1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 24 Revised Para 3.0 inserted; Para 3.10, 3.11, 3.12, 3.13, 3.14, 4 deleted 1991 01 31 DE00E00107002086 Revised 3.6 Std Para added J. Huebner 1963 08 16 CTS4-58846-1 Released Printed copies are uncont
2、rolled Page 1 of 3 Copyright 2003, Ford Global Technologies, Inc. COPPER WIRE, BATTERY CABLE - # 4 GAGE ESF-M1L28-A 1. SCOPE The material defined by this specification is a # 4 gage stranded, insulated battery cable. 2. APPLICATION This specification was released originally for material used as a ba
3、ttery starting cable on automotive passenger vehicles. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 WIRE SIZE Shall conform to SAE # 4 gage. 3
4、.2 CABLE SIZE The finished cable diameter shall not exceed SAE limits for type SGR cable. 3.3 INSULATION COLOR Black, unless otherwise specified on engineering drawing 3.4 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the original approved sample. 3.5 WIRE QUALI
5、TY The strands of the conductors shall comply with bare ESF-M2L1-A, soft or annealed round copper wire, prior to bunching or stranding. ENGINEERING MATERIAL SPECIFICATION ESF-M1L28-A Page 2 of 3 Copyright 2003, Ford Global Technologies, Inc. 3.6 CABLE CONSTRUCTION Shall consist of a minimum of 133 s
6、trands (any manufacturing tolerance must be additive of #25 gage bare copper wire having a minimum area of 20.67 mm2. The strands shall be layed in 7 x 19 rope construction and laterally served with 25.4 x 0.08 mm paper or polyester film insulating tape with 12 1/2 % minimum overlap. 3.7 INSULATION
7、QUALITY The finished cable shall be covered with a good grade of elastomer which must meet all basic SAE type SGR requirements. The insulation must have a 1.17 mm nominal wall thickness. 3.8 RESISTIVITY, FINISHED CABLE, max 875 microohms/m at 20 +/- 2 C 3.9 PHYSICAL AND ELECTRICAL PROPERTIES Three s
8、amples of cable are required. One for each of the high temperature, low temperature and oil absorption tests. All samples are subjected to the dielectric breakdown test at the completion of their respective tests. These samples are 0.6 m in length with 25 mm of insulation stripped from both ends. 3.
9、9.1 High Temperature Resistance No fracture or splitting of the insulation Test Method: Suspend sample over a 254 mm mandrel with a 2.72 kg weight at each end. Soak at 121 +/- 2 C for 120 h in a circulating air oven. Cool to 23 +/- 2 C, remove the weight and bend the sample around the mandrel in a r
10、everse direction at a rate not exceeding 1 turn per minute until a 180 bend is completed. 3.9.2 Low Temperature Resistance No fracture or splitting of the insulation Test Method: Reduce temperature of a straight piece of sample to - 34 C at a rate not to exceed 68 C per minute. Hold for 3 h and then
11、 wrap around a 254 mm mandrel for 180 at a rate of 1 turn per 10 s. 3.9.3 Oil Absorption Resistance Cable dia shall not increase more than 15% nor shall the insulation fracture or split Test Method: Immerse sample to within 38 mm from the end into a solution of 50% kerosene and 50% SAE 10W engine oi
12、l for 20 h at 49 +/ - 2 C. Wrap sample around a 254 mm mandrel for 180 . ENGINEERING MATERIAL SPECIFICATION ESF-M1L28-A Page 3 of 3 Copyright 2003, Ford Global Technologies, Inc. 3.9.4 Dielectric Resistance No rupture of the insulation Test Method: Join exposed ends of sample and immerse loop to within 150 mm of ends in a 5% salt bath (salt content by weight at 27 C). Soak 5 h and then apply 500 V (RMS) 60 cps (Hz) between sample conductor and salt bath for 1 minute.
