildup of the overall diameter.

b. Lacing. Cable assemblies and harnesses shall normally be continuously laced. This

instruction, however, provides the option of using spot tying in lieu of continuous lacing

when it is considered expedient or more practical.

(1) Loose stitching is not permitted. However, stitching must not be so tight as to

cause cold flow of the wire insulation.

(2) Lacing shall not be used under tubing or sleeving unless specifically noted on

the engineering drawing.

(3) Leads shall be separated with a single lockstitch between the black branch and

red lines (main body), as indicated on a cable board.

(4) Wherever practical, all cable and branch bodies being continuously laced shall

be laced with a single strand of braid. Should the braid run short or break, the

following procedure shall be followed:

(a) Tie off the broken or short end with a double lockstitch, followed by a

single lockstitch on two or three wires. (See Figures 4 and 7.)

(b) With the new braid, start behind the double lockstitch with a starting

stitch. (See Figure 1.)

(c) With the running end of the new braid, tie a single lockstitch snug

against the double tie-off, then cross over the double tie-off and

continue lacing in the normal manner.

(5) Continuous lacing. The first tie in continuous lacing shall be a full clove hitch

secured with a square knot. (See Figure 1.)

(6) Alternate stitches. Alternate stitches or knots, for the first tie, are dependent

upon the application. One alternate first tie is used to anchor the cord when

lacing in two directions. (See Figure 2.) The other alternative is shown in

Figure 3 and is used to anchor one end of the cord to lace a branch.

Figure 1 Continuous Lacing

First Tie


Alternate First Tie

00110302

00110303





Alternate First Tie


Succeeding Ties (Lockstitches)

(7) Lockstitches. Succeeding ties in continuous lacing shall be lockstitches. (See

Figure 4.) A lockstitch is commonly referred to as a marline.

(8) End stitch. The ending stitch shall consist of four lockstitches, two on the last

group of leads and two on the longest lead of that group, or, if existing, on the

last lead of the branch.

(9) Stitch and lacing cord requirements. Table I establishes stitch and lacing cord

requirements for cables and harnesses.

Table I Stitch and Lacing Cord Requirements

for Continuous Lacing

CABLE DIAMETER STITCH USED LACING CORD

UP to .75 in. (1.9 cm) Single Lockstitch #18-.094 in. (0.239 cm) width (Link PN 244854)

.75 in. to 1.50 in. (1.9 cm to 3.81 cm) Double Lockstitch #18-.094 in. (0.239 cm) width (Link PN 244854)

1.50 to 2 in. (3.81 cm to 5.08 cm) Double Lockstitch #26-.25 in. (0.635 cm) width (Link PN 281119)

(10) Spot ties. Individual spot ties shall be either of two types defined as Option 1

or Option 2.

Option 1: An individual spot tie composed of a full clove hitch secured with a square knot is shown in

Figure 5. A minimum of .125 inch (0.318 cm) of lacing cord shall be left after cutting off the

ends of the cord.

Figure 5 Option 1 Spot Tie

Option 2: An individual spot tie is executed by drawing both ends of the lacing cord through a type of

loop knot (see Figure 6), pulled snug, and secured with a square knot. A minimum of .125

inch (0.318 cm) of lacing cord shall be left after cutting off the ends of the cord.

00110304

00110305

00110306




Figure 6 Option 2 Spot Tie

(11) Lacing and spot tie requirements. Table II establishes spot tie and lacing cord

requirements on cables and harnesses. Spacing shall be in accordance with

Table VIII.

Table II Lacing Spot Tie Requirements

CABLE DIAMETER SPOT TIES USED LACING CORD

UP to .75 in. (1.9 cm) Single Spot Tie #18-.094 in. (0.239 cm) width (Link PN 244854)

.75 in. to 1.50 in. (1.9 cm to 3.81 cm) Double Spot Tie #18-.094 in. (0.239 cm) width (Link PN 244854)

1.50 to 2 in. (3.81 cm to 5.08 cm) Double Spot Tie #26-.25 in. (0.635 cm) width (Link PN 281119)

(12) Spacing of ties.

(a) See paragraph 1.2a for spacing of stitches and spot ties on cable

assemblies.

(b) See paragraph 1.3 for spacing of stitches and spot ties on harnesses.

