Automotive

ABS Cable Transmission Wire

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Primary Wire

Specialty Wire & Cable

JUDD WIRE INC.

A member of the Sumitomo Electric Industries group of companies

Find the right Judd Wire product fast

ABS Cable
As a complete integrated wire and cable manufacturer, Judd Wire can design a broad spectrum of special applications for OEM or replacement applications in the Automotive Industry. We can work within given specifications or create a combination of construction choices for our customers that allow them the best choice of material and performance attributes for their unique needs. Our proprietary conductor exhibits very high flex life for desired applications. We offer unique jacket compounds to meet short excursion molding temperature up to 200C and continuous operating temperature up to 150C. Our various blends of insulation prevent melting or cracking during a molding process and are designed to easily form to different Nylon and Polyester compounds. Our cables provide superior flame resistance and are rated VW 1 testing parameters. Our engineering expertise has made Judd Wire a leading supplier to many automotive platforms being built today. Our product designs range from simple discrete wire to complex cable constructions. We provide the most effective choices among materials, designs, manufacturing processes, test verifications and custom packaging to meet your standards. For further information about our unique talents, please contact Judd Wire. We want to work with you to develop the right features and functions for your application.

Filler (optional)

Conductors

Outer Jacket Primary Insulation

Typical ABS Cable Design

Typical Product Characteristics s

High Temperature s Outstanding Fatigue and Flex life s Su s High Strength Alloy s Excellent Abrasion, Pinch, and Cut
Typical Applications

Active/Passive Sensor cable s Wheel Be

ABS Cable
Judd
Part Number

Gauge
Size Stranding

Conductor
Conductor Diameter inches mm

Type

Primary Insulation
Nominal Thickness inches mm Nominal Diameter inches mm

Type

Outer Jacket
Nominal Wall inches mm Nominal Diameter inches mm

Type

M7002000 M7002001 M0702221 M0702270 M0002121 M0702247 M0702295 M0702282 M0702277 M0702266 M0702271 M0702284 M0702274 M0702258 M0702297 M0702316 M0702351 M0702312 M0702280 M0702290 M0702300 M0702311 M0704119

20AWG .5mm2 20AWG 20AWG 20AWG 18AWG 20AWG .3mm2 .3mm2 18AWG 18AWG 20AWG 18AWG 20AWG 18AWG .3mm2 22AWG .3mm2 .3mm2 .5mm2 .5mm2 20AWG 20AWG

266 7 266 266 266 41 41 60 60 19 19 266 41 105 19 60 26 60 161 41 20 41 266

.042 .036 .042 .042 .042 .045 .035 .033 .033 .048 .048 .042 .045 .042 .048 .033 .029 .033 .033 .038 .039 .035 .042

1.07 0.91 1.07 1.07 1.07 1.14 0.89 0.84 0.84 1.22 1.22 1.07 1.14 1.07 1.22 0.84 0.74 0.84 0.84 0.96 0.99 0.89 1.07

CAL TC CAL CAL CAL TC TC CAL CAL TC TC CAL TC BC TC CAL TC CAL CAL CAL TC TC CAL

.012 .016 .020 .020 .020 .020 .021 .017 .017 .032 .032 .018 .021 .021 .017 .017 .014 .017 .019 .019 .028 .021 .018

0.03 0.04 0.51 0.51 0.51 0.51 0.53 0.43 0.43 0.81 0.81 0.46 0.53 0.53 0.43 0.43 0.36 0.43 0.48 0.48 0.71 0.53 0.46

.066 .068 .082 .082 .082 .085 .077 .066 .066 .112 .112 .077 .086 .084 .082 .066 .057 .067 .070 .077 .095 .077 .079

1.68 1.73 2.08 2.08 2.08 2.16 1.96 1.68 1.68 2.84 2.84 1.96 2.18 2.13 2.08 1.68 1.43 1.70 1.78 1.96 1.78 1.96 2.01

XLFE XLFE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

0.61 0.74 1.02 1.02 1.02 0.97 1.13 0.86 0.86 0.94 0.94 1.14 1.02 1.02 1.04 0.86 0.84 0.84 0.81 1.14 1.02 1.14 1.19

0.61 0.74 1.02 1.02 1.02 0.97 1.13 0.86 0.86 0.94 0.94 1.14 1.02 1.02 1.04 0.86 0.84 0.84 0.81 1.14 1.02 1.14 1.19

.180 .194 .244 .244 .244 .246 .244 .200 .200 .299 .299 .243 .252 .248 .246 .200 .180 .200 .203 .244 .270 .244 .284

4.57 4.93 6.20 6.20 6.20 6.25 6.20 5.08 5.08 7.59 7.59 6.17 6.40 6.30 6.25 5.08 4.57 5.08 5.16 6.20 6.86 6.20 7.21

XLPU XLFE XLPU XLPU XLPE PU XLPE XLPE XLPE PU XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

BC = ANNEALED BARE COPPER CAL = COPPER ALLOY TC = TIN COATED COPPER XLPU = POLYURETHANE, CROSSLINKED PU = POLYURETHANE, NON-CROSSLINKED XLPE = POLYOLEFIN, CROSSLINKED XLFE = FLOUROELASTOMER, CROSSLINKED

uperior Chemical, Mechanical, and Electrical Properties t-Through Resistance s Excellent Cut-Through Properties

earing Sensor cable s Ride Control cable

Find the right Judd Wire product fast

Transmission Wire
As a complete integrated wire and cable manufacturer, Judd Wire can design a broad spectrum of special applications for OEM or replacement applications in the Automotive Industry. We can work within given specifications or create a combination of construction choices for our customers that allow them the best choice of material and performance attributes for their unique needs. Our proprietary insulated compounds are designed to withstand short duration temperature usage of 250C and constant operating temperature up to 200C. Our unique designs can endure steady fluid temperature up to 150C. We offer compounds that resist chemical attack, improve cut-through and non-deformation resistance. Our engineering expertise has made Judd Wire a leading supplier to many automotive platforms being built today. Our product designs range from simple discrete wire to complex cable constructions. We provide the most effective choices among materials, designs, manufacturing processes, test verifications and custom packaging to meet your standards. For further information about our unique talents, please contact Judd Wire. We want to work with you to develop the right features and functions for your application.

Insulation Conductor (blocking optional)

Typical Transmission Wire Design

Typical Product Characteristics s

High Temperature s Outstanding Fluid Resistance s Superi Retardant s High Durability Insulation Flexibility s Outstan Pinch, and Cut-Through Resistance

Transmission Wire
Judd
Part Number

Gauge
Size Stranding

Conductor
Conductor Diameter inches mm

Type

Insulation
Nominal Thickness inches mm Nominal Diameter inches mm

Type

H7000000 H7000001 H7000003 H7000004 H0000105 H7000008 H7000009 H7000010 H7000016 H7000018 H7000020 H4001160 H7000017 H7000024 H0780180

.8mm2 .5mm2 18AWG 20AWG 20AWG .5mm2 .5mm2 .5mm2 8AWG 18AWG 22AWG 16AWG 18AWG 12AWG 5mm2

19 7 19 7 19 7 19 7 19 19 19 19 19 37 105

.043 .037 .049 .038 .038 .038 .036 .036 .043 .050 .030 .054 .050 .088 .119

1.09 0.94 1.24 0.97 0.97 0.97 0.91 0.91 1.09 1.27 0.76 1.37 1.27 2.24 3.02

TC TC SBB TC TC SBT SBT TC TC SBT BC SBB SBT SBT BC

.019 .015 .016 .016 .016 .015 .017 .016 .019 .016 .017 .016 .016 .018 .031

0.48 0.38 0.41 0.41 0.41 0.38 0.43 0.41 0.48 0.41 0.43 0.41 0.41 0.46 0.79

.080 .068 .080 .070 .070 .068 .070 .070 .080 .080 .064 .085 .080 .123 .180

2.03 1.73 2.03 1.78 1.78 1.73 1.78 1.78 2.03 2.03 1.63 2.16 2.03 3.12 4.57

XLFE XLFE XLFE XLFE XLFE XLFE XLFE XLFE XLFE XLFE XLFE ETFE XLFE XLFE XLPE

BC = ANNEALED BARE COPPER SBT = SILICONE BLOCK TIN PLATED COPPER SBB = SILICONE BLOCK BARE COPPER TC = TIN COATED COPPER XLPE = POLYOLEFIN, CROSSLINKED XLFE = FLUOROELASTOMER, CROSSLINKED ETFE = ETHYLENE TETRAFLUOROETHYLENE, NON-CROSSLINKED

ior Chemical, Mechanical, and Electrical Properties s Flame nding Dimensional Characteristics s Excellent Abrasion,

Judd

Gauge
AWG Stranding

Conductor
Conductor Diameter inches mm

Type

Insulation
Nominal Thickness inches mm Nominal Diameter inches mm

Type

Find the right Judd Wire product fast

Part Number

SAE
SXL H0779200 H0779210 H0779220 H0779230 H0779240 H0779250 H0779260 H0779500 H0779510 H0779520 H0779530 H0779540 H0779550 H0779560 H0779501 H0779511 H0779521 H0779531 H0779541 H0779551 H0779561 GXL H0779400 H0779410 H0779420 H0779430 H0779440 H0779450 H0779460 H0779700 H0779710 H0779720 H0779730 H0779740 H0779750 H0779760 H0779701 H0779711 H0779721 H0779731 H0779741 H0779751 H0779761 TXL H0779300 H0779310 H0779320 H0779330 H0779340 H0779350 H0779360 H0779370 H0779380 H0779600 H0779610 H0779620 H0779630 H0779640 H0779650 H0779660 H0779670 H0779680 H0779601 H0779611 H0779621 H0779631 H0779641 H0779651 H0779661 H0779671 H0779681

Primary Wire
As a complete integrated wire and cable manufacturer, Judd Wire can design a broad spectrum of special applications for OEM or replacement applications in the Automotive Industry. We can work within given specifications or create a combination of construction choices for our customers that allow them the best choice of material and performance attributes for their unique needs. We offer a unique combination of high performance properties to meet high heat and burn through resistance. Our insulation will not melt or flow at hot soldering iron temperature of 350C; consequently, rework due to soldering iron damage is eliminated. Our compounds are rated to temperatures of -55C to 150C for a wide range of applications. We offer various blends of compound to reduce creep caused by insulation stretching. Our insulated wire conforms easily to design shapes for chassis wiring and harness construction. Our engineering expertise has made Judd Wire a leading supplier to many automotive platforms being built today. Our product designs range from simple discrete wire to complex cable constructions. We provide the most effective choices among materials, designs, manufacturing processes, test verifications and custom packaging to meet your standards. For further information about our unique talents, please contact Judd Wire. We want to work with you to develop the right features and functions for your application.

