Requirements and Acceptance for Cable

and Wire Harness Assemblies

SQ-8011E/2015-11-30

Author:

David Croteau Engineer, Hardware design

NAME TITLE

Approver:

José D. Montoya Suppliers Quality Coordinator

NAME TITLE

Revision: v1.1

Date of last revision: 2015-11-30

TM4 Inc. has sole ownership of this document.

It must not be used or copied without written authorization from TM4 Inc.

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 Requirements and Acceptance for Cable
and Wire Harness Assemblies
SQ-8011E/2015-11-30

GENERAL INFORMATION

a - LIST OF REVISIONS
REVISION
REVISION
DATE DESCRIPTION AUTHOR REVIEWER APPROVER
#
YYYY/MM/DD

2010-05-04 0.1 Preliminary release David Croteau Guy Plouffe David Croteau
2015-11-30 1.1 Updated document David Croteau José D. David Croteau
Montoya

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TABLE OF CONTENTS

GENERAL INFORMATION..........................................................................................2
A - LIST OF REVISIONS...........................................................................................2
1 PURPOSE............................................................................................................4
2 APPLICATION......................................................................................................5
3 RESPONSABILITIES..............................................................................................6
4 APPLICABLE STANDARDS......................................................................................7
5 TESTING...............................................................................................................9
6 SHRINK TUBING.................................................................................................10
7 TWISTED PAIR WIRES.........................................................................................12
8 WIRE LENGTHS..................................................................................................13
9 SHIELDING........................................................................................................14
10 NUMBERING AND IDENTIFICATION.......................................................................15
10.1 EXTERNAL CABLE – PHASE CABLE........................................................................15
10.2 OTHER CABLES:................................................................................................15

11 INSPECTION......................................................................................................16
12 PACKAGING........................................................................................................17

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1 PURPOSE
1.1
This document aims to standardize the methods and requirements for the manufacture of cables and harnesses.
Note: It is in the interest of all parties that the information given in the technical drawings and schematics
supplied by TM4 is clear, precise and not open to interpretation. If you do not fully understand the intention or
meaning of the technical drawings or documentation, communicate immediately with a representative of TM4;
we will clarify any misunderstandings and update the drawings or documentation accordingly.

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2 APPLICATION
2.1
These instructions apply to all TM4 cable technical drawings. If some information is specified in the cable
technical drawing, the latter shall prevail.

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3 RESPONSABILITIES
3.1
The cable or harness manufacturer must submit a SQ-5021B, Deviation Request form to TM4 for any change
regarding part(s), instruction, manufacturing method or any deviation from the original technical drawing
and/or BOM. TM4 shall determine if the proposed change is acceptable. This is to ensure good quality control
and to be able to easily identify possible problems that may arise from a change to the original technical
drawing.
3.2
The cable manufacturer must also keep records of these changes in a quality document associated to a lot or
parts having undergone a change.

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4 APPLICABLE STANDARDS
4.1
For the applicable standard, the cable assembly must conform basically to IPC/WHMA-A-620A class 2 for
acceptance requirements, SAE standard or specific TM4 request mentioned below in this document. In case of 2
different values from 2 different standards the cable supplier must meet the hardest to attain value. For
example, an IPC/WHMA-A-620A pull test force for a stamped contact on a 20 awg wire must be 84.6N. For the
SAE standard for the same contact type the pull force must be a minimum of 70N. So in this case the hardest to
attain is the IPC/WHMA-A-620A which exceeds and prevails.
Always refer to the manufacturer specifications for positioning the parts, for the required tools or their
compatibility, for special assembly instructions, terms of use, etc.
4.2 Crimp
Cable crimping must comply with

 J2223-2 : 4.2.2

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 J1742 : 4.4.1

 In the case of harnesses of 50 V or less, cables exposed to automotive conditions should conform to
standards SAE J2223-1, SAE J2223-2, SAE J2223-3 (this generic standard calls others - see Section 5.1 
Reference)
o SAE J2223-2 standard, test method, sampling is preferred.
o SAE J1128 (This standard specifies the type of conductor and its performance level). The conductor
types must be noted on the technical drawings, in compliance with SAE J1128 standard on low-
voltage cables (50 V or less)
 50 V to 600 V harnesses or conductors, must comply with the following standards:
o SAE J1673 - SAE J1654 - SAE J1742 

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5 TESTING
5.1
All Cable assemblies must be tested per IPC/WHMA-A-620A Section 19.4.1 or using specific tests if mentioned.
The supplier and TM4 must agree on all of the tests mentioned in Section 19.4 of the IPC/WHMA-A-620A
standard.
The typical TM4 request will be for, but not limited to, the following tests:
Clause 19.5.1 Continuity test
Clause 19.5.2 Short circuit test
Clause 19.5.3 Dielectric withstanding Voltage (DWV)
Clause 19.5.4 Insulation resistance (IR)
Clause 19.5.8 User defined (when requested by TM4 Inc.)