(13) Fan lacing. Fans shall be laced approximately 1 to 2 inches (2.54 cm to 5.08

cm) from the point of the fan, as illustrated in Figure 7. The pins or leads in a

spares fan shall be numbered to identify each spare. Fan stitching shall start

from the point of the fan with a double lockstitch, then a single half hitch

(Figure 8) halfway between the branch end and the fan lacing line. At the

lacing line, on the first wire (lacing clockwise), there shall be a double half

hitch and then a half hitch on each lead thereafter, with a double lockstitch on

the final lead of the fan. A minimum of .125 inch (0.318 cm) of cord shall be

left. Fan stitching is used only as a manufacturing aid.

00110307




Figure 7 Fan Lacing

(14) Half hitch. A half hitch is a stitch formed by making an overhead knot. The

only difference between this type of stitch and a lockstitch is that the lockstitch

has an extra twist in the loop. (See Figure 8.)

Figure 8 Half-Hitch Stitch

(15) Double half hitch. A double half hitch is two half hitches side by side.

(16) Branch.

(a) Double lockstitch. The first lead or group of leads of any branch shall

be a double lockstitch.

(b) When four or more wires take off from the same body position, they

shall be double lockstitched.

(c) A double lockstitch is required on all take-off branches at the point it

breaks away from a cable body or another branch body.

(17) Cross-stitching. When two branch bodies take off opposite each other from the

cable body, rigidity may be necessary, and, therefore, cross-stitching is

required. If either of the branch bodies are .50 inch (1.27 cm) or larger in

diameter, cross-stitching is required. (See Figure 9.) If both branch bodies are

smaller than .50 inch (1.27 cm) diameter, the cross-stitching is not necessary.

00110308

DOUBLE LOCKSTITCH

DOUBLE HALF STITCH

1 IN. to 2 IN. (2.54 cm to 5.08 cm) APPROX.

8 IN. (20.32 cm) REF(STANDARD FAN LENGTH)

00110309




Figure 9 Lacing Branch Leads Opposite Each Other

(18) Stitching on radius. A double lockstitch is required on each side of all body

pins or hooks when a radius or bend has to be maintained.

(a) When a bend is called for, but is shown as a straight body, a double lockstitch shall be

placed on each side of the added allowance (length) as marked on the cable board.

(b) The curved position of a harness shall be sewn into the harness only when it is indicated

on the harness drawing by a radius.

(c) Right angle bends, dimensioned on the harness drawing as such, shall be laced into the

harness.

(d) All branches, unless otherwise dimensioned on the drawing by a radius or an angle,

shall be considered to be at right angles with the main trunk of the cable and shall be

laced accordingly.

(19) Branch identification. The leads of a branch which terminate at a junction box

or a terminal strip shall be laced to indicate the sequence of termination. (See

Figure 10.)

Figure 10 Terminations at Junction Box or Terminal Strip

00110310

DOUBLE LOCKSTITCH ACROSS

DOUBLE LOCKSTITCH ON EACHBRANCH CONNECTED THROUGHTHE CROSS

00110311

DOUBLELOCKSTITCH

SINGLELOCKSTITCH

DOUBLELOCKSTITCH




(20) Jumper wires. Double lockstitch all jumper wires with both end take-offs 4

inches (10.16 cm) or less in the main or branch bodies.

(21) Connector leads. All leads from a connector to the harness body shall be

double lockstitched, starting close enough to the connector to keep the

insulation sleeving on the connector contacts in place.

(22) Care shall be taken not to subject the wire to abrasions or severe strains which

could cause wire breakage or damage to insulation or contribute to cold flow of

the insulation when laced.

(23) Lacing procedures on large diameter cable/harness.

(a) Any cable/harness which exceeds 2 inches (5.08 cm) in diameter shall

be split into 2 or more sections.

(b) When a number of wires have been run on a cable board to the point

where the main trunk of the cable/harness becomes 1.75 inches (4.445

cm) in diameter, cease running wire and lace or bundle the main trunk

area at this point. (See Figure 11.)

(c) Resume running wire on the cable board until enough has been run to

form another 1.75-inch (4.445-cm) section and repeat the lacing

process as before until the entire cable/harness is run.