8 10 12 14 16 18 20 8 10 12 14 16 18 20 8 10 12 14 16 18 20

19 107 19 19 19 19 19 19 19 19 19 19 19 19 133 105 65 41 26 41 41

.133 .123 .089 .068 .054 .048 .038 .133 .107 .089 .068 .054 .048 .048 .166 .123 .091 .071 .058 .045 .037

3.38 3.12 2.26 2.26 1.37 1.22 0.97 3.38 2.72 2.26 1.73 1.37 1.22 1.22 4.22 3.12 4.22 1.80 1.47 1.14 0.94

BC BC BC BC BC BC BC TC TC TC TC TC TC TC TC TC TC TC TC TC TC

.045 .043 .039 .037 .034 .032 .031 .045 .043 .039 .037 .034 .032 .032 .045 .043 .039 .037 .034 .032 .031

1.14 1.09 0.99 0.94 0.79 0.81 0.79 1.14 1.09 0.99 0.94 0.79 0.81 0.81 1.14 1.09 0.99 0.94 0.79 0.81 0.79

.223 .193 .167 .142 .122 .112 .100 .223 .193 .167 .142 .122 .112 .112 .256 .209 .169 .145 .126 .109 .099

5.66 4.90 4.24 3.61 3.10 2.84 2.54 5.66 4.90 4.24 3.61 3.10 2.84 2.54 6.50 5.31 4.29 3.68 3.20 2.77 2.51

XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

8 10 12 14 16 18 20 8 10 12 14 16 18 20 8 10 12 14 16 18 20

19 19 19 19 19 19 19 19 19 19 19 19 19 19 133 105 65 41 26 41 41

.133 .107 .089 .068 .054 .048 .038 .133 .107 .089 .068 .054 .048 .038 .166 .123 .091 .071 .058 .045 .037

3.38 2.72 2.26 1.73 1.37 1.22 0.97 3.38 2.72 2.26 1.73 1.37 1.22 0.97 4.22 3.12 2.31 1.80 1.47 1.14 0.94

BC BC BC BC BC BC BC TC TC TC TC TC TC TC TC TC TC TC TC TC TC

.039 .033 .028 .023 .023 .023 .023 .039 .033 .028 .023 .023 .023 .023 .039 .033 .028 .023 .023 .023 .023

0.99 0.84 0.71 0.58 0.58 0.58 0.58 0.99 0.84 0.71 0.58 0.58 0.58 0.58 0.99 0.84 0.71 0.58 0.58 0.58 0.58

.211 .173 .145 .114 .100 .094 .084 .211 .173 .145 .114 .100 .094 .084 .244 .189 .147 .117 .104 .091 .083

5.36 4.39 3.68 2.90 2.54 2.39 2.13 5.36 4.39 3.68 2.90 2.54 2.39 2.13 6.20 4.80 3.73 2.97 2.64 2.31 2.11

XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

8 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24

19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 133 105 65 41 26 41 41 41 41

.133 .107 .089 .068 .054 .048 .038 .030 .024 .133 .107 .089 .068 .054 .048 .038 .030 .024 .166 .123 .091 .071 .058 .045 .037 .029 .024

3.38 2.72 2.26 1.73 1.37 1.22 0.97 0.97 0.61 3.38 2.72 2.26 1.73 1.37 1.22 0.97 0.76 0.61 4.22 3.12 2.31 1.80 1.47 1.14 0.94 0.74 0.60

BC BC BC BC BC BC BC BC BC TC TC TC TC TC TC TC TC TC TC TC TC TC TC TC TC TC TC

.024 .022 .020 .018 .018 .018 .018 .018 .018 .024 .022 .020 .018 .018 .018 .018 .018 .018 .024 .022 .020 .018 .018 .018 .018 .018 .018

0.61 0.56 0.51 0.51 0.46 0.46 0.46 0.46 0.46 0.61 0.56 0.51 0.46 0.46 0.46 0.46 0.46 0.46 0.61 0.56 0.51 0.46 0.46 0.46 0.46 0.46 0.46

.181 .151 .129 .104 .090 .084 .074 .066 .060 .181 .151 .129 .104 .090 .084 .074 .066 .060 .214 .167 .131 .107 .094 .081 .073 .065 .060

4.60 3.84 3.28 2.64 2.29 2.13 1.88 1.68 1.52 4.60 3.84 3.28 2.64 2.29 2.13 1.88 1.68 1.52 5.44 4.24 3.33 2.72 2.39 2.06 1.85 1.65 1.52

XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

BC = ANNEALED BARE COPPER TC = TIN COATED COPPER XLPE = POLYOLEFIN, CROSSLINKED

Judd
Part Number

Gauge
mm2 Stranding

Conductor
Conductor Diameter inches mm

Type

Insulation
Nominal Thickness inches mm Nominal Diameter inches mm

Type

JASO
AVSSX H030543 H030506 H030521 H030544 H030508 H030503 H030545 H030510 H030546 H030522 AVX H030538 H030556 H030563 H030551 H030552 H030529 H030530 H030500 H030505 H030532 H030502 H030534 H030504 H030536 H030512 H030511 H030565 AVXTRA H030507 H030541 TVSSX H030549 H030548 H030520 AEX H0781630 H0781632 H0781660 H0781700 VX10 H0305500 AVFX H030527 H030528 TOKAI M0302372 M0303358 M0302356 C0301356 C0301357 FLCEX H0782141 H0782121 H0782111 APXHTSHE C0701067 SHSXSHE C0301390 C0301392 C0301394 C0307350 C0307351 C0307352 C0307353 C0307354 C0301340 SHSXT M0302385 M0302384 M0302383 M0302470 M0302363

.5 .5 .5 .75 .75 .75 1.25 1.25 2 2 3.0 5.0 8.0 10.0 15.0 20.0 .5 .5 .5 .75 .75 1.25 1.25 2.0 2.0 8.0 12.0 .75 .75 .5 .5 .5 .5 .5 .5 1.25 .10 8.0 15.0 .5 .5 .5 .5 .5 .85 2.0 3 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5 .5

19 19 7 19 19 30 37 37 37 37 41 65 154 154 84 247 20 20 20 30 30 50 50 26 26 154 154 30 30 20 19 19 20 20 20 50 63 154 171 20 20 20 20 11 26 41 20 19 19 19 7 7 7 20 20 19 19 19 19 19 19

.037 .037 .037 .046 .046 .045 .058 .058 .069 .069 .093 .117 .168 .179 .213 .258 .039 .039 .039 .045 .045 .059 .059 .074 .074 .168 .197 .045 .045 .039 .037 .037 .039 .039 .039 .059 .184 .168 .212 .039 .039 .039 .039 .039 .051 .074 .093 .039 .037 .037 .037 .037 .037 .037 .039 .039 .037 .037 .037 .037 .037 .037

0.94 0.94 0.94 1.17 1.17 1.14 1.47 1.47 1.75 1.75 2.36 2.97 4.27 4.55 5.41 6.55 0.99 0.99 0.99 1.14 1.14 1.50 1.50 1.88 1.88 4.27 5.00 1.14 1.14 0.99 0.94 0.94 0.99 0.99 0.99 5.00 4.67 4.27 5.38 0.99 0.99 0.99 0.99 0.99 1.30 1.88 2.36 0.99 0.94 0.94 0.94 0.94 0.94 0.94 0.99 0.99 0.94 0.94 0.94 0.94 0.94 0.94

BC BC BC BC BC TC BC BC BC BC BC BC TC TC TC TC BC BC TC BC BC BC BC BC BC TC BC TC TC TC TC TC TC TC TC TC TC TC BC BC BC BC BC TC TC TC TC BC BC BC BC BC BC BC BC BC TC TC TC TC TC

.014 .013 .013 .013 .013 .021 .013 .013 .017 .017 .031 .032 .034 .045 .043 .043 .039 .039 .019 .021 .021 .024 .024 .025 .025 .035 .040 .021 .021 .019 .014 .013 .019 .019 .020 .024 .038 .028 .044 .019 .019 .019 .019 .044 .044 .048 .021 .013 .013 .013 .021 .021 .021 .019 .019 .013 .013 .013 .013 .013 .013

0.36 0.33 0.33 0.33 0.33 0.53 0.33 0.33 0.43 0.43 0.79 0.81 0.86 1.14 1.09 1.09 0.99 0.99 0.48 0.53 0.53 0.61 0.61 0.64 0.64 0.89 1.02 0.53 0.53 0.48 0.36 0.33 0.48 0.48 0.51 0.61 0.97 0.71 1.12 0.48 0.48 0.48 0.48 1.12 1.12 1.22 0.53 0.33 0.33 0.33 0.53 0.53 0.53 0.48 0.48 0.33 0.33 0.33 0.33 0.33 0.33

.064 .063 .063 .072 .072 .087 .083 .083 .103 .103 .155 .181 .236 .268 .299 .345 .079 .079 .078 .087 .087 .106 .106 .123 .123 .238 .277 .087 .087 .079 .064 .063 .079 .079 .079 .087 .026 .224 .300 .079 .079 .079 .079 .138 .161 .189 .081 .063 .064 .064 .079 .079 .079 .079 .079 .064 .063 .063 .063 .063 .063

1.63 1.60 1.60 1.83 1.83 2.21 2.11 2.11 2.62 2.62 3.94 4.60 5.99 6.81 7.59 7.59 2.01 2.01 1.98 2.21 2.21 2.69 2.69 3.12 3.12 6.05 7.04 2.21 2.21 2.01 1.63 1.60 2.01 2.01 2.01 2.21 0.66 5.69 7.62 2.01 2.01 2.01 2.01 3.51 4.09 4.80 1.48 1.60 1.63 1.63 2.01 2.01 2.01 2.01 2.01 1.63 1.60 1.60 1.60 1.60 1.60

XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPE XLPE XLPE XLPE XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPE XLPE XLPE XLPE XLPE XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC XLPVC

Typical Product Characteristics

s High Temperature s Outstanding Flexibility Properties s Superior Chemical, Mechanical, and Electrical Properties s Lightweight Construction s Superior Flame Resistance s Environmental FriendlyHalogen and Lead Free Design s Excellent Abrasion, Pinch, and Cut-Through Resistance

Insulation Conductor (blocking optional)

Typical Primary Wire Design

BC = ANNEALED BARE COPPER TC = TIN COATED COPPER XLPVC = POLYVINYL CHLORIDE, CROSSLINKED XLPE = POLYOLEFIN, CROSSLINKED

Find the right Judd Wire product fast Specialty Wire & Cable
As a complete integrated wire and cable manufacturer, Judd Wire can design a broad spectrum of special applications for OEM or replacement applications in the Automotive Industry. We can work within given specifications or create a combination of construction choices for our customers that allow them the best choice of material and performance attributes for their unique needs. Our cross-linked irradiation technology enables our products to be highly dimensionally stable which improves abrasion and pinch requirements. Our products temperature range from -55C to 250C. Our proprietary conductors and compounds are aimed to meet and exceed specifications. Our engineering expertise has made Judd Wire a leading supplier to many automotive platforms being built today. Our product designs range from simple discrete wire to complex cable constructions. We provide the most effective choices among materials, designs, manufacturing processes, test verifications and custom packaging to meet your standards. For further information about our unique talents, please contact Judd Wire. We want to work with you to develop the right features and functions for your application.