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6 SHRINK TUBING
6.1
The size of a shrink tubing with no manufacturer’s product number is not important. But it must tolerate a
temperature range of -40 oC to +105oC (unless otherwise specified). Some shrink tubing must tolerate 150 oC or
more, in which case it shall be specified.
6.2
When the shrink tubing must contain glue, the shrink tubing name and number shall be clearly identified.
6.3
When some cables are subjected to a hostile environment (automotive), it is important to respect the type of
tubing to use and to rely on the given sheath number. The following table shows the correlation between major
manufacturers of heat-shrinkable tubing. This table aims to assist the manufacturer in the choice, availability or
price.
Shrink tubing cross-reference table 1

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Shrink tubing cross-reference table 2

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7 TWISTED PAIR WIRES

7.1
The cable lengths are mentioned on the technical drawings. When a pair of cables is twisted, the length required
is the length after the wires have been twisted (thus, it is important to plan a longer length of wire).
7.2
A minimum of 1 turn per inch is required for twisted wires (unless otherwise specified).

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8 WIRE LENGTHS
8.1
The wire length mentioned in the BOM is the approximate length used. It helps to establish the approximate
quantity of material needed to make the cable. (NOTE: A little longer length of wire must be planned when
twisted wires are required)
8.2
Cables lengths are measured from one end of the connector to the other end of it (they are normally specified
on the schema). Follow the drawing on the final schematic.

General rules for inspection and requirements.

Cable length Tolerance (inch) Tolerance (mm)

0-12 inches (0-30 cm) -0 / + 0,5 -0 / +12
>12-24 inches (31-60 cm) -0 / + 0,75 -0 / +19
>24 inches and + (61 cm et +) -0 / + 1 -0 / +25,4

NOTE: Some Schematic needs a tighter tolerance depending on application. If a specific tolerance is
required it will be in the schematics and the tolerance in the schematic shall prevail over the general
rule above.

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9 SHIELDING
9.1
Always ensure that NO SHIELDING WILL BE EXPOSED. If necessary, a shrink tubing, tape or other means shall
be used to cover and electrically isolate the shielding.
9.2
Always ensure that the product can withstand 105oC (even sometimes 150oC)
9.3
TM4 systems are often exposed to 500-1000 V voltage. Metal shall never be exposed unnecessarily. Although
unlikely, sometimes a high-voltage electric arc happens with a shield, a signal cable or others.
9.4 Drain wire
9.4.1
By definition a drain wire is used to make an electrical connection with a shield. When a contact is set with the
drain wire, the small end of the shrink tubing must be put on the exposed section of the drain wire to avoid a
possible short circuit between a live signal and the shield. In some cases how to connect or to interconnect the
drain wire is mentioned in the schematics.
9.4.2
When a drain wire passes through a sealed connector, a shrink tubing must be installed to it to create a good
contact on the seal of the connector and also to seal the end of the wire at the joint so that water does not pass
between the strands.
9.5 Various mechanical parts (screw, joint, plate, regulator, etc.)
9.5.1
Some plans require the use of a mechanical part to fix a connector, insulate, protect the wires, etc. If it does
not require installation before final assembly, the part that is not installed must be attached to the cable (e.g. in
a plastic bag) to facilitate its assembly at the plant.

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10 NUMBERING AND IDENTIFICATION

10.1 External cable – PHASE CABLE

The PHASE cables must always be identified by at least 2 labels. Information required for cable identification is
presented below. Label positioning is defined in the WH Drawing.
Note: The label must be able to withstand extreme temperatures (-40 C to 125 C) and under hood
contaminants like gasoline, fuel, cooling fluid, salt, dust, etc.
Typical label is: PANDUIT LJSL19-Y3-1 or equivalent

Example of both label on a WH-0207-L3000

WH-0207-L3000 Rev. A WH-0207-L3000 Rev. A

WE-0003, DRIVE SIDE WE-0006, Motor SIDE

« Supplier ALPHA » Lot #: 1288-0001 « Supplier ALPHA » Lot #: 1288-0001

10.2 Other cables:

Cable must be identified with a label indicating Cable name and lot number. unless otherwise specified the
identification is installed centered on the cable. We prefer a tubular longitudinal identification.
Can be a printed shrink tubing or a wrap over label.

WH-0207-Lxxxx

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WH-xxxx Rev.
Typical label on cable : Lot #: 1288-0001
A

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11 INSPECTION
11.1
A full inspection must be made when the manufacturing process is completed.
This inspection aims to ensure that the length, signal connection (beep test) and a crimp pull test should be
made to validate that the contact has been properly inserted and adequately engaged.
Verify the following points:
 No shield is exposed
 Cable numbering
 Connectors numbering (if applicable)
 Point-to-point connections (beep test or visual inspection if possible)
 Solid crimping and proper insertion (pull test)
 Previously installed parts are in a bag attached to the cable

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12 PACKAGING
12.1
Some plans require making 2 or more separate cables. These cables must be tied together because they
constitute a “KIT”.
12.2
For each technical drawing (wh-xxxx-y) all cables required in the said drawing must be tied together.
For example, if the technical drawing wh-0001 requires making 5 independent wires, these 5 wires must be
made individually and grouped together at the end of the manufactured unit.
So if TM4 orders cable wh-0001 ten times, the supplier must provide 10 groups of 5 wires, and not provide 50
cables in the same bag.
12.3
Each lot or group of cables should be provided in a bag or container with a label indicating the lot number, TM4
number, manufacturing date, etc.

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