(d) Combine all of the trunk sections into one unit trunk, spacing double

spot ties of .25 inch (0.635 cm) of lacing cord approximately 10

inches (25.4 cm) apart. (See Figure 12.)

(e) At branch points on trunks (See point ”C”, Figure 11), secure the

main trunk and the branch trunk with double spot ties within 3 inches

(7.62 cm) of the center of the “tee”. (See Figure 13.)

Figure 11

Splitting Cable/Harness

Figure 12

Combining Split Cable/Harness

00110312

A B

C

D

NOTE: LACE OR BUNDLE AREA “A, B, C, D” WITH NYLON BRAID IN ACCORDANCE WITH THE REQUIREMENTS OF THIS INSTRUCTION.

00110313

EACH SECTION INDIVIDUALLY LACED PRIOR TO FINAL TYING.(TO AID IN INSTALLATION OF A CABLE, THE TIES MAY BE RE-MOVED AT A POINT WHERE ADDED FLEXIBILITY IS DESIRED.)

10 IN. (25.4 cm)




Figure 13 Double Spot Ties of Main Trunk and Branch Trunk

c. Nylon tie straps. Spacing of the straps shall be the same as for spot tying. See Table

VIII. Table III establishes the cable diameter and the strap requirements.

00110314

3 IN. (7.62 cm)

3 IN. (7.62 cm) 3 IN. (7.62 cm)




Table III Nylon Tie Strap Requirements

CABLE DIAMETER

INCHES (cm)

NYLON TIE STRAP

PART NUMBER WIDTH

INCHES (cm) LENGTH

INCHES (cm)

Up to .625 (1.588 cm) MS3367-4-9 .100 (0.254 cm) 2.72 (6.909 cm)

.625 to 1.125 (1.588 to 2.858 cm) MS3367-5-9 .146 (0.371 cm) 4.68 (11.887 cm)

1.125 or 1.75 (2.858 to 4.445 cm) MS3367-1-9 .190 (0.483 cm) 6.30 (16.002 cm)

1.75 to 4 (4.445 to 10.16 cm) MS3367-2-9 .192 (0.488 cm) 13.35 (33.909 cm)

(1) Tool adjustment. The tie strap tool shall be adjusted to result in a snug, fully

locked installation. The tool shall cut off the surplus strap tail approximately

flush with the boss of the strap.

(2) Branch points. At branch points on cables, a strap shall be used before and

after the take-off points and on the branch itself adjacent to the take-off point

(Figure 14, part A).

(a) The use of a single strap, cross-wrapped as in Figure 14, part B is

optional where the diameter of the branch does not exceed .50 inch

(1.27 cm).

Figure 14 Tie Straps on Branch Points

00110315

A. B.




(b) At the branch points on cables, where the spacing is 1 inch (2.54 cm)

apart, the straps shall be applied (as shown in Figure 15), with one

strap between the branches serving as the following tie for the second

branch. The single cross-strap as shown at the right branch in Figure

15 is optional.

Figure 15 Tie Straps on Branch Points 1 Inch (2.54 cm) Apart

(c) On cables which have branch leads opposite each other, and the

branches are less than .50-inch

(1.27-cm) diameter, straps shall be applied as shown in Figure 16,

part A or B. If either branch is greater than .50 inch (1.27 cm)

diameter, separate branch ties and cross-straps are required as in

Figure 16, part C.

00110316

1 IN. (2.54 cm)




Figure 16 Tie Straps on Branch Points Opposite Each Other

(3) Whenever the mounting boss-type of tie strap is called out on a cable assembly

for a specific application, the boss shall be installed at the top of the trunk,

unless otherwise specified. (See Figure 17.)

Figure 17 Location of Mounting Boss Type Tie Strap

d. Zipper tubing/expandable braided sleeving.

(1) Shielded zipper tubing, such as Link PN 454086 through 454095, contains an

internal overlap of metallic shielding that must completely surround the cable

conductors in order to provide efficient radio frequency and ultra-high

frequency shielding of the cable assembly. When used, care must be taken to

insure that the shield overlap is not folded back or under and that all

conductors are enclosed within the shielding. The overlap of the zipper tubing

shall be sealed when completed. (See Figure 18.)

00110317

A.