Binder Tape Drain Filler Insulation Conductors

Outer Jacket Braided Shield Tape Separator

Available Design Features for Specialty Wires & Cables

Typical Product Characteristics s High Temperature s Outstanding Flexibility Properties s Superior Chemical, Mechanical, and Electrical Properties s Lightweight Construction and Dimensional Control s Superior Flame Resistance s Environmental Friendly- Halogen and Lead Free Design s Excellent Abrasion, Pinch, and Cut-Through Resistance s Improved Deformation and Shrink-back Properties s Excellent Shield Effectiveness and EMI, RF and Low Frequency Characteristics Typical Applications s Wheel Speed Sensor Cable s Side Air Bag Ignitor Wire s Seatbelt Pretension and Frontal Air Bag Wire s Gas Tank Wire s Fuselink s Databus s Battery Cable s Steering Wheel Wire s Temperature Sensor Cable s Chassis Sensor Cable s Tire Sensor Cable s Shielded and Blocked Cable s Bearing Grease Wire s DLX Wire s Sliding Door Sensor Cable s Electronic Fan Drive Cable

Specialty Wire & Cable

Judd
Part Number

Gauge
Size Stranding

Conductor
Conductor Diameter inches mm

Type

Insulation
Nominal Thickness inches mm Nominal Diameter inches mm

Type

WHEEL SPEED SENSOR CABLE M0702234 .5mm2 M0704102 .35mm2 M0704104 .35mm2 M0702268 .35mm2 SIDE AIR BAG M0302390 M0302392 M0302395 M0302396 M0302340 M1202304

7 7 7 7

.037 .029 .029 .029

0.94 0.74 0.74 0.74

BC HBC HBC HBC

.016 .016 .015 .015

0.41 0.41 0.38 0.38

.069 .060 .060 .060

1.75 1.52 1.52 1.52

XLPE XLPE XLPE XLPE

.35mm2 .5mm2 .5mm2 .5mm2 .5mm2 20AWG

20 20 20 20 19 7

.039 .039 .039 .039 .037 .037

0.99 0.99 0.99 0.99 0.94 0.94

TC TC TC TC BC BC

.019 .019 .019 .019 .013 .015

0.48 0.48 0.48 0.48 0.33 0.38

.078 .078 .078 .078 .063 .067

1.98 1.98 1.98 1.98 1.60 1.70

XLPVC XLPVC XLPVC XLPVC XLPVC PVC

SEATBELT PRETENSION & FRONTAL AIR BAG WIRE H0305050 .5mm2 20 H0305060 .5mm2 19 H0779101 20AWG 7 H0305086 .75mm2 19 H0305850 .85mm2 11 H0780096 18AWG 41 H0780303 20AWG 7 H0783500 14AWG 19 GAS TANK WIRE H0779110 H0779114 H0779111 H0779170 H0779171 H0779172 H0779185 H0779187 H0779180 H0779920 H0779930 H0779931 FUSELINK H0722050 H0722092 H0722070 H0722094

.039 .037 .037 .046 .049 .045 .038 .068

0.99 0.94 0.94 1.17 1.24 1.14 0.97 1.73

TC BC BC BC BC TC TC BC

.019 .013 .025 .013 .021 .024 .024 .017

0.48 0.33 0.64 0.33 0.53 0.61 0.61 0.43

.078 .063 .086 .072 .091 .092 .086 .102

1.98 1.60 2.18 1.83 2.31 2.34 2.18 2.59

XLPVC XLPVC XLPE XLPVC XLPVC XLPE XLPE XLPE

14AWG 16AWG .8mm2 .8mm2 .8mm2 .8mm2 16AWG 14AWG .8mm2 14AWG .8mm2 22AWG

19 19 19 19 19 19 19 19 19 19 19 7

.068 .057 .045 .045 .045 .045 .054 .068 .045 .066 .045 .030

1.73 1.45 1.14 1.14 1.14 1.14 1.37 1.73 1.14 1.68 1.14 0.76

BC BC BC BC BC BC BC BC BC SPC BC SPC

.016 .016 .016 .016 .016 .016 .018 .018 .017 .019 .016 .016

0.41 0.41 0.41 0.41 0.41 0.41 0.46 0.46 0.43 0.48 0.41 0.41

.100 .089 .078 .078 .078 .078 .089 .102 .078 .103 .078 .062

2.54 2.26 1.98 1.98 1.98 1.98 2.26 2.59 1.98 0.33 1.98 1.57

XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE XLPE

14AWG 12AWG 5mm2 8mm2

19 19 19 37

.068 .090 .107 .132

1.73 2.29 2.72 3.35

BC BC BC BC

.043 .046 .050 .050

1.09 1.17 1.27 1.27

.153 .182 .207 .233

3.89 4.62 5.26 5.86

XLPE XLPE XLPE XLPE

DATABUS J1939 & CAN CABLE M0702301 .5mm2 M0704116 20AWG M0704120 20AWG M0702001 18AWG BATTERY CABLE H0780074 H7000200

20 19 19 19

.039 .038 .038 .048

0.99 0.97 0.97 1.22

TC TC BC TC

.028 .023 .023 .046

0.71 0.58 0.58 1.17

.095 .084 .084 .140

2.41 2.13 2.13 3.55

XLPE XLPE XLPE XLPE

62mm2 32mm2

266 192

.469 .281

3.73 7.14

BC BC

.076 .044

1.93 1.12

.620 .369

6.60 8.36

XLPE XLFE

BC = ANNEALED BARE COPPER TC = TIN COATED COPPER SPC = SILVER PLATED COPPER HBC = HARD DRAWN BARE COPPER PVC = POLYVINYL CHLORIDE, NON-CROSSLINKED XLPVE = POLYVINYL CHLORIDE, CROSSLINKED XLPE = POLYOLEFIN, CROSSLINKED XLFE = FLUOROELASTER, CROSSLINKED

Production Process of Automotive Wire

Ingredient Copper Rod

Drawing

Compounding

Tinning

Production Process of Automotive Wire

Bunching

Extruding

Irradiation

Rewinding

Twisting

Twisting

Shipping

Shielding (or Braiding)

Jacketing

Primary Wire and Transmission Wire

Jacketing Irradiation

Irradiation

Rewinding Rewinding

Shipping

Shipping

Specialty Wire and Cable

ABS Cable

Judd Wire Pioneer in Irradiated Wire

Judd Wire, a wire and cable manufacturer, specializes in electron beam cross-linked irradiation technology for wire insulation. Judd designs a broad spectrum of products recognized by Underwriters Laboratory, Canadian Standards and/or Military Specifications.

Electron Beam Technology and Cross-Linked Wire Insulation Electron beam processing evolved from the particle accelerator into a variety of industrial applications worldwide. One of its major uses is the irradiation of electrical insulation materials the specialty of Judd. Electron beam treatment changes both the chemical structure and physical properties of wire insulation. The principal effect of high velocity electrons is to break the existing chemical bonds between the atoms of insulation materials. Orbital electrons are liberated, producing ions and free radicals. The free radicals react with other molecules creating long chains and crosslinks between molecules. The resulting crosslinked material exhibits thermosetting properties. In the case of insulation materials for wire and cable, the beneficial results of this irradiation cross-linking are: improved resistance to cut-through, deformation and chemical attack; no shrink-back or melting even when the insulation is in direct contact with a hot soldering iron at 349C (660F).