B. C.

00110318




Figure 18 Shielded Zipper Tubing Internal Overlap

(2) When a drawing specifies the grounding of the shield of shielded zipper tubing

to the shell of a connector, trim back the zipper tube insulation at the shell,

leaving approximately 2 inches (5.08 cm) of the .25 inch (0.635 cm) braid

exposed. Fold the braid back over the zipper tubing and under the cable

clamp. Install a lug on the braid and place the lug under the screw of the cable

clamp. An identification sleeve is required on the ground braid.

(3) Unless otherwise specified on the drawing, the method to continually shield

branched legs will be as follows. Each zipper tubing shield will terminate as

close as possible to the junction point. A cable tie or lacing cord will be used

to terminate the insulation. Unless otherwise specified, all shields shall be

made common by soldering. (See Figure 19.)

Figure 19 Terminating Continual Branch Shields of Shielded Zipper Tubing

(4) Plain, unshielded zipper tubing may be spliced by closing and spot tying the

end of one of the tubing sections in two places, inserting it into the second

section, closing the second section and again spot tying in two places. (See

Figure 20.) The maximum number of splices in a cable or harness assembly

shall be in accordance with Table IV.

Table IV Splices Permitted For Unshielded Zipper Tubing

CABLE LENGTH MAXIMUM NO. OF SPLICES

Less than 10 ft (3.048 m) 0

10 ft to 25 ft (3.048 m to 7.62 m) 1

Over 25 ft (7.62 m) 2

00110319

ZIPPERTUBING

CABLECONDUCTORS

SHIELDOVERLAP

00110320

SOLDER CONNECTION

SHIELD




Figure 20 Splicing Unshielded Zipper Tubing

(5) Shielded zipper tubing may be spliced by trimming the section ends similar to

those shown in Figure 21, overlapping and soldering the metal braid, and spot

tying the two sections in two places after closing. Dimensions in inches

(centimeters) in Figure 21 are approximate. Maximum number of splices per

cable or harness assembly shall be as specified in paragraph 1.1d(4).

Figure 21 Splicing Shielded Zipper Tubing

(6) Except at branch points, when zipper tubing/expandable braided sleeving is

used, the cable shall not be laced or tie straps used at any point covered by the

zipper tubing/expandable braided sleeving.

(7) When zipper tubing or expandable braided sleeving is specified, it shall be

applied to all branch and cable lengths 6 inches (15.24 cm) or longer. Table V

defines the cable diameters and corresponding requirements. The next size

larger or smaller of the applicable tubing/sleeving may be used. The same

basic item as specified on the Engineering drawing shall be used, the

substitution being limited to variations in tubing/sleeving diameter.

(a) Expandable braided sleeving. When using expandable sleeving on

the main body of cables, single wire branches may be pulled through

the sleeving with a hook-type instrument. A spot tie or tie strap shall

be applied (as specified on the drawing) on each side of the branch

over the sleeving.

(b) Cutting expandable sleeving. To eliminate fraying, expandable

sleeving shall only be cut with a hot knife.

00110321

2.0 to 4.0 In. (5.08 cm to 10.16 cm)depending on tubing diameter.

00110322

END “A”

END “A”

END “B”

END “B”

1.25 IN.(3.175 cm)

.25 IN.(0.635 cm)

2.0 TO 4.0 IN.(5.08 cm TO 10.16 cm)DEPENDING ON DIAMETER

BRAID

TRIM SHIELDING AND INNER LINER TOPOINT WHERE INNER LINER IS BONDEDTO TUBING

KEEP GAP TO A MINIMUM

END “B” BRAID SOLDERED TO END “A” BRAID,FAR SIDE, FULL LENGTH OF OVERLAP

CLOSE AND SPOT TIE BOTH ENDS AS SHOWN




Table V Zipper Tubing, Expandable Braided Sleeving Requirements

CABLE DIAMETER ZIPPER TUBING

LINK PN

ZIPPER

TUBING ID

EXPANDABLE

BRAIDED SLEEVING

LINK PN ID

BRAID

SLEEVING

UP to .250 (0.635) 1005478-024 .375 (0.953) 1007010-004 .25 (0.35)

.250 to .375 (0.635 to 0.953) 1005478-025 .500 (1.27) 1007010-001 .50 (1.27)