Judd Wire Inc. Headquarters and Manufacturing Facility 124 Turnpike Road Turners Falls, MA 01376-2699 USA Telephone (413) 863-4357 1- 800 545-5833 Fax (413) 863-2305

Judd Wire Inc. 870 Los Vallecitos Boulevard San Marcos, CA 92069 USA Telephone (760) 744-7720 1- 800 344-5251 Fax (760) 744-6089

Judd Wire Inc. is an ISO 9001 and QS 9000 Registered Firm

Company Profile
Todays Judd Wire Inc. started out as the Judd Wire Manufacturing Company, founded by Thomas Judd in 1953 in a 1,000 square foot warehouse in downtown Turners Falls, MA. He had one extruder, one respooler, and for the next three years, a single customer who purchased steel insulated wire, which was used as a support member in vacuum cleaner hoses. Early in 1962, he opened a new 20,000 square foot facility on the site where the factory remains today. Sales took off and the plant size doubled in just two years! Business had grown to include products for the telephone industry, automobiles (ignition cables, antenna leads and wire harnesses), and electronics (lead wires, elevator cables and traffic signal cables). The real growth of Judd was still to come. In September of 1967, Tom Judd sold the business to Electronized Chemical Corporation. ECC was a manufacturer of plastic compounds and the innovators of a new product, Irradiation Crosslinked heat shrink tubing. Their new Judd Wire division became an industry source of Irradiated PVC (XLPVC) wire. The concept of irradiating wire to improve its resistance to heat and allowing it to be easily processed helped Judd Wire capture approvals and contracts with manufacturers in the emerging computer and telecommunications industries. In 1971, Judd Wires capabilities increased with the installation of our first particle accelerator for crosslinking wire. This machine was supplied by High Voltage Engineering, the parent company of ECC. In 1977, the purchase of another plant in Escondido, California gave Judd Wire a Manufacturing presence on both coasts of the United States. This facility was expanded and moved to San Marcos in 1980. High Voltage Engineering was purchased by a group of investors in early 1988, and the future of the Judd Wire division was unknown. A sale to another company was inevitable, but how would that new parent see Judd Wire? The bad news became great news when in August of 1988, the announcement was made that the Judd Wire Division of High Voltage Engineering had been sold to Sumitomo Electric U.S.A. Sumitomo Electric U.S.A. (SEUSA), with the guidance of Sumitomo Electric Industries of Japan, supported an immediate program of growth and modernization of both Judd Wire factories. New buildings, manufacturing equipment and new computer systems were all introduced. But more important than any of the structures and equipment, Sumitomo Electric and Judd Wire Inc. have invested in the people that make these products. Today, the employees of Judd Wire Inc. are an integral part of the company, responsible for writing the operating systems that govern the quality and manufacturing processes, as well as developing the designs and the materials which have fueled this decade of growth. Judd Wire Inc. now employs over 450 people in two modern, state-of-the-art facilities. Judd Wire products are used throughout the globe in some of the most technically complex and demanding applications in our industries. Our customers in such markets as Automotive, Aerospace, Telecommunications, Data Processing, Consumer Electronics, Medical Imaging, Industrial Controls and many others can count on Judd Wire Inc. and Sumitomo Electric to be the leaders in wire and cable applications. As proud as we are of our past, we remain committed to our future. The horizon is full with opportunities that will allow Judd Wire Inc. to achieve our mission of continuous improvement and total customer satisfaction.

w w w. j u d d w i r e . c o m

JUDD WIRE INC.

Judd Wire Inc. Headquarters and Manufacturing Facility 124 Turnpike Road Turners Falls, MA 01376-2699 USA Telephone (413) 863-4357 1- 800 545-5833 Fax (413) 863-2305 Judd Wire Inc. 870 Los Vallecitos Boulevard San Marcos, CA 92069 USA Telephone (760) 744-7720 1- 800 344-5251 Fax (760) 744-6089 web: www.juddwire.com

5,000/12.2000

Automotive
References
Conductor Reference Insulation Reference Part Number System Reference Cross-Reference Guide Conversion Reference Glossary Certification Automotive Application Sheet page 1 page 5 page 6 page 7 page 10 page 12 page 16 page 17

JUDD WIRE INC.

A member of the Sumitomo Electric Industries group of companies

Conductor Reference

Stranding Definitions
Unilay Stranding Conductor constructed with a central core surrounded by more than one layer of helically laid single-end wires. All layers have a common direction of lay and the same length of lay. Unidirectional Stranding Conductor constructed with a central core surrounded by more than one layer of helically laid single-end wires. All layers have a common direction of lay. Bunched Stranding A collection of wire or cable elements twisted together in the same direction without predetermined pattern. Concentric Stranding A central wire or core surrounded by one or more layers of helically laid wires. Rope Stranding A concentric-stranded construction with component wires stranded.

unilay and unidirectional

bunched

concentric

rope

Effects of Stranding
Unilay Stranding Electrical Conductivity: Slightly lower than true concentric; higher conductivity than and Unidirectional Stranding bunched for 18 gauge and finer, lower for 16 gauge through 10 gauge. Diameter Control: Best in diameter control and smaller diameters. Weight Control: Best weight control and lowest weight for equivalent conductivity. Flexibility: Higher flexibility than true concentric or bunched with fewer strands. Crimp Terminiation: Concentric strandings are best for crimping due to less give. General: Excellent diameter control and very smooth surface; used for thin wall insulations, both extruded and tape wrapped. Bunched Stranding Electrical Conductivity: Designed to have same conductivity as equivalent solid gauges. Diameter Control: Poor diameter control because of non-geometric configuration. Weight Control: Poor weight control but usually not important for bunched. Flexibility: Dependant upon number of strands; more strands equals better flexibility. Crimp Terminiation: Poor for quality crimp terminations, usually soldered. General: Generally used for lower temperature, heavier insulation thickness.

Concentric Stranding Electrical Conductivity: Slightly higher than unilay; same comparison with bunched as unilay. Diameter Control: Better than bunched or ropes. Weight Control: Good weight control. Flexibility: Least flexibility when compared to other types of stranding with the same number of strands. Crimp Terminiation: Concentric strandings are best for crimping due to less give. General: Very good diameter control and smooth surface; used for thin wall insulations, both extruded and tape wrapped. Rope Stranding Electrical Conductivity: Generally designed to have same conductivity as equivalent solid gauges except 19 x 7 end construction, which is greater. Diameter Control: Dependent upon configuration; generally more strands means less control. Weight Control: Dependent upon configuration; generally more strands means less control. Flexibility: Best flexibility due to greater number of strands. Crimp Terminiation: Generally good for crimping because of mass, depending upon configuration. General: Can be used with any insulation, depending upon configuration.

Conductor AWG Reference Chart

SIZE NUMBER OF STRANDS SINGLE END SIZE CONFIGURATION DIAMETER CIRCULAR MIL AREA WEIGHT

**DC

RESISTANCE AT 20C (MAXIMUM)

ANNEALED BARE COPPER

AWG

AWG/inches

type
concentric unilay concentric unilay concentric unilay unilay unilay unilay unilay unidirectional unidirectional rope rope rope rope rope rope rope rope rope

inches
0.030 0.030 0.038 0.038 0.046 0.048 0.054 0.068 0.070 0.085 0.084 0.111 0.169 0.208 0.263 0.328 0.367 0.410 0.457 0.520 0.581

cmils
707 763 1170 1216 1788 1920 2452 3991 4151 6151 5936 10487 16851 26880 42560 66833 82109 105023 133665 166931 211452

lbs/kft
2.17 2.41 3.57 3.84 5.63 6.06 7.73 12.2 13.1 19.4 18.7 32.2 51.8 82.5 131 208 254 326 417 525 652

ohms/kft
15.6 15.1 10.0 9.20 6.30 5.80 4.52 2.87 2.87 1.81 1.90 1.19 0.66 0.42 0.26 0.17 0.11 0.108 0.085 0.068 0.054

22 22 20 20 18 18 16 14 14 12 12 10 8 6 4 2 1 1/0 2/0 3/0 4/0

7 19 7 19 7 19 19 19 19 19 37 37 133 133 133 665 817 1045 1330 1665 2109

30 34 28 32 26 30 29 27 0.0147 25 28 26 19x7/29 19x7/27 19x7/25 19x35/30 19x43/30 19x55/30 19x70/30 37x45/30 37x57/30

**DC Resistance given for Annealed Bare Copper, also available for Tin Coated Copper and Nickel Plated Copper.

Tabulation of Cable-Shield Qualities Chart

QUALITY COPPER BRAID COPPER SERVED CONDUCTIVE TEXTILE ALUMINUM / MYLAR FOIL CONDUCTIVE PLASTIC SOLID SHEATH

Shield Effectiveness Low Frequency Good Shield Effectiveness RF Good Normal Percent of Coverage 60-95% Fatigue Life Good Tensile Strength Excellent Termination Method Comb & Pigtail

Good Poor 90-97% Fair Fair Pigtail

Fair Poor 100% Excellent Poor Drain Wire

Excellent Excellent 100% Fair* Poor Drain Wire

Fair Poor 100% Good Poor Drain Wire

Excellent Excellent 100% Poor Excellent Clamp

* Special techniques can provide excellent fatigue life for use in retractile cords.

Common Conductor Material

MATERIAL ASTM STD SAE STD TEMPERATURE RATING ( C ) TENSILE STRENGTH NOMINAL (MPa) CONDUCTIVITY % IACS* FLEXURE ENDURANCE (ASTM 470)

a) Annealed Bare Copper b) Hard Drawn Bare Copper c) Tin Coated Copper d) Silver Plated Copper e) Nickel Plated Copper f) Nickel Plated High Strength Alloy g) CA Flexible Alloy

B3 B1

J1127-J1128 J1127-J1128

150 150 150 200 150 200 150

235 450 235 235 235 415 490

100% 100% 93-97% 100% 91-96% 85-86% 83%

B33 J1127-J1128 B298 N/A B355 J1127-J1128 B624 J1127-J1128 N/A N/A

852 cycles (reference) 1.2 times greater than Annealed Bare Copper 852 cycles (estimated) 852 cycles (estimated) 852 cycles (estimated) 5 times greater than Annealed Bare Copper 4.5 times greater than Annealed Bare Copper

* National Bureau of Standard HB100 Note: Flex life will, in general, be improved by use of higher strength material. Theoretically, annealed material will have longer fatigue life than hard. However, in practice the stiffness of hard material frequently tends to restrict the sharpness of bend, resulting in improved life.