.375 to .500 (0.953 to 1.27) 1005478-026 .625 (1.588) 1007010-001 .50 (1.27)

.500 to .625 (1.27 to 1.588) 1005478-027 .750 (1.905) 1007010-005 .75 (1.905)

.625 to .750 (1.588 to 1.905) 1005478-028 .875 (2.223) 1007010-005 .75 (1.905)

.750 to .875 (1.905 to 2.223) 1005478-029 1.000 (2.54) 1007010-005 .75 (1.905)

.875 to 1.125 (2.223 to 2.858) 1005478-031 1.250 (3.175) 1007010-002 1.25 (3.175)

1.125 to 1.375 (2.858 to 3.493) 1005478-033 1.500 (3.81) 1007010-002 1.25 (3.175)

1.375 to 1.625 (3.493 to 4.128) 1005478-035 1.750 (4.445) 1007010-003 2.5 (6.35)

1.625 to 1.875 (4.128 to 4.763) 1005478-036 2.000 (5.08) 1007010-003 2.5 (6.35)

NOTE: All dimensions are in inches (centimeters).

e. Small diameter cable. When the diameter of a cable or harness is too small for a

connector clamp, and a grommet or filler is not specified, the clamp may be filled by

wrapping the cable or harness with a sufficient number of turns of solid rubber strip

(such as Link PN 263022) to provide a good clamping action. (Reference paragraph

1.2c.)

f. Large diameter cables. When the engineering drawing specifies a cable clamp rubber

grommet and the diameter of the cable or harness is too large to assemble the grommet

under the clamp, the grommet may be omitted. However, if omission of the grommet

creates a loose clamping condition, the clamp may be filled as specified in paragraph

1.2c.

g. Wire braid, shielding. In order to better utilize materials, it is permissible to splice wire

braid when used as shielding in a cable or harness assembly. Splicing shall be

accomplished by overlapping the two ends by 1 or 2 inches (2.54 cm or 5.08 cm),

depending on the braid diameter and soldering the complete length and circumference

of the overlapped portion. The maximum number of splices in a cable or harness

assembly shall be in accordance with Table VI.

Table VI Splicing Requirements For Wire Braid Shielding

CABLE LENGTH MAXIMUM NUMBER OF SPLICES


10 ft to 25 ft (3.048 m to 7.62 m) 1

Over 25 ft (7.62 m) 2

h. Flexible, plastic-covered metal conduit.

(1) Flexible, plastic-covered metal conduit, similar to Link PN 1002052, may be

spliced by use of two box connectors (Link drawing No. GN88048) and one

rigid conduit nipple (Link drawing No. 1002631). Refer to the referenced

drawings for complete part (dash) numbers of the various sizes. The maximum

number of splices per cable assembly shall be in accordance with Table VII.




Table VII Splices Permitted For Flexible, Plastic-Covered Metal Conduit

CABLE LENGTH MAXIMUM NUMBER OF SPLICES


10 ft to 25 ft (3.048 m to 7.62 m) 1

Over 25 ft (7.62 m) 2

(2) Conduit splicing. Box connectors come complete with a compression nut,

ferrule, and connector body. Use of these conduit connectors is shown below.

(a) Cut conduit to the desired length, making certain that the neoprene

jacket and conduit are flush, and place compression nut over conduit.

(See Figure 22.)

(b) Screw ferrule into the spiralled steel liner wall of the conduit. (See

Figure 23.)

(c) Place the conduit with the ferrule into the connector body and tighten

the compression nut as far as it will go, so that it touches the

connector body stop. (See Figure 24.) This will assure correct

collaring of the conduit so that the end of the ferrule pinches around

the conduit, forcing the metal edge of the ferrule to curve out slightly.

(See Figure 25.)

Figure 22 Splicing Conduit




(d) Assemble the two conduit ends with assembled box connectors into

the conduit nipple, completing the splice. (See Figure 26.)


i. Spare wires. Spare wires shall be handled in accordance with the following:

00110323

COMPRESSIONNUT

FERRULE CONNECTORBODY

CONDUIT CUT FLUSH

00110324

COMPRESSIONNUT

FERRULE

CONDUIT

00110325

COMPRESSIONNUT

CONNECTORBODY

00110326

COMPRESSEDFERRULE

00110327CONDUIT NIPPLE




(1) Prejacketed cables. When the drawing specifies spare wires run to a connector

but not terminated in connector pins, the wires shall be the same length as the

connected wires and shall be spot tied to the cable.