Conductor Metric Reference Chart

METRIC SIZE NUMBER OF STRANDS SINGLE END SIZE CONFIGURATION DIAMETER SECTIONAL AREA CROSS SECTIONAL AREA WEIGHT

**DC

RESISTANCE AT 20C (MAXIMUM)

ANNEALED BARE COPPER

mm2
0.3 0.3 0.3 0.35 0.5 0.5 0.5 0.5 0.5 0.75 0.75 0.8 0.8 0.8 0.85 1.00 1.25 1.25 1.25 1.25 1.5 2.0 2.0 2.0 3.0 3.0 3.0 5.0 5.0 8.0 8.0 8.0 8.0 10.0 10.0 12.0 13.0 15.0 19.0 32.0 50.0 50.0 62.0 81.0 103.0 19 49 60 7 7 19 20 41 266 19 30 7 16 19 11 19 16 19 37 50 19 19 26 37 19 37 41 65 19 19 37 50 154 63 189 154 37 171 133 133 299 342 266 342 342

mm
0.16 0.10 0.08 0.25 0.32 0.19 0.18 0.13 0.05 0.23 0.18 0.38 0.25 0.23 0.32 0.28 0.32 0.29 0.21 0.18 0.307 0.36 0.32 0.32 0.45 0.34 0.32 0.32 0.57 0.71 0.51 0.45 0.26 0.45 0.26 0.32 0.66 0.31 0.43 0.57 0.46 0.43 0.57 0.57 0.63

type
unilay rope rope concentric concentric unilay bunched bunched rope unilay bunched concentric bunched unilay bunched unilay bunched unilay unidirectional bunched unilay unilay bunched unidirectional unilay unidirectional bunched bunched unilay unilay unidirectional bunched rope rope rope rope unidirectional rope rope rope rope rope rope rope rope

mm
0.78 0.91 0.84 0.73 1.00 0.94 1.00 0.96 1.07 1.14 1.20 1.13 1.16 1.13 1.20 1.33 1.50 1.47 1.41 1.50 1.45 1.71 1.88 1.90 2.14 2.25 2.40 3.00 2.68 3.38 3.34 3.70 4.27 4.09 4.29 5.32 4.37 5.40 6.07 8.35 9.07 10.3 11.83 14.00 15.18

mm2
0.38 0.39 0.31 0.35 0.60 0.54 0.50 0.53 0.54 0.79 0.76 0.78 0.79 0.81 0.88 1.18 1.29 1.32 1.33 1.27 1.41 1.95 2.12 2.09 3.05 3.28 3.30 5.23 4.78 7.60 7.45 7.95 8.19 10.0 10.1 12.5 12.8 13.2 19.3 34.3 49.6 49.5 66.7 85.8 106.7

kg/km
3.14 3.52 2.72 3.14 5.36 4.82 4.55 4.78 5.36 7.14 6.83 7.05 7.07 7.31 7.99 10.6 11.6 11.8 12.0 11.4 13.9 17.5 19.0 18.1 27.3 25.4 29.5 47.2 42.9 68.4 67.1 70.5 73.6 90.8 88.8 112.6 114.4 120.2 177.4 312.0 520.9 454.0 609.4 781.8 982.0

ohms/km
48.8 50.5 77.0 * 50.5 32.7 36.7 36.7 40.9 * 44.0 * 24.4 24.4 22.5 23.0 21.9 20.8 15.1 14.3 14.7 14.7 14.7 12.7 9.30 8.60 8.81 5.82 5.58 5.59 3.52 3.68 2.34 2.42 2.32 2.33 1.91 1.99 1.44 1.40 1.37 0.94 0.56 0.39 0.36 0.27 0.21 0.17

** DC Resistance given for Annealed Bare Copper, also available for Tin Coated Copper and Nickel Plated Copper. * Copper Alloy Conductor Construction used.

Conductor Coatings Chart

Heavy Tinned Individual strands doubly tinned then twisted Top Coat Bare strands twisted together then tinned overall Overcoat Strands individually tinned, twisted together and then tinned overall Fused Strands doubly tinned, twisted together and then fused together
TYPE COST OXIDATION SOLDER COMMENT

Annealed Bare Copper (no coating) Tin Coated Copper Silver Plated Copper Nickel Plated Copper

low moderate very high high

rapid resistant resistant resistant

difficult easy easy discourages wicking

high contact resistance low contact resistance low RF loss, higher than 200C not recommended for high vibration applications, good for crimping

Characteristics and Comparisons of Conductors

TYPE LIFE STABILITY CRIMP TERMINATION SOLDERBILITY

Annealed Bare Copper (BC) Hard Drawn Bare Copper (HBC) Tin Coated Copper (TC)

Excellent- Slight loss of conductivity with heat aging. Good- Slight loss of conductivity with heat aging. Conductivity and solderability deteriorates with heat aging at rated temperature due to migration of tin and copper and tin oxidation. Excellent- no loss of conductivity with heat aging at rated temperature. Solderability shelf life remains good. Conductivity remains stable with heat aging at rated temperature.

Excellent- Contact resistance may vary with type of terminal. Good- Contact resistance may vary with time. Good- But contact resistance increases with time and can be variable.

Good- When clean.

Poor- Crimp termination preferred. Good originally. Deteriorates with shelf life.

Silver Plated Copper (SPC)

Excellent- Contact resistance remains low.

Excellent.

Nickel Plated Copper (NPC)

Good- Contact resistance may vary with time. Use plated steel terminal in some cases. Very Good- Contact resistance may vary with type of terminal and degree of cleaning. Very Good- Contact resistance may vary with type of terminal and degree of cleaning. Good- Contact resistance may vary with time.

Requires active flux.

Silicone Blocked Bare Copper (SBB) Silicone Blocked Tinned Copper (SBT) Copper Alloy (CAL)

Excellent- Slight loss of conductivity after heat aging. Excellent- Slight loss of conductivity after heat aging. Good- Slight loss of conductivity after heat aging.

Poor- Crimp termination preferred.

Poor- Crimp termination preferred.

Poor- Crimp termination preferred.

Insulation Reference

Insulation Classifications
Based on crosslinking degree and reprocessing abilities, polymers can be divided into three groups:
TYPE CHARACTERISTICS BENEFITS

Thermoplastics

Chemically non-crosslinked Melt repeatedly upon heating Soluble in suitable solvents Fully cross-linked in chemical structure Non-melt upon heating Swellable but insoluble in solvents

Low cost Reprocessable

Thermosets

Improved heat resistance Increased tensile strength Improved cut-through and abrasion resistance Increased chemical resistance

Elastomer

Chemically or physically crosslinked Generally having properties in between thermoplastics and thermosets depending on structure

High elasticity and flexibility High elongation

Insulation Type
TYPE CODE
MAXIMUM CONTINUOUS

SPECIAL OPTIONS

TENSILE STRENGTH

ELONGATION

FLAME RESISTANCE

PINCH ABRASION RESISTANCE

TYPE

CHEMICAL RESISTANCE

OPERATING TEMPERATURE

(%)

(C)

MPa

Polyvinyl Chloride, non-crosslinked Polyvinyl Chloride, crosslinked Chlorinated Polyethylene, crosslinked Thermoplastic Elastomer crosslinked High Density Polyethylene Polyolefin, crosslinked Polyamide, non-crosslinked Polyurethane, non-crosslinked Polyurethane, crosslinked Polyester, crosslinked Chlorotrifluoroethylene /ethylene copolymer, non-crosslinked Fluoropolymer, non-crosslinked Fluoroelastomer, crosslinked v Leaded 0 = POOR TP = Thermoplastic

PVC XLPVC XLCPE TPE HDPE XLPE PA PU XLPU XLPES ECTFE

90-105 105 105 90-105 90 125-150 105 80-90 105 150 150

wv s wv s ws wy a wy a wy a w ywa ywa wys w

15-20 18-25 18-25 8-20 28-35 10-25 15-25 25-55 25-35 25-30 39-55

220-330 150-450 250-400 300-500 500-800 250-350 150-300 400-700 300-450 300-400 250-380

3 3 3 0-1 0 1-3 2-3 2-3 2-3 2 3

1 2 2 1 1-2 2-3 3 3 3 3 3

TP TS TS E TP TS TP E TS TS TP

1 2 2 0-1 2-3 2-3* 2-3 1 2 2 3

FP XLFE

150-250 150-200

w w

35-55 15-35

150-350 200-400

3 3

3 2 w Ozone resistant

TP TS

3 3

s Lead-free 1 = GOOD TS = Thermoset

y Halogenated 2 = BETTER E = Elastomer

a Halogen-free 3 = BEST

* fuel resistant product available

Part Numbering System

Construction C - Coax H - Hook-up

Material Type of Primaries 03 - XLPVC 07 - XLPE 12- PVC 16- HDPE 28- ECTFE 49- ETFE 64- Polyester 67- PA 70- Fluoroelastomer

building

A Primary Wire
Wire/Coax Print Options 1Not Printed 2Printed with Customer Specific Legend

Sequential Number by Customer Specification This number is a sequentially assigned number for each customer product group.

03

05
Wire/Coax Color 00Black 01Brown 02Red 03Orange 04Yellow 05Green 06Blue 07Violet 08Gray 09White

320

09

Sequential Number This sequential number is assigned for each product within the customer product group. 001First 002Second 003Third 320Three hundred twenty

Wire/Coax Stripe Options 0No Stripes 1One Printed Stripe or Two Extruded Stripes 2Two Stripes (Printed) 3Three Stripes ABlack Colored Stripe BBrown Colored Stripe CRed Colored Stripe DOrange Colored Stripe EYellow Colored Stripe FGreen Colored Stripe GBlue Colored Stripe HViolet Colored Stripe JWhite Colored Stripe KGray Colored Stripe

building

A Multi Conductor Cable

Material Type of Primaries 03 - XLPVC 07 - XLPE 12- PVC 16- HDPE 28- ECTFE 49- ETFE 64- Polyester 67- PA 70- Fluoroelastomer Number of Conductors 01N/A 02Two (Twisted Pair) 03Three (Twisted Triad) 04Four (Twisted Quad) 05Five 06Six 07Seven etc.

Construction M - Multi Conductor Cable P - Parallel Conductor Cable

Jacket Print Options 1Not Printed 2Printed with Customer Specific Legend

M
Sequential Number 001First 002Second 003Third 284Two Hundred, eighty-four

03

02
Jacket 00010203040506070809xxColor Black Brown Red Orange Yellow Green Blue Violet Gray White No Jacket

284
Cable 0123-

00

Stripe Options No Stripes One Printed Stripe or Two Extruded Stripes Two Stripes (Printed) Three Stripes

Cross Reference Guide

Society of Automotive Engineers (SAE)

SAE J-156 J-1127 J-1127 J-1127 J-1127 J-1127 J-1127 J-1127 J-1127 J-1127 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1128 J-1560 J-1560 J-1560 J-1560 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1678 J-1939 J-1939 J-1939 J-1939 J-1939 J-1939 J-1939 J-1939 /11 /12 /15 /21 /31 /71 /73 xxA xTx Uxx TWP TXL TWE TWP GPT HDT STS HTS TXL GXL SXL TWE GTE HTE STT SGT STR SGR STX SGX STE SGE Type Description Surface Vehicles Std; (R) Fusible Links [per J1128, Type TWP tests] (.35, .5, .8, 1, 2, 3, 5, & 8mm2 ) Surface Vehicles Std; Battery Cable (SAE 6 ~ 4/0, Metric 13, 19, 32, 40, 50, 62, 81, 103 mm2 ) Starter or Ground, Thin Wall, Thermoplastic Insulated Starter or Ground, General Purpose, Thermoplastic Insulated Starter or Ground, Thin Wall, Thermoset Elastomer (Synthetic Rubber) Insulated Starter or Ground, General Purpose, Thermoset Elastomer (Synthetic Rubber) Insulated Starter or Ground, Thin Wall, Crosslinked (X) Polyolefin Insulated Starter or Ground, General Purpose, Crosslinked (X) Polyolefin Insulated Starter or Ground, Thin Wall, Thermoplastic Elastomer Insulated Starter or Ground, General Purpose, Thermoplastic Elastomer Insulated Surface Vehicles Std; Low-Tension Primary Cable (SAE 8 ~ 24, Metric .22, .35, .5, .8, 1, 2, 3, 5, 8 mm2 ) Thin Wall, Thermoplastic Insulated General Purpose, Thermoplastic Insulated Heavy-Duty, Thermoplastic Insulated Standard-Duty, Thermoset Elastomer (Synthetic Rubber) Insulated Heavy-Duty, Thermoset Elastomer (Synthetic Rubber) Insulated Thin Wall, Crosslinked (X) Polyolefin Insulated General Purpose, Crosslinked (X) Polyolefin Insulated Special Purpose, Crosslinked (X) Polyolefin Insulated Thin Wall, Thermoplastic Elastomer Insulated General Purpose, Thermoplastic Elastomer Insulated Heavy-Duty, Thermoplastic Elastomer Insulated Surface Vehicles Std; Low tension Thin Wall Primary Cable (SAE 8 ~ 24, Metric .22 ~ 8mm2 ) Thin Wall, Thermoplastic Insulated Thin Wall, Crosslinked (X) Polyolefin Insulated Thin Wall, Thermoplastic Elastomer Insulated Low Voltage, Ultra Thin Wall primary Cable U - 0.20mm (0.008") Wall thickness W - 0.25mm (0.010") Wall thickness T - Thermoplastic X - Thermoset A - 85C; 3000 hr Temp. Class Rating B - 100C; 3000 hr Temp. Class Rating C - 125C; 3000 hr Temp. Class Rating D - 150C; 3000 hr Temp. Class Rating E - 175C; 3000 hr Temp. Class Rating F - 200C; 3000 hr Temp. Class Rating G - 225C; 3000 hr Temp. Class Rating H - 250C; 3000 hr Temp. Class Rating Draft: Serial Control and Communications Vehicle Network - (Class C) Physical Layer - 250K bip/s Shielded Twisted Pair [.5mm2 (20 AWG), 120 12 ohm @ 1MHz] Preliminary: Twisted Quad Transmission Cable [.5mm2 (20 AWG), 75 5 ohm @ 1MHz ] Reduced Physical Layer - 250K bits/s Un-shielded Tw Pr (UTP) [.5mm2 (20 AWG) or .8 mm2 (18 AWG), 120 12 ohm @ 1 MHz] Data Link Layer Recommended Practice for Serial Control and Communications Vehicle Applications Layer Applications Layer - Diagnostics

Japanese Automotive Standard Organization (JASO) Abbreviations

Specification Abbreviation Note Description

D 608-92 D 608-92 D 611-86

AEX AVX AVS Thin Wall

Crosslinked Polyethlyene (XLPE 120C Rated: .5f;20/.18, .5;7/.32, .75f;30/.18, .85;11/.32, 1.25f;50/.18, 1.25;16/.32, 2.0;26/.32, 3.0;41/.32, 5.0;65/.32, 8.0;50/.45 mm2 - colors: blk, wht, rd, grn, yel, brn, blu) Crosslinked Vinyl (XLPVC 100C Rated: .5/20, .75/30, 1.25/50, 2/26/37, 3/41, 5/65, 8/50, 15/84 mm2 colors: blk, wht, rd, grn, yel, brn, blu) Crosslinked Vinyl (XLPVC ~100C Rated: .3/7, .5/7, .85a/16, .85b/11, 1.25/16, 2/26, 3/41, 5/65 mm2, no color specified)

Other Japanese Abbreviations

Abbreviation

Note

Description Crosslinked Polyethylene (XLPE - .5/20, .75/30, 1.25/50, 2/26 or /37, 3/41, 5/65, 8/50, 15/84 mm2)

AEX AEX AESSX APEXH APXHT AVFX AVSSX AVX AVX AVX AVX AVX AVXTA AVSX BXRA BXRA BXRA FL-CEX FL-CEX FRBXRA FRBXRA IRRAX A SHSX SHSXT TVSSX TOKAI APXHTSHE Flexible Flexible (AEX10) (ABS) (BK) (ABS) Flexible Flexible Thin wall (ABS) (ABS) (ABS) Flexible Super Thin wall Flexible Super Thin wall

Crosslinked Polyethlyene (XLPE 120C Rated: .5f;20/.18, .5;7/.32, .75f;30/.18, .85;11/.32, 1.25f;50/.18, 1.25;16/.32, 2.0;26/.32, 3.0;41/.32, 5.0;65/.32, 8.0;50/.45 mm2) Crosslinked Polyethylene (XLPE - .5f/19, .75f/19, 1.25/19, 1.25f/37, 2f/37 mm2) Crosslinked Polyethylene Coax (XLPE - 0.5 mm2 20/.18 mm BC XLPE BSH PVC JAC 3.45 mm OD) Crosslinked Polyvinyl Chloride (XLPVC - .5 mm2 19/0.19 mm TVSSX 0.5f ) Crosslinked Polyethylene (XLPE, 140C rated; .3, .5, .85, 1.00, 1.25, 1.5, 2.0, 8.0, 10.0, 12.0, 15.0 mm2) Crosslinked Polyvinyl Chloride (XLPVC - .5f/19, .75f/19, 1.25/19, 1.25f/37, 2f/37 mm2) Crosslinked Polyvinyl Chloride (XLPVC - .5/20, .75/30, 1.25/50, 2/26, 2/37, 3/41, 5/65, 8/50, 15/84 mm2) Crosslinked Polyvinyl Chloride (XLPVC -1C~6C .5 mm2 (20/.18 mm) SHE050 ~ 6SHE050 Crosslinked Polyvinyl Chloride (XLPVC - 10/63 [7/9] mm2) Crosslinked Polyvinyl Chloride (XLPVC 100C Rated: .5/20, .75/30, 1.25/50, 2/26, 2/37, 3/41, 5/65, 8/50, 15/84 mm2) Crosslinked Polyvinyl Chloride (XLPVC - 8f/7, 8f/22, 10f/7, 10f/22, 15f/7, 15f/36 mm2) Crosslinked Polyvinyl Chloride (XLPVC - .5f/20, .75f/30 mm2) Crosslinked Polyvinyl Chloride (XLPVC - 3/41 mm2, wall = .60 mm (.0236"), OD = 3.60 mm (.1417")) Crosslinked Polyethylene (XLPE, 140C rated; 2/C .5 mm2 7 x 38/.05 mm 6.2 mm OD) Crosslinked Polyethylene (XLPE, 140C rated; 2/C .3 mm2 3 x 20/.08 mm 5.0 mm OD) Crosslinked Polyethylene (XLPE, 140C rated; 2/C .5 mm2 7 x 38/.05 mm 7.2 mm OD) Crosslinked Chlorinated Polyethylene (XLFL-CEX - .3/7, .5/7, .85/11, 1/13, 1.25/16, 1.5/19, 2/26, 3/41 mm2) Crosslinked Polyethylene (XLPE, 150C rated; 8.0 mm2 & 10.0 mm2 - [.5~100 mm2]) Crosslinked Polyethylene (XLPE, 140C rated; 2/C .3 mm2 3 x 30/.08 mm 5.0 mm OD) Crosslinked Polyethylene (XLPE, 140C rated; 2/C .3 mm2 7 x 23/.05 mm 5.0 mm OD) Crosslinked Polyethylene (XLPE, 100C rated; .3 mm2 & .5 mm2) Crosslinked Polyvinyl Chloride (XLPVC - 2/C 0.5f/19 mm2 XLPVC tw pr / tpc sws / PVC jkt, 2SH050 ) Crosslinked Polyvinyl Chloride (XLPVC - 2/C 0.5f/19 mm2 XLPVC tw pr / tpc sws / PVC jkt, 2SH050 ) Crosslinked Polyvinyl Chloride (XLPVC - .5 mm2 19/0.19 mm [tinned] TVSSX 0.5f ) Crosslinked Polyvinyl Chloride (XLPVC - 1/C~3/C .5 mm2 20/.18 mm XLPVC tw pr / serve shield / PVC jkt) Crosslinked Polyethylene (XLPE - 1/C .5 mm2 20/.18 mm XLPE Braid PVC jkt 3.45 mm OD)

Note: f denotes flexible conductor

International Organization for Standardization (ISO) Abbreviations

ISO Class Description

6722-1 6722-1 6722-1 6722-1 6722-1 6722-1 6722-1 6722-2 6722-3 6722-4

A B C D E F

-40C to + 85C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) -40C to + 100C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) -40C to + 125C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) -40C to + 155C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) -40C to + 175C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) -40C to + 200C, 50 Vrms (sizes: .5, .75, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 95, 120 mm2) Road Vehicles - Unscreened Low-tension cables, Part 1 test methods Road Vehicles - Unscreened Low-tension cables, Part 2 requirements Road Vehicles - Unscreened Low-tension cables, Part 3 Conductors & dimensions for thick-wall insulated cables Road Vehicles - Unscreened Low-tension cables, Part 3 Conductors & dimensions for thin-wall insulated cables

Deutsches Institut fur Normung (DIN) Abbreviations

ISO Construction Material Type Description

76 722 Wire Types: 76 722 76 722 Special Design Features: 76 722 76 722 76 722 76 722 76 722 76 722 76 722 F M R S U W Z FL FZL

Strassenfahrzeuge Niederspannungsleitungen Low-voltage cable, road vehicles High-voltage ignition cable, road vehicles

Flat cable Compound conductor or conductor materials other than electrolytic copper or resistance alloys Reduced wall thickness of insulating Thickness of insulation greater than that specified in DIN ISO 6722, Part 3, with conventional insulation Thickness of insulation as specified in DIN ISO 6722, Part 5 Resistance Conductor, effective resistance core for resistance ignition cables Multicore, splittable cable