(2) Nonprejacketed cables. When the drawing specifies spare wires run to a

connector but not terminated in connector pins, the spare wires shall be a

minimum of 6 inches (15.24cm) longer than the connector wires. The spare

wires shall be looped back inside or outside the cable tubing or sheathing.

When looped back outside, the wires shall be spot tied to the cable as shown in

Figure 27. Each spare wire shall be tied in a single overhand knot at the end of

the wire to prevent loss of the identification sleeve. (See Figure 27.)

Figure 27 Spares in Nonprejacketed Cables

(3) When the drawing specifies short lengths of spare wires to be

terminated in a connector, the spare wires shall be looped back and

tied to the cable in a manner similar to that shown in Figure 28. Each

such spare wire shall be tied in a single overhand knot at the end of

the wire to prevent loss of the identification sleeve. (See Figure 28.)

(4) NC (No Connection) wires shall be handled in the same manner as

spare wires.

Figure 28 Short Lengths of Spares Terminated in Connector

j. Wiring list. The manufacturing departments shall make a wiring list for each cable

board fabricated in their respective departments if a wiring list does not exist. The

wiring list shall be kept on file in the department fabricating the cable board.

k. Harness fabricating procedures.

(1) Check the Bill of Material block on the cable or harness board for wire part

number, gauge, and color of wire. Check the Engineering Change Notice

Number on the board to see if it agrees with the change number on the Harness

Assembly drawings. If there is no assembly drawing, then the board should be

checked against the Schematic Diagram or the Schematic List.

00110328

P1 P2

LACING

SPARE WIRESIDENT SLEEVES


LACING

00110329

P1 P2

LACING





(2) The drawings, wire list, and plug sheets (Schematic List) are to be followed at

all times. No deviation will be allowed unless the drawings are marked and

stamped with an approved change control stamp and signature, or the change is

included on an ECN against the affected drawing.

(3) If the wiring list does not agree with the best running sequence, a change

should be suggested to the industrial engineer.

(4) Visually inspect the cable or harness board for bent pins, bent hooks, or any

other defects which could change the physical dimension of the harness.

(5) The wire shall be run on the board in accordance with the wire list. Usually

the largest gauge wire is run first, followed by twisted pairs, if any, then

completed by running the small-gauge wires.

(6) Wires are not to be run on the board so tightly that it may cause wire breakage,

or damage to insulation or contribute to cold flow of the insulation when

lacing.

(7) All wires are to be run within the body guide lines and pins so that wires will

lie in the correct channels.

(8) When terminating a wire on a given pin, it is to be cut. Terminating the wire by

snapping is not permitted.

(9) Lead wires shall be run to the correct connection pin via the position pin as

indicated on the harness drawings and harness board.

(10) After the last wire is run on the board, physically check the wire terminations

against the schematic list in order to make sure all wires called out have been

run on the board.

1.2 Fabrication of cable assemblies.

a. Spacing of stitches (continuous lacing) and spot ties (when used in lieu of continuous

lacing) on cable assemblies shall be in accordance with Table VIII.

Table VIII Spacing of Lacing Stitches

CABLE DIAMETER SPACING

Up to .50 in. (1.27 cm) 3 in. (2.62 cm) .50 in. (1.27 cm)

Over .50 in. (1.27 cm) 4 in. (10.16 cm) .50 in. (1.27 cm)




b. Cable and harness length dimensions, as specified on the assembly drawings, shall be interpreted as dimensions to the front face of the connector(s), terminal lug(s), or termination(s). Dimensions for branch lengths shall be from the branch side at the take-off point to the face of the connector. Tolerances on cable lengths, unless otherwise specified on the drawing, shall be in accordance with Table IX.