Shielding and Additional Processes: 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 B C D G J L P T Taped screen Copper wire braiding Copper wire cover Glass fiber braiding Impregnated Varnish Insulating film Textile Braiding

Insulation and Jackets: 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 76 722 Y YK YW X 2Y 2X 4Y 5Y 6Y 7Y 9Y 53G 33X 41X PVC PVC PVC XLPVC PE XLPE PA PTFE FEP ETFE PP CPE XLPES XLPO Polyvinyl-chloride Polyvinyl-chloride cold resistant Polyvinyl-chloride heat resistant Polyvinyl-chloride, cross-linked Polyethylene Polyethylene, cross-linked Polyamide Polytetrafluoroethylene Fluorinated ethylene propylene copolymer Ethylene tetrafluoroethylene Polypropylene Chlorinated polyethylene Polyester, cross-linked Polyolefin copolymer, cross-linked

NOTE: In foamed materials the code is preceded by a 0, e.g. 02Y = foamed or cellular PE

10

Conversion Reference

AWG vs mm2
SIZE GOVERNING SPECIFICATION per SAE J1127 & SAE J1128 per ASTM B286 Data for respective conductors using UL 1581

AWG

mm2

DESCRIPTION

sizes (Min cma)

AWG

mm2 sizes (Min mm2) 98.5 77.6 59.8 48.3 38.1 31.1 18.3 12.1 7.23 4.65 2.91 1.85 1.13 0.760 0.508 0.324 0.205 ----

sizes (Min cma)

AWG

using 20~29 AWG strds (Min cma) 207368 164444 130438 103488 82016 65033 40905 25715 16180 10172 6399 4028 2528 1588 1000 627 396 248 156 98

using 30~36 AWG strds (Min cma) ---------10069 6334 3987 2503 1571 989 621 392 ----

4/0 3/0 2/0 1/0 1 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

103.0 81.0 62.0 50.0 40.0 32.0 19.0 13.0 8.0 5.0 3.0 2.0 1.0 .80 .50 .35 .22 .13 .08 .05

SAE J1127 SAE J1127 SAE J1127 SAE J1127 SAE J1127 SAE J1127 SAE J1117 SAE J1127 SAE J1128 SAE J1128 SAE J1128 SAE J1128 SAE J1128 SAE J1128 SAE J1128 SAE J1128 SAE J1128 ASTM B 286 / UL 1581 ASTM B 286 / UL 1581 ASTM B 286 / UL 1581

205500 158600 125100 98980 77790 62450 37360 24538 14810 9343 5833 3702 2336 1537 1072 681 405 ----

210900 167200 133000 106400 83600 66500 42615 26818 16983 10500 6500 4100 2600 1900 1216 754 475 304 175 112

Note: ASTM B 286 also has maximum resistance values depending on plating and core material type.

Temperature Conversion Chart

Degrees Centigrade = 5/9 (F - 32)
C 65 60 55 50 45 40 35 30 25 20 15 10 5 0 5 F 85 76 67 58 49 40 31 22 13 4 5 14 23 32 41

11

Degrees Fahrenheit = (9/5 * C) + 32

C 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 F 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 C 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 F 185 194 203 212 221 230 239 248 257 266 275 284 293 302 311 C 160 165 170 175 180 185 190 195 200 250 300 350 F 320 329 338 347 356 365 374 383 392 482 572 662

Conversion Factors

meters meters meters kilometers inches miles pounds grams inches feet millimeters meters millimeters kilometers

to to to to to to to to to to to to to to

inches feet millimeters meters millimeters kilometers grams pounds meters meters meters kilometers inches miles

multiply by multiply by multiply by multiply by multiply by multiply by multiply by divide by multiply by multiply by multiply by multiply by divide by multiply by

39.37 3.281 1000 1000 25.4 1.609 453.59 453.59 0.0254 0.3048 0.001 0.001 25.4 0.6214

Testing Capabilities
Routine Specification Testing Special testing for automotive wire & cable Special material testing and analysis SAE J-1128, J-1127, J-1678, J-156 Major OEM specifications Flexure Endurance Abrasion Resistance Flame Resistance Pinch Resistance Degree of Crosslinking Fluid Immersion & Aging Resistance DSC/TGA/DMA Density Volatiles Instron Testing Hot Cut Through FT-IR Heat Aging Test Viscosity Cold Bend Short Circuit Hot Modulus Shield Effectiveness Testing Ozone Resistance Controlled Current

Note: In-House Fabrication- Judd Wire has its own conductor fabrication department. This makes it possible for Judd to have control over the supply and quality of many of the conductors used in its product line. The finished size of the conductor ranges from 12 to 26 AWG and the single end size range is 27 to 44 AWG. Many different constructions are made ranging from 7 to 266 individual strands. Conductors fabricated from bare copper, tin-coated copper and high flex life alloy are produced in-house. Special custom conductors can be designed for unique applications as well as quick deliveries for sample orders or emergency situations.

12

Automotive Wire Glossary

Abrasion Resistance Ability to resist surface wear. A measure of the ability of a wire covering or jacket to resist surface wear or damage by mechanical means. ABS Cable Anti-lock Brake System cable, which usually consists of a twisted pair of primary wire and a jacket that is resistant to abrasion and certain chemicals, and has good flex endurance. Accelerated Aging / Life Test A test in which voltage, temperature, etc. are increased above normal operating values to obtain observable deterioration in a relatively short period of time. Adhesion The physical joining of two substances. Adhesion is also used to describe strip force, which is the force required to strip the insulation away from the conductor, or the jacket away from the cabled singles. Alloy A metal formed by combining two or more different metals to obtain desirable properties. Ambient Environmental condition that an item is exposed to, such as temperature or humidity. Ampere The basic unit of electrical current. A wire might have a rating which limits the acceptable amperage in order to prevent overheating. Annealed Wire Conductor which has been softened by slow heating during manufacture, in order to remove the effects of cold-working. Sometimes referred to as soft drawn wire. ANSI American National Standards Institute.

ASTM American Society for Testing and Materials. Attenuation Loss of power or signal in a cable, expressed in decibels (dB) per unit length. This is measured in a lab at one or more frequencies as determined by a specification. Average Wall Thickness The average of minimum and maximum walls. The method of measuring these may be determined by specification (see also Nominal Wall). AWG American Wire Gage, a system of conductor sizes that connects strand sizes and constructions with cross-sectional areas and therefore current-carrying capacity. These roughly correspond to most metric sizes. Bend Radius The radius of curvature that a wire or cable can bend without causing any damaging effects. Braid Woven bare metallic or tinned copper wire used as shielding for wires and cables and as ground wire for batteries or heavy industrial equipment. Also, fibrous members interwoven in cylindrical form to form a protective outer covering over a conductor or cable. Braid Angle The angle between the axis of a cable and any strand of a braid. A higher angle results in greater flexibility. Breakdown Voltage The voltage at which the insulation between two conductors or a conductor and a shield breaks down (shorts out). Refers also to a test employing a salt-water bath, where a certain voltage must be achieved without breakdown.

Bunched Stranding Term applied to a group of strands twisted together in a random manner in the same direction in one operation, without regard to geometric arrangement of specific strands. Cable Insulated wire of fairly large size, or a multiconductor insulated wire that is jacketed together into one unit. Note: Wire and cable are sometimes used interchangeably. CA-6 A high strength copper alloy used in special applications. Capacitance Storage of electric charge in a cable as a function of applied voltages, as measured in a lab. There are several forms of this measurement. Circuit A complete electrical path, in which power is transmitted from a source (such as a battery) to components that can perform useful work or develop a useful signal. Circular Mil A unit of area equal to a square mil x 0.7854. Used chiefly in specifying cross-sectional areas of round conductors. CMA Circular mil area, or the metallic cross-sectional area of a conductor, expressed in circular mils. Coaxial Cable A cable consisting of two cylindrical conductors with a common axis. The outer conductor, or shield, is also commonly used to prevent external radiation from affecting the signal in the inner conductor, and usually consists of woven strands of wire or metalized tape.

Automotive Wire Glossary

13

Cold Bend Test procedure whereby a sample of wire or cable is wound around a metal cylinder of a specified size within a cold chamber. The sample is then removed and examined for defects or deterioration. Compressed Conductor A stranded conductor that has been put through a sizing die to reduce the diameter, slightly flattening the outermost strands in the process. Concentric Stranding Referring to a single conductor constructed of layers over a central core, forming a geometric pattern which is constant throughout the wire, as opposed to a bunched stranding. Conductor Precisely speaking, a metal component of a wire which carries electrical current. However, in some contexts it can refer to the insulated wire(s) which, together with a jacket, make up a cable. Copolymer A polymer resulting from addition polymerization of two different monomers. The resulting copolymers have properties different from either of the homopolymers from the two monomers or the mechanical mixture of the homopolymers. Copper Alloy Copper to which has been added other elements in specific amounts while in the molten state. This results in improvement of certain properties, such as strength and corrosion resistance. Cross-linked (XL) A term denoting intermolecular bonds between long chain molecules, effected by chemical or irradiation techniques. Judds cross-linked products are irradiation cross-linked.

Crosslinked Polyethylene (XLPE) Cross-linking converts PE from a thermoplastic to a material with thermosetting properties. Properties are quite similar to conventional PE except for a significant improvement in heat resistance, mechanical properties (including toughness and abrasion resistance), aging characteristics, and freedom from environmental stress cracking. Curing The change in a materials physical properties by chemical reaction, which may be carried out by heat, irradiation or moisture. Dielectric Breakdown See breakdown voltage. Drain Wire In a cable, the uninsulated wire in intimate contact with a shield to provide for easier termination of such a shield to electrical ground. Elastomer A class of elastic, long-chain polymers capable of being crosslinked to produce elastic compounds with high-temperature rating and excellent resistance to physical abuse. ETFE Ethylene-TetraFluoroEthylene. Usually unirradiated in automotive applications, it is a tough, high temperature material. Filler 1) A member of a multi-conductor cable used to maintain a round shape and/or to fill voids. 2) A pressured inner-jacket layer. 3) An inert material added to a polymer resin to reduce cost or enhance certain properties. Flame Resistance Ability of a material to self-extinguish a flame once the source of heat is removed.