Table IX Cable and Harness Tolerances

LENGTH * TOLERANCE

UP to 6.0 IN. (15.24 cm) +1.0 IN. (2.54 cm) - 0

OVER 6.0 IN. to 36.0 IN (15.24 cm to 0.914 m) +2.0 IN. (5.08 cm) - 0

OVER 36.0 IN. to 60.0 IN. (0.914 m to 1.524 m) +4.0 IN. (10.16 cm) - 0

OVER 5.0 FT to 10.0 FT (1.524 m to 3.048 m) +6.0 IN. (15.24 cm) - 0

OVER 10.0 FT to 50.0 FT (3.048 m to 15.24 m) +2 FT (0.6096 m) - 0

OVER 50.0 FT to 75 FT (15.24 m to 22.86 m) +3 FT (0.9144 m) - 0

OVER 75.0 FT (22.86 m) +4 FT (1.219 m) - 0

* Exception. Twisted-pair, flat-ribbon cable. Proper termination of twisted-pair ribbon cable, such as Link PN 1005857, requires that the connector be applied only on flat surfaces of the cable at increments of 20 inches (50.8 cm). If the assembly drawing requires a length that does not coincide with a flat surface, the overall length shall be increased to the next flat surface in the ribbon cable.

c. Due to the inflexibility of some types of special purpose electrical multiconductor cable, it is permissible to strip the outer jacket a maximum of 4 inches (10.16 cm) to facilitate wiring the connector. After wiring the connector, it is necessary to protect the conductors and provide adequate strain relief under the connector clamp. Strain relief is accomplished using one of the following methods:

(1) The preferred method is to wrap a strip of rubber sheet or linerless rubber splicing tape around the exposed conductors. The rubber cushion shall be of the appropriate width and length according to the cable size and clamp size. The cushion is made from MIL-R-6855 synthetic rubber sheet or splicing tape wrapped to a.062 inches thickness. (See Figure 29.) The synthetic rubber shall comply with the requirements of ASTM-D-4388 or MIL-R-6855.

(2) Heat shrink tubing shall be placed over the exposed conductors.

(3) Wire braid shall be doubled back and laced over the exposed conductors.

(4) Rubber grommets shall be used only when specified on the drawing.

NOTE: Electrical tape and pressure-sensitive adhesive identification tape

(reference LMS 11-8) shall not be used for strain under any condition.

NOTE: Conductors shall be firmly secured within the strain relief when the clamp

is tightened.




Figure 29 Rubber Sheet Cushion Under Strain Relief

d. When the drawing specifies multiconductor cable utilizing splices, the outer jacket may

be stripped more than 4 inches (10.16 cm), provided an abrasive protective sleeving is

used to replace the outer jacket that was removed.

1.3 Harness instructions. The spacing of stitches (continuous lacing) and spot ties (when used in

lieu of continuous lacing) shall be approximately one inch (2.54 cm) apart on small harness

wiring such as card bins and relay chassis, and approximately two inches (5.08 cm) apart on

cabinet and unit harness wiring.

00110330

CONNECTOR

STRAIN RELIEF CLAMP ADD RUBBER SHEET CUSHION

CABLE OUTER JACKET

4.0 IN. (10.16 cm) MAX.




1.4 Other applications.

a. Applicable portions of this instruction shall be utilized in the fabrication of panel

assemblies and units which require the application of lacing, protective coverings such

as zipper tubing, identification sleeves, and/or dangle connectors. Spacing of stitches

shall conform to paragraph 1.3. Tolerances for length of wire/bundle branches, which

terminate in dangle connectors or crimp-type terminations, shall conform to paragraph

1.2b.

b. All dangle connectors shall be protected in accordance with paragraph 1.5.

1.5 Protective measures. All unmated connectors shall be suitably protected from contamination

(e.g., dirt, dust, moisture, etc.) during maintenance, storage, and shipment. Connectors on

enclosed cabinet mounted equipment are not required to be protected unless an environmental

hazard exists.

2. Quality Assurance Requirements

2.1 The Quality Assurance Organization shall be responsible for assuring that the workmanship

meets the minimum requirements specified herein.

2.2 Inspection shall be conducted to assure that all cables and harnesses meet the requirements of

this Manufacturing Standard, the applicable engineering drawings, and associated documents.

3. Preparation For Delivery. (Not Applicable)

CHANGE LOG

Ver Date Details

Rev U 01/26/2009 Last release to LINK Process Asset Library (PAL)

2 12/01/2020 Initial release to Military Training Process Asset Library (PAL). New Template,

Removed L-3 references, & updated Change Log.

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