Flex Life Ability of a conductor, wire, or cable to withstand repeated bending, as determined by a specified testing apparatus. Flexibility That quality of a cable or cable component which allows for bending under the influence of an external force. Fluoroelastomer An elastomer containing fluorine, such as Judds J5. The fluorine component is tightly bound to the polymer backbone and greatly increases the resistance to chemical attack. Halogen-Free Materials that do not contain elements known as Halogens (such as Chlorine Bromine and Fluorine), in order to satisfy certain environmental requirements. Hard-Drawn Wire Wire that has been drawn to final size without annealing, so as to approach the maximum tensile strength possible. Homopolymer A polymer resulting from one kind of monomer. Hook-Up Wire Insulated wire used for low current, low voltage applications. ID Inner Diameter IEEE Institute of Electrical and Electronics Engineers ISO International Standards Organization

14

Automotive Wire Glossary

Lay Length The axial length of one turn of the helix of a wire or member. Usually 8 to 15 times the diameter of the construction. Life Cycle A test to determine the length of time before failure in a controlled, usually accelerated, environment. Metric Size or Metric Conductor Refers to constructions and strand sizes commonly expressed in metric units, usually originating from European specifications. Strand sizes are in millimeters, and conductor sizes are in square millimeters. Many of the typical strandings also exist in the AWG system, but in some cases there is no convenient match. Mil 0.001" - One 1000th of an inch. A unit used in measuring diameter of wire or thickness of an insulation over a conductor. Millimeter (mm) One thousandth of a meter. One millimeter (or 1mm) equals 0.03937 inches. Minimum Wall Thickness The smallest distance between the outer rim of the insulation and the outermost strand of the conductor. Often given as a requirement. Moisture Resistance The ability of a material to resist absorbing moisture from the air or when immersed in water. Monomer The basic chemical precursor unit used in building a polymer. The monomer becomes the repeating unit in the molecular structure polymer chain. Multiple-Conductor Cable A combination of two or more conductors cabled together and insulated from one another and from the sheath.

Nominal Wall Thickness Name or dimension by which a wall thickness is identified by a specification. Where a wire OD is specified, the target wall thickness may not equal the implied nominal, although the wire is still required to meet certain test requirements. OD Outside Diameter Parallel Cable A cable in which two or more untwisted conductors or insulated wires are jacketed. PE See Polyethylene Plastics High polymeric substances, including both natural and synthetic polymer resin but excluding the rubbers, that are capable of flowing under heat and pressure at one time or another. Polyamide (PA) A group of polymers which are used for wire and cable jacketing, suitable for ultra-thin wall constructions. Polyester (PES) A material used for wiring in hydrocarbon environments (such as gasoline) with temperature ratings between those of crosslinked polyolefins and fluoroelastomers. It is suitable for ultra-thin wall constructions. Polyethylene (PE) A thermoplastic material composed of polymers of ethylene. Polyethylene has excellent electrical properties for wire and cable insulation. It features superior abrasion and solvent resistance, moisture resistance, and durability. Flame retardant types of polyethylene are available. See also XLPE. Polymer A compound formed by polymerization which results in the chemical union of monomers or the continued reaction between lower molecular weight polymers.

Polyolefin A family of thermoplastics based on the ethylene family of hydrocarbons. Includes polyethylene and polypropylene. Cross-linked versions are XLPOs. Polyurethane (PU) Used for jacketing layer in cables, it has good abrasion and solvent resistance. Crosslinked types (XLPU) have further enhanced properties. Polyvinyl Chloride (PVC) A general purpose thermoplastic material composed of polymers of vinyl chloride. Many different formulations are available including grades for high temperatures, cold resistance, flame resistance, deformation resistance, etc. Dielectric strength is excellent and flexibility is very good. Some formulations may have limitations when considering toughness, moisture resistance, and resistance to chemicals. Pressured Layer Material extruded onto a conductor or cable construction with sufficient pressure to fill in the interstices of the conductor or cable components. Also called the Filler in some cables. Primary Wire One or more insulated conductors that resides within a jacket, often called single. Note: primary and single are often used interchangeably. In addition, a manufacturer may produce a primary or single without jacketing it. RFI Radio Frequency Interference Rope Stranding A conductor that is composed of a group of stranded members twisted together like a rope.

Automotive Wire Glossary

15

SAE Abbreviation for Society of Automotive Engineers. Many basic wire types are specified by SAE J 1128. SEI Sumitomo Electric Industries, Ltd. Sheath The outer covering or jacket of a multiconductor cable. Shield A metallic layer placed around an insulated conductor or group of conductors to prevent electrostatic or electromagnetic interference between the enclosed wires and external fields. Shield Coverage The physical area of a cable that is actually covered by the shielding material and is expressed in percent. Silicone Block Soft material that is pressured into a conductor during stranding, in order to have an anti-wicking property. Silicone Blocked Bare Copper (SBB) Bare copper strands twisted together with silicone blocking agent applied between and around each strand to prevent fluid wicking. Silicone Blocked Tin Plated Copper (SBT) Tin plated copper strands twisted together with silicone blocking agent applied between and around each strand to prevent fluid wicking. Specific Gravity The weight of a material divided by the weight of water of the same volume. Spiral Wrap The helical wrap of a material over a core.

Splice A connection of the conductors in a wire or cable to provide good mechanical strength as well as good conductivity. Strip Force The force required to remove a specified length of insulating material from the conductor it covers. Tape A woven or cut strip of fabric, paper, or film material used as a separator or electrically conductive component. Temperature Rating The maximum temperature at which the insulating material may be used in continuous operation without substantial deterioration of its basic properties. Tensile Strength The pulling stress required to break a given specimen, often measured in pounds per square inch (psi) or in Pascals. Not the same as break strength, which is the maximum force required without regard to the cross-sectional area. Terpolymers A polymer resulting from addition polymerization of three different kinds of monomers. Thermal Shock A testing regimen in which samples are conditioned in an oven at a high temperature for a short period(s) of time, alternating with exposure in a refrigeration chamber in some cases. Thermoplastic A classification of resin that can be readily softened and re-softened by repeated heating. Thermoset A material which hardens or sets by heat, chemical or radiation cross-linking techniques and which, once set, cannot be re-softened by heating.

Tinned Copper Conductor in which each individual strand has gone through a tin-plating bath, which aids in soldering and in inhibiting corrosion. Top Coat Metal coating on bunched or stranded bare copper conductor. The metal coating is applied on the final conductor construction. Most common coating material is tin. Transmission Wire Primary Wire with special properties suitable for installation within an electronic style transmission. Tube Layer Material extruded onto a conductor or cable construction which forms a tube, and which is easier to separate than a pressured layer. Twisted Pair Typically the inner portion of a cable consisting of two insulated conductors (primaries) twisted together. Voltage Rating The highest voltage that may be continuously applied to a wire or cord in conformance with standards or specifications. VW-1 A flammability rating established by Underwriters Laboratories for wires and cables that pass a specially designed vertical flame test, formerly designated FR-1. Wicking The travel of a fluid along a wire by capillary action, either through the spaces amongst the conductor strands or between jacket layers.

16

Certifications

Achieved QS-9000 / ISO-9002 at TF in June, 1996 Achieved ISO-9001 at SM in June 1997 Achieved QS-9000 at SM in November 1997 Created Corporate Quality Policy, 1994:
It is the policy of JUDD WIRE, INC. to deliver

Total Customer Satisfaction Through Continuous Improvement.

Note: Current certification available upon request

A Comprehensive Guide to Reference Information in an Easy-to-Follow Format provided by JUDD WIRE INC.
A member of the Sumitomo Electric Industries group of companies

We solve
Return this form for immediate engineering and cost analysis of your wire and cable requirements Conductor Material r Annealed Bare Copper r Tin Coated Copper r Silver Plated Copper r Other ________ Insulation Primary r TPE r XLPVC r XLPE r XLFE r XLPU r XLPES r Other _________ Jacket r TPE r XLPVC r XLPE r XLFE r XLPU r XLPES r Other _________ Wire Requirements Tensile Strength______________________ Elongation___________________________ Heat Age Retention___________________________ Nom OD/Tolerance ___________________ Nom Wall ___________________________ Min Wall____________________________ Cold Bend ___________________________ Flame_______________________________ Pinch _______________________________ Abrasion ____________________________ Solder Resistance _____________________ Conductor Solderability ________________

JUDD WIRE INC.

Headquarters and Manufacturing Facility 124 Turnpike Road Turners Falls, Ma 01376 (413) 863-4357 (tel) 1-800-545-5833 (413) 863-2305 (fax)

wire and cable problems

Automotive Application Sheet

Date: _______ Vehicle _________ Platform: ____________ Application __________________ Model Yr: ___________ Reference Specification _____________________________

Physical Construction Checklist Hook-up Wire AWG/mm2 ________________________ Wall Thickness ____________________ O.D. ______________ # of colors/stripes ____________Put ups ________________ Cable Component # of Conductors _______ # of Pairs _______________ Pair Lay ________________ Shielding __________________________Drain ____________________________ Coverage/Overlap ______________Conductor/Pair JKT ______________________ Jacketed Cable Cable lay _________________Shielding _______________Drain ______________ Coverage/overlap ___________________ Cable Jacket _______________________ O.D. ___________ Environmental Heat Resistance ___________________ Fluid Compatibility ________________
Jacket Assembly Flex Life ____________________________ Cold Bend __________________________ Fluid Ref Fuel C ___________________________ Methanol/Ref Fuel C __________________ Diesel Fuel ___________________________ Engine Oil ___________________________ Power Steering Fluid ___________________ Transmission Fluid ____________________

Battery Acid ______________________ Antifreeze/Coolant ________________

Cable Jacket Nom Wall ___________________________ Nom OD/Tolerance ___________________ Tensile Strength ______________________ Elongation ___________________________ Heat Resistance ______________________ Pinch _______________________________ Abrasion ____________________________ Moldability __________________________ Adhesion ____________________________ Thermal Shock _______________________

Name __________________________________________________________________________________________ Title ____________________________________________ Company _____________________________________ Address ______________________________________ City, State, Zip _________________________________ Telephone ____________________________ Fax _____________________ email ________________________

Usage (EAU): _______________ Target Price: ________________